Watts Aerco BENCHMARK 750 User Manual
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Watts Aerco BENCHMARK 750 User Manual

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Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL
Natural Gas Modulating
& Condensing Hot Water
Heating Boiler Models:
• BMK 750
• BMK 1000
THIS MANUAL APPLIES TO
CHINA LOW PRESSURE
(0.9 Bar) APPLICATIONS ONLY
Applicable to Serial Numbers:
G-16-0450 and Above
Latest Update: 11/03/2016
OMM-0119_0A
GF-130-I
Installation, Operation & Maintenance Manual
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
USER MANUAL
Installation, Operation and Maintenance
BENCHMARK
750 and 1000
Gas-Fired Boilers
Page 1 of 170
11/03/2016

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  • Page 1 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL Installation, Operation & Maintenance Manual USER MANUAL Installation, Operation and Maintenance BENCHMARK 750 and 1000 Natural Gas Modulating Gas-Fired Boilers & Condensing Hot Water Heating Boiler Models: • BMK 750 • BMK 1000 THIS MANUAL APPLIES TO CHINA LOW PRESSURE (0.9 Bar) APPLICATIONS ONLY...
  • Page 2 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL Installation, Operation & Maintenance Manual 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 750 – 1000 Boiler User Manual - INTERNATIONAL Installation, Operation & Maintenance Manual TABLE OF CONTENTS FOREWORD ............................7 CHAPTER 1. SAFETY PRECAUTIONS ..................11 1.1 WARNINGS & CAUTIONS ........................11 1.2 EMERGENCY SHUTDOWN ......................... 12 1.3 PROLONGED SHUTDOWN ......................... 12 CHAPTER 2.
  • Page 4 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL Installation, Operation & Maintenance Manual 3.4 OPERATING MENU ..........................41 3.5 SETUP MENU ............................42 3.6 CONFIGURATION MENU ........................42 3.7 TUNING MENU ............................. 45 3.8 COMBUSTION CAL MENU ........................45 3.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU ...............
  • Page 5 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL Installation, Operation & Maintenance Manual 6.11 IGNITION SWITCH OPEN DURING IGNITION ................. 82 6.1 SAFETY PRESSURE RELIEF VALVE TEST ..................84 CHAPTER 7. MAINTENANCE ......................85 7.1 MAINTENANCE SCHEDULE ....................... 85 7.2 IGNITER-INJECTOR ..........................
  • Page 6 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL Installation, Operation & Maintenance Manual APPENDIX G: PART LIST DRAWINGS ..................151 APPENDIX H: WIRING DIAGRAMS ..................... 159 APPENDIX I: PIPING DRAWINGS ....................163 APPENDIX J: C-MORE CONTROL PANEL VIEWS ..............165 APPENDIX K: RECOMMENDED SPARES ...................

  • Page 7: Foreword

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL FORWARD FOREWORD The AERCO Benchmark (BMK) 750 MBH (220 kW) and 1000 MBH (293 kW) boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns.
  • Page 8 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL FORWARD Phrases, Abbreviations and Acronyms Phrase, Abbreviation Meaning or Acronym A (Amp) Ampere AERCO Control System, AERCO’s boiler management systems ADDR Address AGND Analog Ground ALRM Alarm ANSI American National Standards Institute, ASME American Society of Mechanical Engineers Auxiliary...
  • Page 9 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL FORWARD Phrase, Abbreviation Meaning or Acronym Hexadecimal Number (0 – 9, A – F) Horse Power Heat Exchanger Hertz (Cycles Per Second) I.D. Inside Diameter Ignition IGST Board Ignition/Stepper Board, contained in C-More Control Box INTLK (INTL’K) Interlock 英寸...
  • Page 10 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL FORWARD Phrase, Abbreviation Meaning or Acronym Point-to-Point (usually over RS232 networks) P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref) Reference...

  • Page 11: Chapter 1. Safety Precautions

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 1 – SAFETY PRECAUTIONS 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 12: Emergency Shutdown

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 1 – SAFETY PRECAUTIONS --WARNING! - A switch must be installed on the electrical supply line of the unit. The switch must be installed in an easily accessible position to quickly and safely disconnect electrical service.

  • Page 13: Chapter 2. Installation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION CHAPTER 2. INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark Model BMK 750 and BMK 1000 Heating Boiler. 2.2 RECEIVING THE UNIT Each Benchmark Heating Boiler System is shipped as a single crated unit.

  • Page 14: Site Preparation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark 750/1000 Heating Boiler includes: • Access to AC Input Power at 220 VAC, Single-Phase, 50 Hz @ 15 Amps •...

  • Page 15: Setting The Unit

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION --WARNING! - Keep the unit area clear and free from all combustible materials and flammable vapors or liquids --CAUTION - While packaged in the shipping container, the unit must be moved by pallet jack or forklift from the FRONT ONLY.

  • Page 16: Supply And Return Piping

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION Attachment of Lifting Bar Remove the lifting bar from its shipping location at the rear of the unit (Figure 2-2, View A). Retain the attaching hardware consisting of two (2) hex head cap screws, hex nuts and flat washers.
  • Page 17 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION BOILER HOT WATER OUTLET (SUPPLY) 1” (254 mm) NATURAL GAS INLET SECONDARY WATER INLET (WARMER WATER RETURN) AIR INLET PRIMARY WATER INLET (COOLER WATER RETURN) EXHAUST MANIFOLD DRAIN VALVE CONDENSATE DRAIN PORT...

  • Page 18: Pressure Relief Valve Installation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.6 PRESSURE RELIEF VALVE INSTALLATION NOTE Pressure relief valves are not required for low pressure applications, but we recommend that they be installed as a safety measure to avoid the build-up of pressure inside the device (although this rarely occurs).

  • Page 19: Condensate Drain & Piping

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.7 CONDENSATE DRAIN & PIPING The Benchmark Heating Boiler is designed to condense water vapor from the flue products. Therefore, the installation must have provisions for suitable condensate drainage or collection. The condensate drain port located on the exhaust manifold (Figure 2-5) must be connected to the condensate trap (P/N 24441) which is packed separately within the unit’s shipping container.
  • Page 20 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION WARNING! Use PVC, stainless steel, aluminum or polypropylene for condensate drain piping (Figure 2-6). Do NOT use carbon or copper components. TRAP INLET INTEGRAL COMBUSTION ADAPTOR AND THUMBSCREW ANALYZER PROBE PORT...

  • Page 21: Gas Supply Piping

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide, GF-2035 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 --CAUTION -...

  • Page 22: External Gas Supply Regulator

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.8.3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions. Regulators must conform to the following specifications: •...
  • Page 23 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION Box, which is mounted in the upper right corner of the unit as shown in Figure 2-8. Loosen the two upper screws of the Power Box cover and remove cover to access the internal connections shown in Figure 2-8.

  • Page 24: Electrical Power Requirements

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION NOTE All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers, inhibit service/maintenance, or prevent access between the unit and walls or another unit.

  • Page 25: Field Control Wiring

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.10 FIELD CONTROL WIRING Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the C-More Control system used with all Benchmark units does allow for some additional control and monitoring features.

  • Page 26: Outdoor Air In (Out) & Air Sensor Common (Com)

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION Figure 2-12: I/O Box Terminal Strips 2.10.1 Outdoor Air In (OUT) & Air Sensor Common (COM) The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (P/N GM-123525) as required primarily for the INDOOR/OUTDOOR RESET mode of operation.

  • Page 27: Air Temp Sensor Terminals

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.10.2 AIR TEMP SENSOR Terminals The AIR TEMP SENSOR terminals are used to monitor the air inlet temperature sensor (P/N 61024). This input is always enabled and is a “to view only” input that can be seen in the Operating menu.

  • Page 28: Shield Terminals (Shld & Shld)

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION NOTE If the Valve Feedback option is used, Shorting Jumper #JP2 on the I/O Board MUST be inserted. 2.10.7 SHIELD Terminals (SHLD & SHLD) The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit.

  • Page 29: Fault Relay (Nc, Com, & No)

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION Remote Interlock In (OUT & IN) 2.10.12.1 The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit if desired. The circuit is 24 VAC and comes factory pre-wired closed (jumped). Delayed Interlock In (OUT &...

  • Page 30: Combustion Air

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.12 COMBUSTION AIR The AERCO Benchmark Boiler Venting and Combustion Air Guide, GF-2055 MUST be consulted before any flue or inlet air venting is designed or installed. Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes.

  • Page 31: Sequencing Isolation Valve Installation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION 2.14 SEQUENCING ISOLATION VALVE INSTALLATION All Benchmark units are shipped with a connection for an optional motorized external sequencing isolation valve (P/N 92084-TAB) included in the shipping container. This valve is an integral component of the AERCO’s on-board Boiler Sequencing Technology (BST) solution.

  • Page 32: Benchmark Pump Relay

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION Installing Sequencing Isolation Valve – Continued The Heating Boiler’s shell harness has one unused cable. One end of this cable is connected to the DELAYED INTERLOCK IN terminals in the I/O board (see Figure 2-14) while the other end contains a Molex connector with a jumper wire inserted in it (this jumper wire allows units that do not have a sequencing isolation valve to operate normally).
  • Page 33 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION (Orange) – N/O The Benchmark pump relay (SPDT) contact is (Yellow) - COM rated for: • Pump Relay Terminals 10 A Resistive @ 277 VAC or 28 VDC •...
  • Page 34 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 2 – INSTALLATION (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 35: Chapter 3. Operation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION CHAPTER 3. OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark Heating 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 36 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Figure 3-1: Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...
  • Page 37 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays CONTROL, ITEM FUNCTION INDICATOR OR DISPLAY LED Status Indicators Four Status LEDs indicate the current operating status as follows: COMM Lights when RS232 communication is occurring –...
  • Page 38 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays – Continued CONTROL, ITEM INDICATOR OR FUNCTION DISPLAY MENU Keypad Six (6) keys which provide the following functions for the Control Panel menus: Steps through the main menu categories shown in Figure 3-2.

  • Page 39: Control Panel Menus

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 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 40 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION * Only if BST is enabled (see Chapter 9) Figure 3-2: Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option.

  • Page 41: Operating Menu

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 3.4 OPERATING MENU The Operating menu displays a number of key operating parameters for the unit as listed in Table 3-2. This menu is “Read-Only” and does not allow personnel to change or adjust any displayed items.

  • Page 42: Setup Menu

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 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 43 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Table 3-4: Configuration Menu Available Choices or Limits Menu Item Display Default Minimum Maximum Internal Setpt Lo Temp Limit Hi Temp Limit 130°F (54.4° BMK Blr Std, BMK Blr Std Dual, Unit Type BMK Boiler LN BMK Blr LN, BMK Blr LN Dual...
  • Page 44 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Table 3-4: Configuration Menu Available Choices or Limits Menu Item Display Default Minimum Maximum Setpt Limit Band 0°F (0°C) 10°F (5.5°C) 5°F (2.75°C) Network Timeout 5 sec. 999 sec.

  • Page 45: Tuning Menu

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 3.7 TUNING MENU The Tuning menu items in Table 3-5 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by factory-trained personnel. Table 3-5: Tuning Menu Available Choices or Limits Menu Item Display...

  • Page 46: Bst (Boiler Sequencing Technology) Menu

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 3.9 BST (Boiler Sequencing Technology) Menu The BST menu must be enabled in order to be displayed and accessed. The BST Menu item, located at the end of the Configuration menu (item 32 in Table 3-4), must be se to Enabled. The BST menu contains all of the items required to configure, operate and monitor the functionality of the BST System.
  • Page 47 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Table 3-7: BST Menu Available Choices or Limits Menu Item Display Default Minimum Maximum Header Temp Point BST Outdoor Sens Disabled Enabled Disabled Outdr Tmp Source Outdoor Temp Network Outdoor Temp Outdoor Tmp Addr...
  • Page 48 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION Table 3-7: BST Menu Available Choices or Limits Menu Item Display Default Minimum Maximum BST Temp Hi Limit 40°F (4.4°C) 210°F (98.9°C) 210°F (98.9°C) BST Setpt Lo Limit 40°F (4.4°C) BST Setpt HI Limit 60°F (15.5°C)

  • Page 49: Start Sequence

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 3.10 START SEQUENCE When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge safety switches to ensure they are closed. These switches include: •...
  • Page 50 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 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. See Figure 3-3 for SSOV location. AIR/FUEL VALVE MANUAL SHUT-OFF...
  • Page 51 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN Figure 3-4: Air/Fuel Valve In Purge Position Next, the blower proof switch on the Air/Fuel Valve (Figure 3-5) closes. The display will show PURGING and indicate the elapsed time of the purge cycle in seconds.
  • Page 52 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION (b) The “Spark Cycle Time” item in the Factory menu can be set to either 0 Sec, 2 Sec or 7 Sec to define the duration of the Spark Element Cleaning Cycle. This cycle turns on the spark transformer to produce a spark (with no gas flowing) to clean the spark element of moisture or carbon buildup.

  • Page 53: Start/Stop Levels

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION 3.11 START/STOP LEVELS The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows: Start Level: Stop Level: Normally, these settings should not require adjustment.
  • Page 54 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 3 – OPERATION (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 55: Chapter 4. Initial Start-Up

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP CHAPTER 4. INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark Heating Boiler consist of the following: • Complete installation (Chapter 2) •...

  • Page 56: Required Tools & Instrumentation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP 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 57: Accessing The Analyzer Probe Port

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration (section 4.3), install the 16” W.C. (4.0 kPa) manometer(s) as described in the following steps: Installing Gas Supply Manometer Turn off the main gas supply upstream of the unit.

  • Page 58: Natural Gas Combustion Calibration

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP 4.3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark Heating Boiler is combustion calibrated at the factory prior to shipping. This gas pressure must be within the following ranges for each model of Heating Boiler at full fire: Table 4-1: Nominal Gas Pressure BMK Heating Boiler Model Nominal Gas Pressure...
  • Page 59 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP Natural Gas Combustion Calibration – Continued 13. Compare the oxygen readings on the combustion analyzer to the on-board O sensor value displayed in the Operating menu of the C-More Control Panel. If the values differ by more than ±1.5% and your combustion analyzer is correctly calibrated, the on-board O sensor may be defective and need to be replaced.
  • Page 60 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP Natural Gas Combustion Calibration – Continued 25. Press the CHANGE key and observe that CAL Voltage 80% is flashing. 26. The oxygen level at the 80% valve position should be as shown below. Also, ensure that the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the following values: Table 4-3: Combustion Calibration Readings –...
  • Page 61 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). Figure 4-3: Gas Pressure Adjustment Screw Location TAC VALVE IDLE SCREW Figure 4-4: TAC Valve Adjust (Idle Screw) AERCO International, Inc.

  • Page 62: Reassembly

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP 4.4 REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation. Reassembly 1. Set the ON/OFF switch in the OFF position. 2.

  • Page 63: Digital Alarm Switch Checks And Adjustments

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP 4.5.1 Digital Alarm Switch Checks and Adjustments The Over-Temperature Alarm switch settings can be checked or adjusted using the controls and display on the front panel of the switch illustrated and described in Figure 4-6 and Table 4-8. Figure 4-6: Digital Over-Temperature Alarm Switch Front Panel Table 4-8: Over-Temperature Alarm Switch Controls and Display CONTROL OR...
  • Page 64 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 4 – INITIAL START-UP 9. Press SET to view the value stored in memory. 10. If the desired value is not displayed, modify the setting using the ▲ and ▼ arrow keys. The value can be changed from -10°...

  • Page 65: Chapter 5. Mode Of Operation

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 5 – MODE OF OPERATION CHAPTER 5. MODE OF OPERATION 5.1 INTRODUCTION The Heating Boiler is capable of being operated in any one of six different modes. The following sections in this Chapter provide descriptions of each of these operating modes. Each Heating Boiler is shipped from the factory tested and configured for the ordered mode of operation.

  • Page 66: Indoor/Outdoor Startup

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 5 – MODE OF OPERATION 5.2.4 Indoor/Outdoor Startup Startup in the INDOOR/OUTDOOR RESET mode is accomplished as follows: NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data Indoor/Outdoor Startup Refer to the Indoor/Outdoor reset ratio charts in Appendix E.

  • Page 67: Setting The Setpoint

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 5 – MODE OF OPERATION 5.3.1 Setting the Setpoint The setpoint temperature of the unit is adjustable from 40°F to 240°F (4.4°C to 115.6°C). To set the unit for operation in the CONSTANT SETPOINT mode, the following menu settings must be made in the Configuration menu: Table 5-1: Constant Setpoint Mode Settings Setting...

  • Page 68: Remote Setpoint Field Wiring

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 5 – MODE OF OPERATION While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings.

  • Page 69: Direct Drive Field Wiring

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 5 – MODE OF OPERATION CPU Board located in the Control Box Assembly. Contact your local AERCO representative for details. To enable the DIRECT DRIVE mode, the following menu setting must be made in the Configuration menu: Table 5-3: Direct Drive Mode Settings Menu Option...
  • Page 70 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 5 – MODE OF OPERATION (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 71: Chapter 6. Safety Device Testing

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 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.

  • Page 72: Low Gas Pressure Test

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.2 LOW GAS PRESSURE TEST To simulate a low gas pressure fault, refer to Figure 6-1a and perform the following steps: TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH SSOV...

  • Page 73: High Gas Pressure Test

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.3 HIGH GAS PRESSURE TEST To simulate a high gas pressure fault, refer to Figure 6-1b and perform the following steps: TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH SSOV...

  • Page 74: Low Water Level Fault Test

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: 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.
  • Page 75 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING Reset button for Manual Temperature Digital Over- Limit Switch Temperature Limit Controller Manual Temperature Limit Switch See Detail ‘A’ below Adjustable Temperature Limit Switch (auto-reset) Front view with Panel removed Figure 6-2: Temperature Limit Switch Location AERCO International, Inc.

  • Page 76: Interlock Tests

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2-12) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.

  • Page 77: Flame Fault Tests

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.7 FLAME FAULT TESTS Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: Flame Fault Tests Set the ON/OFF switch to the OFF position.
  • Page 78 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING BLOWER PROOF SWITCH BLOWER BLOCKED INLET VALVE AIR/FUEL VALVE AIR FILTER MANUAL SHUT-OFF VALVE SSOV Figure 6-3: Bare Heating Boiler – Partial View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 170 OMM-0119_0A Ph.: 800-526-0288...

  • Page 79: Air Flow Fault Tests

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 6-3. 6.8.1 Blower Proof Switch Test Blower Proof Switch Test Disable the blower output drive voltage as follows: (a) Press the MENU key until CONFIGURATION MENU is displayed.
  • Page 80 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING Blocked Inlet Switch Test – Continued Turn off the gas supply ball valve to the Heating Boiler and then complete the following steps: (a) Use jumper wires to jump out the Low Gas Pressure switch and the Blower Proof switch.

  • Page 81: Ssov Proof Of Closure Switch

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6-1 contains the Proof Of Closure switch. The Proof Of Closure switch circuit is checked as follows: SSOV Proof of Closure Switch Set the unit’s ON/OFF switch to the OFF position.

  • Page 82: Purge Switch Open During Purge

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.10 PURGE SWITCH OPEN DURING PURGE The Purge switch (and Ignition switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Purge Switch Open During Purge Set the unit’s ON/OFF switch to the OFF position.
  • Page 83 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING AIR/FUEL VALVE COVER (Rotate counter-clockwise to remove) Figure 6-7: Air/Fuel Valve Cover Location Ignition Position Switch Purge Position Switch AIR IN TO BLOWER Figure 6-8: Air/Fuel Valve Purge and Ignition Switch Locations AERCO International, Inc.

  • Page 84: Safety Pressure Relief Valve Test

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 6 – SAFETY DEVICE TESTING 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 170 OMM-0119_0A Ph.: 800-526-0288...

  • Page 85: Chapter 7. Maintenance

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE CHAPTER 7. MAINTENANCE 7.1 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 86: Igniter-Injector

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE 7.2 IGNITER-INJECTOR The igniter-injector (Kit P/N 58023) is located on the burner plate at the top of the Heating 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 87 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE Igniter-Injector Maintenance Procedures – Continued Refer to the partial exploded view in Figure 7-2. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly.

  • Page 88: Flame Detector

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE IGNITER-INJECTOR MAINTENANCE PROCEDURES – Continued NOTE If a replacement igniter-injector (Kit P/N 58023) is being installed, a compression nut containing a built-in ferrule will be included with the replacement part.

  • Page 89: O 2 Sensor

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE Flame Detector Maintenance – Continued Remove the two (2) screws securing the flame detector to the plate (Figure 7-2). The flame detector is secured to the burner plate with one #10-32 screw and one #8-32 screw.

  • Page 90: Burner Assembly Inspection

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE 7.6 BURNER ASSEMBLY INSPECTION The burner assembly is located at the top of the unit's heat exchanger. The burner assembly may be hot. Therefore, allow the unit to cool sufficiently before removing the burner assembly. The following parts will be required for reassembly after burner inspection: Part No.
  • Page 91 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedures – Continued REAR FRONT BLOWER BURNER PLATE 3/16”–16 HEX NUTS (8) BLOWER PROOF SWITCH BLOCKED INLET SWITCH IGNITER-INJECTOR STAGED IGNITION ASSEMBLY 1/2"...
  • Page 92 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedures – Continued Remove the burner assembly from burner flange by pulling straight up. Remove and replace the burner gasket. NOTE During reassembly, apply a light coating of high-temperature, anti- seize lubricant to the threads of the igniter-injector and grounding screw.

  • Page 93: Condensate Drain Trap

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE 7.7 CONDENSATE DRAIN TRAP Benchmark Heating Boilers contain a condensate trap (P/N 24441), located external to the unit and attached to the drain connection from the exhaust manifold. The location on the unit is shown in Chapter 2, Figure 2-5.

  • Page 94: Air Filter Cleaning & Replacement

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE 7.8 AIR FILTER CLEANING & REPLACEMENT The Benchmark Heating Boiler is equipped with an air filter (P/N 59138) which should be cleaned and re-oiled every 12 months and replaced every 24 months. The air filter is located at the air fuel valve inlet, as shown in Figure 7-7.

  • Page 95: Water Cutoff (Lwco) Capacitor Integrity Test

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE 7.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST The LWCO capacitor should be tested for electrical shorts every 12 months and replaced, then tested, every 24 months. The LWCO capacitor integrity test consists of two parts as described in the next two sections.
  • Page 96 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE LWCO Capacitor Electrical Short Test – Continued 2. Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on the rear panel of the C-More controller (see Figure 7-9). Unplug Shell Harness Cable from...

  • Page 97: Low Water Cutoff (Lwco) - Standard C-More Test

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE LWCO Capacitor Integrity Test – Continued 5. Confirm that the ohmmeter does NOT read a short. NOTE If the ohmmeter reads a short, the capacitor assembly needs to be replaced.

  • Page 98: Placing The Heating Boiler Back In Service After A Prolonged Shutdown

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 7 – MAINTENANCE 7.11 PLACING THE HEATING BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown (one year or more), the following procedures must be followed: Placing Heating Boiler in Service After Long Shutdown Review installation requirements included in Chapter 2.

  • Page 99: Chapter 8. Troubleshooting Guide

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE 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 Benchmark 750 and 1000 Heating Boilers. The troubleshooting procedures contained herein are presented in tabular form on the following pages.
  • Page 100 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...
  • Page 101 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Blower stopped running due to thermal Check combustion blower for signs of excessive heat or high or current overload.
  • Page 102 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Blower not running or running too Start the unit. If the blower does not run check the blower solid slow.
  • Page 103 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Delayed Interlock Jumper not Check to insure jumper is properly installed across the delayed properly installed or missing.
  • Page 104 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Carbon or other debris on Remove View-Port and inspect Burner with Boroscope. If Burner.
  • Page 105 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Incorrect supply gas pressure. Check to ensure gas pressure at inlet of SSOV does not exceed 14”...
  • Page 106 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Air/Fuel Valve not rotating. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position.
  • Page 107 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Interlock jumper not installed or Check for a jumper properly installed across the interlock terminals in the removed.
  • Page 108 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Defective or shorted switch. If the Air/Fuel Valve does rotate to the ignition position, check the purge switch for continuity between the N.O.
  • Page 109 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Internal recirculation pump failed. 1. Replace recirculation pump. RECIRC PUMP FAILURE Remote setpoint signal not present: Check I/O Box to ensure signal is hooked up.
  • Page 110 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: HEATING BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Actuator not allowing for full Observe operation of the Safety Shut-Off Valve (SSOV) closure of gas valve.

  • Page 111: Additional Faults Without Specific Fault Messages

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 8-2: HEATING BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION...
  • Page 112 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 8 – TROUBLESHOOTING GUIDE COMPRESSION FITTING & ELBOW FLAME STAGED DETECTOR IGNITION & GASKET SOLENOID GAS INJECTOR TUBE BURNER PLATE INDEXING WASHERS (Qty. 0 -3 as required) O2 SENSOR & WASHERS IGNITER-INJECTOR Figure 8-2: Staged Ignition Connection to Gas Injector Tube BRASS HEX HEAD CAP...

  • Page 113: Chapter 9. Boiler Sequencing Technology

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.1 INTRODUCTION The C-More on-board Boiler Sequencing Technology system (BST) is an integrated 8 Heating Boiler control system designed into the C-More controller. The BST has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 8 Heating Boilers while achieving maximum operational efficiency.

  • Page 114: Installation Notes

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.1.1 Installation Notes If you are installing a BST system that also includes a ProtoNode SSD (Slave-Slave Device), you must adhere to the procedure listed below. Failure to complete these steps can result in the failure of the BST system.

  • Page 115: Aerco Bst Quick Start Chart

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.2 AERCO BST Quick Start Chart Select the single option that suites your installation and then complete the instructions in the corresponding sub-sections of section 9.3 BST Implementation Instructions. Constant Setpoint (choose option 1 or 2) Option 1 –...

  • Page 116: Bst Implementation Instruction

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3 BST Implementation Instruction 9.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (P/N 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled Header Temp sensor in the I/O Box.

  • Page 117: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor Step 1: MODbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the units.

  • Page 118: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor NOTE: Both Header Sensor AND Outdoor Sensor must be wired. Step 1 - Direct Wired Header Sensor Wiring 1.
  • Page 119 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY Option 3 – Continued Step 3 - Configure ALL C-More Units On ALL Heating Boilers: 1. Go to the Configuration menu item and set the BST Menu item to Enabled. 2.

  • Page 120: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor NOTE: Both Header Sensor AND Outdoor Sensor must be wired. Step 1 - Modbus Header Sensor Wiring 1.
  • Page 121 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY Option 4 – Continued • There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded. Temp Sensor P/N Modbus Transmitter I/O Box...

  • Page 122: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4- 20ma Setpoint Drive NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired. Step 1: Direct Wired Header Sensor Wiring 1.
  • Page 123 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY Option 5 – Continued Step 3: Configure ALL C-More Units On ALL Heating Boilers: 1. Go to the Configuration menu item and set the BST Menu item to Enabled. 2.

  • Page 124: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive NOTE: Both Header Sensor AND the ProtoNode SSD Device must be wired. Step 1: Direct Wired Header Sensor Wiring 1.

  • Page 125: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired. Step 1: MODbus Header Sensor 1.
  • Page 126 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY Option 7 – Continued Step 3: Configure ALL C-More Units On ALL Heating Boilers: 1. Go to the Configuration menu item and set the BST Menu item to Enabled. 2.

  • Page 127: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY 9.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive NOTE! Both Header Sensor AND ProtoNode SSD Device must be wired. Step 1: MODbus Header Sensor 1.
  • Page 128 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL CHAPTER 9. BOILER SEQUENCING TECHNOLOGY Option 8 – Continued Step 3: Configure ALL C-More Units On ALL Heating Boilers: 1. Go to the Configuration menu item and set the BST Menu item to Enabled. 2.

  • Page 129: Appendix A: Heating Boiler Menu Item Descriptions

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS Appendix A: HEATING BOILER MENU ITEM DESCRIPTIONS Table A-1: Operating Menu Item Descriptions See section 3-4 for a range of choices and the default values. Table A-1: OPERATING MENU ITEM DESCRIPTIONS MENU OPTIONS DESCRIPTION This is the setpoint temperature to which the control is set...
  • Page 130 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS Table A-2: Setup Menu Item Descriptions See section 3-5 for a range of choices and the default values. SETUP MENU MENU OPTIONS DESCRIPTION Allows Level 1 or Level 2 password to be entered. Entering the Level 1 Password (159) allows options in the Setup, Configuration and Tuning menus to be modified.
  • Page 131 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS Table A-3: Configuration Menu Item Descriptions See section 3-6 for a range of choices and the default values. The Configuration menu settings are Factory-Set in accordance with the requirements specified with each individual order.
  • Page 132 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS CONFIGURATION MENU MENU OPTIONS DESCRIPTION Specifies the amount of time to wait, up to 120 seconds, Aux Start On Dly between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the Heating Boiler.
  • Page 133 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS CONFIGURATION MENU MENU OPTIONS DESCRIPTION Deadband High and Deadband Low settings create an “Outlet Temperature” Zone in which no Valve Position corrections will be attempted. The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint + Deadband High and Active Setpoint –...
  • Page 134 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS Table A-4: Tuning Menu Item Descriptions See section 3-7 for a range of choices and the default values. TUNING MENU MENU OPTIONS DESCRIPTION Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature.
  • Page 135 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS Table A-5: Combustion Calibration Menu Item Descriptions See section 3-8 for a range of choices and the default values. NOTE The Level 2 Password must be entered to view the options in the Combustion Cal menu.
  • Page 136 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX A: BOILER MENU DESCRIPTIONS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 137: Appendix B: Startup, Status & Display Messages

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Appendix B: STARTUP, STATUS & DISPLAY 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.
  • Page 138 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT The Blower Proof switch opened during purge, or air inlet is blocked. DURING PURGE AIRFLOW FAULT The Blower Proof switch opened during ignition.
  • Page 139 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages – Continued FAULT MESSAGE FAULT DESCRIPTION LOW WATER The Low Water Cutoff board is indicating low water level. LEVEL NETWORK COMM The RS-485 network information is not present or is corrupted.
  • Page 140 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 141: Appendix C: Sensor Resistance/Voltage Chart

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART Appendix C: SENSOR RESISTANCE/VOLTAGE CHART Temperature Sensor Resistance Voltage Chart (Balco) TEMPERATURE °F °C RES (OHMS) VOLTS* 779.0 1.93 -34.4 797.5 1.96 -28.9 816.3 1.99 -23.3 835.4 2.02...
  • Page 142 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 143: Appendix D: Recommended Periodic Testing

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX D – RECOMMENDED PERIODIC TESTING Appendix D: RECOMMENDED PERIODIC TESTING --WARNING! - Periodic testing of all Heating 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 144 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX D – RECOMMENDED PERIODIC TESTING This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 145: Appendix E: Indoor/Outdoor Reset Ratio Charts

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX E – INDOOR/OUTDOOR RESET RATIO CHARTS Appendix E: INDOOR/OUTDOOR RESET RATIO CHARTS Table E-1. Header Temperature for a Building Reference Temperature = 50°F (10.0°C) RESET RATIO Air Temp °F °C 10.0 -1.1 -3.9...
  • Page 146 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX E – INDOOR/OUTDOOR RESET RATIO CHARTS Table E-3. Header Temperature for a Building Reference Temperature = 65°F (18.3°C) RESET RATIO Air Temp °F °C 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2...
  • Page 147 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX E – INDOOR/OUTDOOR RESET RATIO CHARTS Table E-5. Header Temperature for a Building Reference Temperature = 75°F (23.9°C) RESET RATIO Air Temp °F °C 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7...
  • Page 148 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX E – INDOOR/OUTDOOR RESET RATIO CHARTS Table E-7. Header Temperature for a Building Reference Temperature = 90°F (32.2°C) RESET RATIO Air Temp °F °C 32.2 29.4 26.7 23.9 21.1 18.3 15.6 12.8 10.0...

  • Page 149: Appendix F: Dimensional And Clearance Drawings

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX F – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix F: DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-891 rev H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0119_0A Page 149 of 170 Ph.: 800-526-0288 11/03/2016 GF-130-I...
  • Page 150 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX F – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: SD-A-871 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 151: Appendix G: Part List Drawings

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS Appendix G: PART LIST DRAWINGS Benchmark 750 - 1000 Part List Item # Part # Description Item # Part # Description EXHAUST MANIFOLD CONTROLS (Continued) 43086 MANIFOLD: EXHAUST 61002-5...
  • Page 152 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS Benchmark 750 - 1000 Part List – Continued Item # Part # Description Item # Part # Description SHEET METAL/PANEL ASSEMBLY OTHER ACCESSORIES & PARTS 37110 PANEL: LEFT 37111...
  • Page 153 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS TOP VIEW 22286 ITEM 4 – GAS TRAIN FRONT VIEW Benchmark 750-1000 Part List 03/11/2016 AERCO International, Inc. Whole Boiler: BMK 750 – 28321-CHI Blauvelt, NY 10913 Sheet 3 of 6 BMK 1000 –...
  • Page 154 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS Benchmark 750-1000 Part List 03/11/2016 AERCO International, Inc. Whole Boiler: BMK 750 – 28321-CHI Blauvelt, NY 10913 Sheet 4 of 6 BMK 1000 – 28253-CHI AERCO International, Inc.
  • Page 155 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS TOP VIEW REAR VIEW Benchmark 750-1000 Part List 03/11/2016 AERCO International, Inc. Whole Boiler: BMK 750 – 28321-CHI Blauvelt, NY 10913 Sheet 5 of 6 BMK 1000 –...
  • Page 156 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS Benchmark 750-1000 Part List 03/11/2016 AERCO International, Inc. Whole Boiler: BMK 750 – 28321-CHI Blauvelt, NY 10913 Sheet 6 of 6 BMK 1000 – 28253-CHI AERCO International, Inc.
  • Page 157 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS Benchmark 750-1000 Gas Train – 22286 Item Qty Part # Description Item Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92006-5 VALVE: BALL 1" NPT 92036 VALVE: SSOV 1"...
  • Page 158 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX G – PART LIST DRAWINGS Benchmark 750-1000 Burner, Blower, Air/Fuel Valve – 24276 Item Qty Part # Description Item Qty Part # Description 42140 PLATE: BURNER 53033 WASHER: CLOCKING 81143 GASKET: BURNER 46026 BURNER:...

  • Page 159: Appendix H: Wiring Diagrams

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX H – WIRING DIAGRAMS Appendix H: WIRING DIAGRAMS Drawing Number 68090 rev B page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0119_0A Page 159 of 170 Ph.: 800-526-0288 11/03/2016 GF-130-I...
  • Page 160 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX H – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...
  • Page 161 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX H – WIRING DIAGRAMS Drawing Number 68090 rev B page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0119_0A Page 161 of 170 Ph.: 800-526-0288 11/03/2016 GF-130-I...
  • Page 162 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX H – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 163: Appendix I: Piping Drawings

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX I – PIPING DRAWINGS Appendix I: PIPING DRAWINGS Diagram 1: Single Boiler Low Pressure (0.9 Bar) Piping Arrangement AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0119_0A Page 163 of 170 Ph.: 800-526-0288 11/03/2016...
  • Page 164 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX I – PIPING DRAWINGS Reference SD-A-1114 rev B NOTES: For actual sizes and locations of piping and other connections to the heating boiler, see dimensional drawing. Shell drain valve and condensate hose should be arranged to permit the fluids to drain freely, by gravity, to a floor drain.

  • Page 165: Appendix J: C-More Control Panel Views

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX J – C-MORE CONTROL PANEL VIEWS Appendix J: C-MORE CONTROL PANEL VIEWS 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...
  • Page 166 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX J – C-MORE CONTROL PANEL VIEWS INTERLOCK HARNESS CONNECTOR (16 PIN) TO INPUT/OUTPUT (I/O) BOX SHELL HARNESS CONNECTOR (19 PIN) GAS TRAIN HARNESS CONNECTOR (9 PIN) A/F VALVE HARNESS CONNECTOR (16 PIN) EXT.

  • Page 167: Appendix K: Recommended Spares

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX K – RECOMMENDED SPARES Appendix K: RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix G for the locations of the recommended and optional spare parts listed in the following Tables. Table K-1: Recommended Emergency Spare Parts DESCRIPTION PART NUMBER...
  • Page 168 Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX K – RECOMMENDED SPARES (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

  • Page 169: Appendix L: 220V To 110V Transformer

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL APPENDIX L – 220V TO 110 V TRANSFORMER Appendix L: 220V to 110V Transformer Benchmark 750 and 1000 units that connect to a 220 VAC power source include a pre-installed 220 VAC to 120 VAC transformer. This transformer (P/N 24468) is installed inside the unit, as shown in Figure L1.

  • Page 170: Omm-0119_0A Aerco International, Inc. • 100 Oritani Dr. • Blauvelt, Ny 10913

    Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL NOTES: © AERCO International, Inc., 2016 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 170 OMM-0119_0A Ph.: 800-526-0288 11/03/2016 GF-130-I...

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