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Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual
6.12 SAFETY PRESSURE RELIEF VALVE TEST ................................................................................. 89
CHAPTER 7. MAINTENANCE .................................................................................................................. 91
7.1 MAINTENANCE SCHEDULE ............................................................................................................ 91
7.2 IGNITER-INJECTOR ......................................................................................................................... 91
7.3 FLAME DETECTOR .......................................................................................................................... 94
7.4 O
SENSOR ...................................................................................................................................... 95
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7.5 SAFETY DEVICE TESTING ............................................................................................................. 95
7.6 BURNER ASSEMBLY INSPECTION ................................................................................................ 96
7.7 CONDENSATE DRAIN TRAP ........................................................................................................... 99
7.8 AIR FILTER CLEANING & REPLACEMENT .................................................................................. 100
7.9 CABINET EXHAUST FAN INSPECTION & REPLACEMENT ........................................................ 101
7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................... 102
7.11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ................. 102
CHAPTER 8. TROUBLESHOOTING GUIDE .......................................................................................... 103
8.1 INTRODUCTION ............................................................................................................................. 103
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ............................................... 116
CHAPTER 9. RS232 COMMUNICATION ............................................................................................... 119
9.1 INTRODUCTION ............................................................................................................................. 119
9.1.1 Acquiring the PuTTY Application ................................................................................................................................ 119
9.1.2 Logging on to a Remote Machine Using PuTTY ......................................................................................................... 119
9.1.3 Running a Command on a Remote Machine Using PuTTY ........................................................................................ 120
9.2 RS232 COMMUNICATION SETUP ................................................................................................ 121
9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION ...................................................... 121
9.4 DATA LOGGING ............................................................................................................................. 122
9.4.1 Fault Log ..................................................................................................................................................................... 122
9.4.2 Operation Time Log .................................................................................................................................................... 123
9.4.3 Sensor Log .................................................................................................................................................................. 124
CHAPTER 10. BOILER SEQUENCING TECHNOLOGY ....................................................................... 125
10.1 INTRODUCTION ........................................................................................................................... 125
10.2 AERCO BST Quick Start Chart ..................................................................................................... 126
10.3 BST Implementation Instruction .................................................................................................... 127
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor .......................................................... 127
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor ......................................................................... 128
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor ................ 129
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ..................................... 131
10.3.5 Option 5 - Remote Setpoint w/ DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ................................ 133
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive .......................... 134
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive ........................................ 135
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive .................................... 137
APPENDIX A - BOILER MENU ITEM DESCRIPTIONS ................................................................................... 139
APPENDIX B - STARTUP, STATUS & DISPLAY MESSAGES ........................................................................... 147
APPENDIX C - SENSOR RESISTANCE/VOLTAGE CHART .............................................................................. 151
APPENDIX D - BOILER DEFAULT SETTINGS ................................................................................................ 153
APPENDIX E - RECOMMENDED PERIODIC TESTING .................................................................................. 155
APPENDIX F - INDOOR/OUTDOOR RESET RATIO CHARTS ......................................................................... 157
APPENDIX G - DIMENSIONAL DRAWING ................................................................................................... 161
APPENDIX G - CLEARANCE DRAWINGS ..................................................................................................... 162
APPENDIX I - PART LIST DRAWINGS .......................................................................................................... 163
APPENDIX J - WIRING DIAGRAMS ............................................................................................................. 187
APPENDIX K - PIPING DRAWINGS ............................................................................................................. 219
APPENDIX L - C-MORE CONTROL PANEL VIEWS ....................................................................................... 227
APPENDIX M - RECOMMENDED SPARES ................................................................................................... 229
OMM-0099_0A
GF-145
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 5 of 234
PR1: 05/21/2014
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