Aerco BENCHMARK 2500DF User Manual
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Aerco BENCHMARK 2500DF User Manual

Dual fuel gas-fired boiler
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Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual
BENCHMARK
2500DF – 3000DF
Modulating & Condensing
Dual Fuel Gas-Fired Boiler
Hot Water Boiler
USER MANUAL
Installation, Operation and Maintenance
Applicable to Serial Numbers
G-14-0304 and Above
Latest Update: 05/21/2014
OMM-0099_0A
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 234
GF-145
Ph.: 800-526-0288
PR1: 05/21/2014

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  • Page 1 Hot Water Boiler USER MANUAL Installation, Operation and Maintenance Applicable to Serial Numbers G-14-0304 and Above Latest Update: 05/21/2014 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    3.3.1 Menu Processing Procedure ............................37 3.4 OPERATING MENU .......................... 39 3.5 SETUP MENU ........................... 39 3.6 CONFIGURATION MENU ......................... 40 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 4 6.9 SSOV PROOF OF CLOSURE SWITCH ................... 86 6.10 PURGE SWITCH OPEN DURING PURGE ..................87 6.11 IGNITION SWITCH OPEN DURING IGNITION ................87 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 234 OMM-0099_0A...
  • Page 5 APPENDIX K – PIPING DRAWINGS ......................219 APPENDIX L – C-MORE CONTROL PANEL VIEWS ..................227 APPENDIX M – RECOMMENDED SPARES ....................229 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 5 of 234 GF-145 Ph.: 800-526-0288...
  • Page 6 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 7 FORWARD FOREWORD The AERCO Benchmark (BMK) 2500 & 3000 MBH Dual Fuel Boilers are modulating and condensing boilers. They are a true industry advancement 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 1 pound of water 1° F. Cal. Calibration Combustion Control Panel C-More Controller A control system developed by AERCO and currently used in all Benchmark, (or Control Box) Innovation and KC1000 Series product lines. Carbon Monoxide COMM (Comm)
  • Page 9 A standard for serial, half-duplex (HDX) transmission of data based on the (or EIA-485) RS485 Standard RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 10 Microamp (0.000001 amp), one millionth of an amp Volts, Alternating Current Volts, Direct Current Vacuum Fluorescent Display, or Variable Frequency Drive Watt W.C. Water Column (W.C.) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 11: Chapter 1. Safety Precautions

    In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No.

  • Page 12: Emergency Shutdown

    Chapter 6 of this manual be performed to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream of the unit. The installer must identify the emergency shut-off device.
  • Page 13 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 13 of 234 GF-145 Ph.: 800-526-0288...
  • Page 14 [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 234 OMM-0099_0A...

  • Page 15: Chapter 2. Installation

    NOTE AERCO is not responsible for lost or damaged freight. Each unit has a Tip-N-Tell indicator on the outside of the crate. This indicates if the unit has been turned on its side during shipment.

  • Page 16: Site Preparation

    The unit must be installed with the prescribed clearances for service as shown in Figure 2-1. The minimum clearance dimensions, required by AERCO, are listed below. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements. Minimum acceptable clearances required are as follows: •...

  • Page 17: Setting The Unit

    WARNING! When lifting or moving the boiler: do not attempt to manipulate the boiler using the gas train or blower. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 18: Supply And Return Piping

    HOT WATER OUTLET (SUPPLY) AIR INLET PRIMARY WATER INLET (RETURN) EXHAUST MANIFOLD CONDENSATE DRAIN DRAIN VALVE Figure 2-3: Supply and Return Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 19: Pressure Relief Valve Installation

    (P/N 24060) which is packed separately within the unit’s shipping container. The condensate trap outlet connection features a tapped 3/4” NPT drain port. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 234 GF-145 Ph.: 800-526-0288...
  • Page 20 The base of the condensate trap must be supported to ensure that it is level (horizontal). • The trap must be removable for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port.

  • Page 21: Gas Supply Piping

    ASSEMBLY. Figure 2-6: Sample Condensate Trap Installation (Right Side View) 2.8 GAS SUPPLY PIPING The AERCO Benchmark 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 22: Gas Supply Specifications

    Figure 2-7, is highly recommended. No regulator is required for gas pressures below 7” W.C. of pressure. Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 234 OMM-0099_0A...

  • Page 23: Ac Electrical Power Wiring

    Figure 2-7: Manual Gas Shut-Off Valve Location 2.9 AC ELECTRICAL POWER WIRING The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to connecting any AC power wiring to the unit. External AC power connections are made to the unit inside the Power Box, which is located on the upper right front of the unit (Figure 2-8).

  • Page 24: Electrical Power Requirements

    AC power connections and the amperage rating of the unit is provided on the front cover of the Power Box as shown in Figure 2-10. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 234...

  • Page 25: Field Control Wiring

    National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code. For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF-2060). 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.
  • Page 26 DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 27: Outdoor Air In (Out) & Air Sensor Common (Com)

    “to view only” input that can be seen in the operating menu. The sensor is an AERCO BALCO wire sensor P/N 12449. A resistance chart for this sensor is provided in APPENDIX C. This sensor is an active part of the combustion control system and must be operational for accurate air/fuel mixing control.

  • Page 28: O 2 Sensor (O2+ & O2-)

    0 to 20 mA / 0 to 5 VDC using the Configuration Menu described in Chapter 3. If voltage rather than current is selected as the drive signal, a DIP switch must be set on the PMC Board located inside the C-More Control Box. Contact the AERCO factory for information on setting DIP switches.

  • Page 29: Rs485 Comm (+, Gnd, & -)

    2.10.9 RS485 Comm (+, GND, & -) The RS485 communication terminals are used when the boiler plant is being controlled by an Energy Management System (EMS) or an AERCO Control System (ACS) using Modbus (RS485) communication. 2.10.10 RS232 Comm (TxD & RxD) The RS232 communication terminals permit a laptop computer or other suitable terminal to be connected to the boiler.

  • Page 30: Auxiliary Relay Contacts (Nc, Com, & No)

    AUXILLIARY RELAY terminals for wiring connections. 2.11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-2050 must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification.

  • Page 31: Combustion From Outside The Building

    All Benchmark units are shipped with a connection for an optional motorized external sequencing 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. BST allows sites with multiple boilers to have one boiler, acting as a “master”...
  • Page 32 Figure 2-14: Sequencing Valve Installed Remove the jumper wire from the Molex connector and then plug it into the sequencing valve’s connector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 32 of 234 OMM-0099_0A 05/21/2014...

  • Page 33: Chapter 3. Operation

    These operating controls, indicators and displays are listed and described in Table 3-1. Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this Chapter. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 33 of 234 GF-145 Ph.: 800-526-0288...
  • Page 34 DB9 connector for connection to older computers with serial ports or can be used with a Serial-to-USB adaptor for use in modern computer USB ports. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 234 OMM-0099_0A...
  • Page 35 • BST Messages Port permits a Laptop Computer or External Modem to be connected to the unit’s Control Panel. AERCO offers for purchase the RS232 Adaptor Cable (P/N 124675), which is designed to work with this RS-232 Port port. This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial-to-USB adaptor for use in modern computer USB ports.
  • Page 36 20 segment red LED bargraph continuously shows the VALVE POSITION Air/Fuel Valve position in 5% increments from 0 to 100%. Bargraph AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 37: Control Panel Menus

    The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 37 of 234 GF-145 Ph.: 800-526-0288...
  • Page 38 Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 39: Operating Menu

    RS-232 port. A view-only software version display is also provided to indicate the current Control Box software version. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 39 of 234 GF-145 Ph.: 800-526-0288...

  • Page 40: Configuration Menu

    The Configuration Menu settings shown in Table 3-4 are Factory- Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 234 OMM-0099_0A 05/21/2014...
  • Page 41 *NOTE The Bldg Ref Temp and Reset Ratio Menu Items are only displayed when the Outdoor Sensor is set to “Enabled”. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 234 GF-145 Ph.: 800-526-0288...

  • Page 42: Tuning Menu

    Warmup Int Gain 2.00 0.50 Warmup PID timer 0 sec. 240 sec. 20 sec. Reset Defaults? Yes, No, Are You Sure? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 43: Combustion Cal Menu

    Monitor Blower Output Voltage Set Stdby Volt 0.0 V Set Stdby Volt 0.0 V Oxygen Level Variable Oxygen Level Variable OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 43 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 44: Bst (Boiler Sequencing Technology) Menu

    Remote Setpoint Outdoor Reset Constant Setpt Head Temp Source Network FFWD Temp FFWD Temp Header Temp Addr Header Temp Point AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 45 BST Setpt HI Limit 60°F BST Setpt HI Limit BST Setpt Lo Limit 220°F 195°F BST Prop Band 1°F 120°F 100°F OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 45 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 46: Start Sequence

    Also, the appropriate messages will be displayed throughout the start sequence, if the required conditions are not observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 234 OMM-0099_0A...
  • Page 47 The Air/Fuel Valve rotates to the full-open purge position and closes purge position switch. The dial on the Air/Fuel Valve (Figure 3-4) will read 100 to indicate that it is full-open (100%). OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 47 of 234 GF-145 Ph.: 800-526-0288...
  • Page 48 OUTLET TO BLOWER BLOWER PROOF SWITCH AIR/FUEL VALVE INLET FROM GAS TRAIN BLOCKED INLET SWITCH Figure 3-5: Blower Proof Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 49 Once the demand for heat has been satisfied, the Control Box will turn off the SSOV gas valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will be displayed. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 234 GF-145 Ph.: 800-526-0288...

  • Page 50: Start/Stop Levels

    (BTU/Hr) (% of Full Capacity) 18% (Stop Level) 200,000 6.7% 520,000 920,000 1,270,000 1,570,000 1,960,000 2,330,000 2,700,000 100% 3,000,000 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 51 Position (% Open) (BTU/Hr) 18% (Stop Level) 155,000 6.2% 400,000 808,000 1,055,000 1,330,000 1,671,000 1,998,000 2,280,000 100% 2,500,000 100% OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 51 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 52 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 53: Chapter 4. Initial Start-Up

    Testing procedures specified in Chapter 6 to complete all initial unit start-up requirements. An AERCO Gas Fired Startup Sheet, included with each Benchmark, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO via e-mail at: STARTUP@AERCO.COM...

  • Page 54: Installing Gas Supply Manometer

    (Install manometer here for PROPANE combustion calibration) Figure 4-1: 1/4 Inch Gas Port Locations for Combustion Calibration (BMK 3000DF DBB Gas Train Pictured) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 55: Accessing The Analyzer Probe Port

    WATER INLET DRAIN VALVE EXHAST MANIFOLD ANALYZER PORT CONDENSATE DRAIN Figure 4-2: Analyzer Probe Port Location (Right Side Partial View) OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 55 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 56: Natural Gas Combustion Calibration

    Combustion Calibration Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation. It is important to perform the following procedure as outlined. This will keep readjustments to a...
  • Page 57 1% higher than the listed calibration range. Record the increased O value on the Combustion Calibration sheet. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 57 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 58 1% higher than the listed calibration range shown in the table. Record the increased O value on the Combustion Calibration sheet. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 234 OMM-0099_0A 05/21/2014...
  • Page 59 29. This completes the NATURAL GAS combustion calibration procedures. TAC VALVE IDLE SCREW Figure 4-4: TAC Valve Adjust (Idle Screw) OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 60: Propane Gas Combustion Calibration

    BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw) Figure 4-5: Gas Pressure Adjustment Screw Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...
  • Page 61 1% higher than the listed calibration range. Record the increased O value on the Combustion Calibration sheet. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 61 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 62 1% higher than the listed calibration range shown in the table. Record the increased O value on the Combustion Calibration sheet. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 234 OMM-0099_0A 05/21/2014...

  • Page 63: Reassembly

    5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold. Replace the 1/8” NPT plug in the manifold. 6. Replace all previously removed sheet metal enclosures on the unit. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 63 of 234 GF-145 Ph.: 800-526-0288...

  • Page 64: Dual-Fuel Switchover Instructions

    18. Press the ENTER key to store the Propane Fuel type. 19. Replace the front door panel. 20. This completes the steps necessary to switch from Natural Gas to Propane Gas operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 234 OMM-0099_0A 05/21/2014...

  • Page 65: Switchover From Propane To Natural Gas

    14. Next, access the Configuration Menu by pressing the MENU key once. 15. Using the ▲ and ▼ arrow keys, scroll through the Configuration Menu and stop at Fuel Type. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 65 of 234 GF-145 Ph.: 800-526-0288...

  • Page 66: Over-Temperature Limit Switches

    The digital 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 4-8 and Table 4-1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 234...
  • Page 67 Access code value 0 should appear in the display. The switch comes from the factory with the code set at 0. AERCO recommends that you do not change this code. Press the SET button again to enter the code. The first parameter label (SP) will appear in the display.
  • Page 68 Once the programming mode has been exited, the display will show the current outlet water temperature of the boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 234 OMM-0099_0A...

  • Page 69: Chapter 5. Mode Of Operation

    2. Choose the chart corresponding to the desired Building Reference Temperature. 3. Go down the left column of the chart to the coldest design outdoor air temperature expected in your area. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 69 of 234 GF-145 Ph.: 800-526-0288...

  • Page 70: Constant Setpoint Mode

    Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted. For descriptions of temperature-related functions and their factory defaults, see Appendices A and E.

  • Page 71: Remote Setpoint Field Wiring

    While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions and their factory defaults, refer to Appendices A and E.

  • Page 72: Direct Drive Modes

    To change back to the Direct Drive mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 234...

  • Page 73: Aerco Control System (Acs)

    ACS can utilize only RS485 signaling to the Boiler. The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible. For this mode of operation, an ACS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant's supply water header.

  • Page 74: Combination Control System Field Wiring

    That water is then circulated through a heat exchanger in a domestic hot water storage tank. Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay Panel is required in...
  • Page 75 These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Appendix E.
  • Page 76 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 77: Chapter 6. Safety Device Testing

    24 volts AC. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 77 of 234 GF-145 Ph.: 800-526-0288...

  • Page 78: Low Gas Pressure Fault Test

    • BMK2500 DF = Approx. 7.5” W.C. for Natural Gas and 3.6” W.C. for Propane Gas. The FAULT indicator should also start flashing. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 234 OMM-0099_0A 05/21/2014...

  • Page 79: High Gas Pressure Test

    PROPANE GAS high gas pressure fault test) Figure 6-1B: High Gas Pressure Test (BMK 3000DF DBB Gas Train Pictured) OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 79 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 80: Low Water Level Fault Test

    If the unit does start, shut the unit off immediately and refer fault to qualified service personnel. 7. Close the drain and pressure relief valve used in draining the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 234 OMM-0099_0A...

  • Page 81: Water Temperature Fault Test

    FUEL SELECTOR SWITCH C-MORE CONTROLER PARTIAL FRONT VIEW WITH FRONT DOOR REMOVED Figure 6-2: Temperature Limit Switch Location and Setting OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 81 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 82: Interlock Tests

    5. Reconnect the wire or jumper removed in step 3 to restore the interlock. 6. Press the CLEAR button to reset the fault 7. The unit should start. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 234 OMM-0099_0A...

  • Page 83: Flame Fault Tests

    BLOCKED INLET SWITCH MANUAL GAS SHUT-OFF VALVE AIR FILTER Figure 6-3: Bare Boiler – Partial View (BMK 3000DF Pictured) OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 83 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 84: Air Flow Fault Tests

    (see Figure 6.4, below). For units that have an air filter in place of a Combustion Air Duct (not shown), remove the air filter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 234...
  • Page 85 9. Remove the jumper wires installed in step 2 and replace the black connector boot on the Flame Detector. 10. Press the CLEAR button. The unit should restart. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 85 of 234 GF-145 Ph.: 800-526-0288...

  • Page 86: Ssov Proof Of Closure Switch

    10. The unit should shut down and display SSOV FAULT DURING PURGE. 11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 234...

  • Page 87: Purge Switch Open During Purge

    4. Remove one of the two wires (#169 or #170) from the Ignition Switch (Figure 6-7). OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 87 of 234 GF-145 Ph.: 800-526-0288...
  • Page 88 PROOF SWITCH AIR/FUEL VALVE COVER (Rotate Counter-Clock-Wise to Remove) AIR/FUEL VALVE BLOCKED INLET SWITCH Figure 6-6: Air/Fuel Valve Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 89: Safety Pressure Relief Valve Test

    6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 234 GF-145 Ph.: 800-526-0288...

  • Page 91: Chapter 7. Maintenance

    Figure 7-1 shows the complete burner assembly OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 234 GF-145 Ph.: 800-526-0288...
  • Page 92 Disconnect the staged ignition assembly from the igniter-injector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 234 OMM-0099_0A...
  • Page 93 Refer to Chapter 4 for combustion calibration procedures. 9. Prior to reinstalling the igniter-injector, a high temperature, conductive, anti-seize com- pound must be applied to the threads. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 93 of 234 GF-145 Ph.: 800-526-0288...

  • Page 94: Flame Detector

    2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 234...

  • Page 95: Sensor

    Test schedules must conform to local jurisdictions. The results of the tests should be recorded in a log book. See Chapter 6-Safety Device Testing Procedures. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 95 of 234 GF-145 Ph.: 800-526-0288...

  • Page 96: Burner Assembly Inspection

    11. Remove the eight (8) 3/8-16 nuts, using a 9/16” (or 11/16”) wrench, attaching the blower plenum to the burner beneath (see Figure 7-4a and 7-4b). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 234...
  • Page 97 16. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 234 GF-145 Ph.: 800-526-0288...
  • Page 98 Nuts (8) 5/16” X 1-3/4” BOLTS, WASHERS, & NYLOCK AIR/FUEL VALVE WASHERS (4) AIR FILTER Figure 7-4b: Burner Assembly Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 99: Condensate Drain Trap

    4. Remove the float from the condensate trap. 5. Remove the O-ring from the trap. AERCO recommends that these items be replaced annually. 6. Thoroughly clean the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap.

  • Page 100: Air Filter Cleaning & Replacement

    5/16” nut driver. 7. Replace the top shroud on the unit and return boiler to service use. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 234 OMM-0099_0A...

  • Page 101: Cabinet Exhaust Fan Inspection & Replacement

    12V CABINET EXHAUST FAN FRONT-LEFT VIEW Figure 7-8: Cabinet Exhaust Fan Location OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 101 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 102: Shutting The Boiler Down For An Extended Period Of Time

    4. Perform initial startup per Chapter 4. 5. Perform safety device testing and scheduled maintenance procedures per Chapters 6 and 7 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 234 OMM-0099_0A...

  • Page 103: Chapter 8. Troubleshooting Guide

    If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 103 of 234 GF-145 Ph.: 800-526-0288...
  • Page 104 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 105 Hard light. Check igniter-injector for soot or erosion of electrode. Check injector solenoid valve to insure proper open/close operation. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 105 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 106 6. See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT 6. PROBABLE CAUSES from 3 to 16 for DURING IGNITION. AIRFLOW FAULT DURING IGNITION applies for this fault. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...
  • Page 107 120VAC at the valve input terminals. If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 234 GF-145 Ph.: 800-526-0288...
  • Page 108 2. Carboned heat exchanger due to 2. If exhaust temperature is greater than 200 F, check combustion incorrect combustion calibration calibration. Calibrate or repair as necessary. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...
  • Page 109 1. Press CLEAR button and restart unit. If fault persists, contact qualified IGN BOARD between the PMC board and Service Personnel. COMM FAULT Ignition/Stepper (IGST) board OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 109 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 110 4. Defective IGST Board 4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 234 OMM-0099_0A...
  • Page 111 Unit seeing information from Check network connections. If fault persists, contact qualified Service MODBUS COMMFAULT Modbus network Personnel. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 112 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. 3. Incorrect Sensor. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 234 OMM-0099_0A 05/21/2014...
  • Page 113 Install a manometer or gauge at the leak detection port between the SSOV and Gas Shut Off Valve. If a gas pressure reading is observed replace the SSOV Valve and/or Actuator. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 113 of 234 GF-145 Ph.: 800-526-0288...
  • Page 114 4. Incorrectly wired switch. 4. Ensure that the SSOV Proof of Closure switch is correctly wired. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 234 OMM-0099_0A...
  • Page 115 6. Defective IGST Board 6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 234 GF-145 Ph.: 800-526-0288...

  • Page 116: Additional Faults Without Specific Fault Messages

    1. Check to ensure that the IGST and Power Supply Boards are 80% Valve Position Control Box are outdated. Rev. E or higher. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 234 OMM-0099_0A 05/21/2014...
  • Page 117 BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). Figure 8-2: SSOV Actuator With Gas Pressure Adjustment OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 117 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 118 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 119: Chapter 9. Rs232 Communication

    For further configuration options (data bits, stop bits, parity, flow control), you can use the Serial Configuration panel (right image in Figure 9-1) by selecting “Serial” in the left navigation pane. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 119 of 234 GF-145 Ph.: 800-526-0288...

  • Page 120: Running A Command On A Remote Machine Using Putty

    Open button at the bottom of the dialog. 6. You will have to provide an account name and password in the terminal window to complete the process. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 234 OMM-0099_0A...

  • Page 121: Rs232 Communication Setup

    3. At the prompt, enter the valid RS232 password (jaguar) in lower case letters and press Enter. 4. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices: M = Display next Menu...

  • Page 122: Data Logging

    T and press Enter. To go back 200 or 1000 records, enter T200 or T1000, etc. and press Enter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 234 OMM-0099_0A...

  • Page 123: Operation Time Log

    S and press Enter. To go back 200 or 700 records, enter S200 or S700, etc. and press Enter. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 123 of 234 GF-145 Ph.: 800-526-0288...

  • Page 124: Sensor Log

    0 1/15/02 5:16pm 179 OPEN OPEN OPEN OPEN OPEN 0 1/15/02 5:11pm 180 OPEN OPEN OPEN OPEN OPEN 0 1/15/02 5:06pm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 125: Chapter 10. Boiler Sequencing Technology

    Next On VP (% valve position), the BST master will light off the next available unit. A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 9-1 below. Figure 10-1. Simplified BST Block Diagram OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 125 of 234 GF-145 Ph.: 800-526-0288...

  • Page 126: Aerco Bst Quick Start Chart

    Option 7 – 4-20ma Drive AND Modbus Header Complete section 10.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 10.3.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 127: Bst Implementation Instruction

    10.3.1 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 (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...

  • Page 128: 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 (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.

  • Page 129: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1 - Direct Wired Header Sensor Wiring 1. On the MASTER Unit, connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...
  • Page 130 When ALL C-More units have been configured: 9. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 234...

  • Page 131: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    Step 1 - Modbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 132 When ALL C-More units have been configured: 13. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 234...

  • Page 133: Option 5 - Remote Setpoint W/ Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...

  • Page 134: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 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 135: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Step 1: MODbus Header Sensor 1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 136 When ALL C-More units have been configured: 9. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 234...

  • Page 137: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Step 1: MODbus Header Sensor 1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 138 Benchmark 2500DF-3000DF CHAPTER 10. BOILER SEQUENCING TECHNOLOGY (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 139: Appendix A - Boiler Menu Item Descriptions

    Displays total run time of unit in hours from 0 to 9,999,999. Fault Log Displays information on the last 20 faults. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 139 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 140 Allows selection of KC Boiler, KC Boiler LN, BMK Boiler Std, BMK Blr Std Dual, BMK Boiler LN, BMK Blr LN Dual, KC Water Heater, KC Wtr Heater LN, Innovation WH AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 234 OMM-0099_0A...
  • Page 141 Specifies the amount of time (0 to 30 min.) to keep the pump running after the unit turns off. Default is zero. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 141 of 234 GF-145 Ph.: 800-526-0288...
  • Page 142 Start Level value. There will not be a one minute delay when firing at the 29% Valve Position level. Setting range is 0 to 25. (Default is 10) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 234 OMM-0099_0A...
  • Page 143 Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature. Span is 40% to 100%, Default is 60%. OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 143 of 234 GF-145 Ph.: 800-526-0288...
  • Page 144 Range = 1-240 Default = 20 Reset Defaults? Allows Tuning Menu options to be reset to their Factory Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 145 Set Stby V out 4.00 Volts. Permits the combustion oxygen level to be Oxygen Level displayed (0% to 25%) OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 145 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 146 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 147: Appendix B - Startup, Status & Display Messages

    WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 147 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 148 INTERLOCK The Remote Interlock is open. OPEN LINE VOLTAGE The Line (Hot) and Neutral wires are reversed. OUT OF PHASE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 149 A failure has been detected in one of the relays that control the SSOV. FAILURE STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to the desired position. FAILURE OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 149 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 150 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 151: Appendix C - Sensor Resistance/Voltage Chart

    2.41 1209.5 2.43 1234.7 2.45 1260.0 2.47 1285.6 2.50 1311.4 2.52 1337.7 2.54 1364.2 2.56 1391.0 2.58 1418.2 1445.7 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 151 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 152 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 153: Appendix D - Boiler Default Settings

    Valve Position 0-10V Analog Output CAUTION: DO NOT Change Lo Fire Timer 2 sec Table E-1: Boiler Default Settings Continued – OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 153 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 154 Hi DB Setpt En Demand Offset Deadband High Deadband Low Tuning Menu Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 155: Appendix E - Recommended Periodic Testing

    See section 7.7 Annually Verify oxygen level is between 3% and 8% during Oxygen (O ) Level Monthly Operator boiler operation OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 155 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 156 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX E: RECOMMENDED PERIODIC TESTING (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 157: Appendix F - Indoor/Outdoor Reset Ratio Charts

    -15F -20F Table F-2: Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp -10F -15F -20F OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 157 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 158 RESET RATIO Temp Table F-4: Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 159 RESET RATIO Temp -10F -15F Table F-6: Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 159 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 160 APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-7: Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 161: Appendix G - Dimensional Drawing

    Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G: DIMENSIONAL DRAWING APPENDIX G – DIMENSIONAL DRAWING Drawing Number: AP-A-900 rev C OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 161 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...

  • Page 162: Appendix G - Clearance Drawings

    Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G: CLEARANCE DRAWINGS APPENDIX G – CLEARANCE DRAWINGS Drawing Number: SD-A-898 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288...

  • Page 163: Appendix I - Part List Drawings

    Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 1 of 8 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 163 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 164 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 2 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 165 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 3 of 8 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 165 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 166 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 4 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 167 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 5 of 8 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 167 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 168 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 6 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 169 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 7 of 8 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 169 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 170 Benchmark 2500DF – 3000DF Part List AERCO 02/10/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-5 – 28382-5 Sheet 8 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 171 Benchmark 3000 DF FM Gas Train AERCO 07/15/2013 Natural Gas International, Inc. Blauvelt, NY 10913 Sheet 1 of 2 22177 rev C OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 171 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 172 Benchmark 3000 DF FM Gas Train AERCO 07/15/2013 Natural Gas International, Inc. Blauvelt, NY 10913 Sheet 2 of 2 22177 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 173 Benchmark 3000 DF DBB Gas Train AERCO 07/15/2013 Natural Gas International, Inc. Blauvelt, NY 10913 Sheet 1 of 2 22177-1 rev C OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 173 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 174 Benchmark 3000 DF DBB Gas Train AERCO 07/15/2013 Natural Gas International, Inc. Blauvelt, NY 10913 Sheet 2 of 2 22177-1 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 175 Benchmark 3000 DF FM Gas Train AERCO 07/15/2013 Propane International, Inc. Blauvelt, NY 10913 22178 rev C Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 175 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 176 Benchmark 3000 DF FM Gas Train AERCO 07/15/2013 Propane International, Inc. Blauvelt, NY 10913 22178 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 177 Benchmark 3000 DF DBB Gas Train AERCO 07/15/2013 Propane International, Inc. Blauvelt, NY 10913 22178-1 rev C Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 177 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 178 Benchmark 3000 DF DBB Gas Train AERCO 07/15/2013 Propane International, Inc. Blauvelt, NY 10913 22178-1 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 179 Benchmark 2500 DF FM Gas Train AERCO 12/17/2013 Natural Gas International, Inc. Blauvelt, NY 10913 22210-1 rev A Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 179 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 180 Benchmark 2500 DF FM Gas Train AERCO 12/17/2013 Natural Gas International, Inc. Blauvelt, NY 10913 22210-1 rev A Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 181 Benchmark 2500 DF FM Gas Train AERCO 12/17/2013 PROPANE International, Inc. Blauvelt, NY 10913 22210-2 rev A Sheet 1 of 1 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 181 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 182 Benchmark 2500 DF DBB Gas Train AERCO 12/17/2013 NATURAL GAS International, Inc. Blauvelt, NY 10913 22209-1 rev A Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 183 Benchmark 2500 DF DBB Gas Train AERCO 12/17/2013 NATURAL GAS International, Inc. Blauvelt, NY 10913 22209-1 rev A Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 183 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 184 Benchmark 2500 DF DBB Gas Train AERCO 12/17/2013 PROPANE International, Inc. Blauvelt, NY 10913 22209-2 rev A Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 185 Benchmark 2500 DF DBB Gas Train AERCO 12/17/2013 PROPANE International, Inc. Blauvelt, NY 10913 22209-2 rev A Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 185 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 186 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX I – PART LIST DRAWINGS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 187: Appendix J - Wiring Diagrams

    APPENDIX G – WIRING DIAGRAMS APPENDIX J – WIRING DIAGRAMS Drawing Number: 68044 rev C, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 187 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 188 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 189 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68044 rev C, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 189 of 234 GF-145 Ph.: 800-526-0288...
  • Page 190 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 190 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 191 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68045 rev C, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 191 of 234 GF-145 Ph.: 800-526-0288...
  • Page 192 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 193 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68045 rev C, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 193 of 234 GF-145 Ph.: 800-526-0288...
  • Page 194 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 194 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 195 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68046 rev B, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 195 of 234 GF-145 Ph.: 800-526-0288...
  • Page 196 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 196 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 197 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68046 rev B, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 197 of 234 GF-145 Ph.: 800-526-0288...
  • Page 198 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 198 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 199 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68047 rev B, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 199 of 234 GF-145 Ph.: 800-526-0288...
  • Page 200 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 200 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 201 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68047 rev B, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 201 of 234 GF-145 Ph.: 800-526-0288...
  • Page 202 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 202 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 203 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68073 rev B, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 203 of 234 GF-145 Ph.: 800-526-0288...
  • Page 204 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 204 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 205 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68073 rev B, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 205 of 234 GF-145 Ph.: 800-526-0288...
  • Page 206 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 206 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 207 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68067 rev B, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 207 of 234 GF-145 Ph.: 800-526-0288...
  • Page 208 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 208 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 209 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68067 rev B, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 209 of 234 GF-145 Ph.: 800-526-0288...
  • Page 210 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 210 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 211 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68066 rev B, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 211 of 234 GF-145 Ph.: 800-526-0288...
  • Page 212 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 212 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 213 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68066 rev B, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 213 of 234 GF-145 Ph.: 800-526-0288...
  • Page 214 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 214 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 215 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68072 rev B, Sheet 1 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 215 of 234 GF-145 Ph.: 800-526-0288...
  • Page 216 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 216 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 217 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX G – WIRING DIAGRAMS Drawing Number: 68072 rev B, Sheet 2 of 2 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 217 of 234 GF-145 Ph.: 800-526-0288...
  • Page 218 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX J – WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 218 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 219: Appendix K - Piping Drawings

    Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS APPENDIX K – PIPING DRAWINGS Drawing Number: SD-A-957 rev A OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 219 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 220 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS Drawing Number: SD-A-958 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 220 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 221 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS Drawing Number: SD-A-959 rev A OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 221 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 222 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS Drawing Number: SD-A-960 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 222 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 223 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS Drawing Number: SD-A-961 rev A OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 223 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 224 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS Drawing Number: SD-A-962 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 224 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 225 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS Drawing Number: SD-A-963 rev A OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 225 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 226 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX K: PIPING DRAWINGS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 226 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 227: Appendix L - C-More Control Panel Views

    P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 BENCHMARK CONTROL PANEL EXPLODED VIEW Figure L-1: Benchmark Control Panel Exploded View OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 227 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 228 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure L-2: Benchmark Control Panel Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 228 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

  • Page 229: Appendix M - Recommended Spares

    Table M-3: Optional Spare Parts DESCRIPTION PART NUMBER C-More Control Box 181197 46038 (BMK3000 DF) Burner 46039 (BMK2500 DF) Lean Oxygen Sensor 61026 OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 229 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 230 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual APPENDIX M– RECOMMENDED SPARES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 230 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...
  • Page 231 ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ______________________________________________________________________________ ____________________________________________________________________________ OMM-0099_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 233 of 234 GF-145 Ph.: 800-526-0288 PR1: 05/21/2014...
  • Page 232 Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual Change Log Date Description Changed By 5/21/2014 Rev-A: Initial release. Curtis Harvey © AERCO International, Inc., 2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 234 of 234 OMM-0099_0A 05/21/2014 Phone: 800-526-0288 GF-145...

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