Aerco GF-116 Installation, Operation & Maintenance Instructions Manual
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Aerco GF-116 Installation, Operation & Maintenance Instructions Manual

Benchmark 3.0ln series gas fired low nox boiler system
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Instruction
GF-116
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
Benchmark 3.0LN
Series
Gas Fired
Low NOx
Boiler System
Condensing, Modulating
Forced Draft, Hot Water Boiler
3,000,000 BTU/H Input
Applicable for Serial Numbers G-06-1069 and above
REVISED JANUARY, 2009
Printed in U.S.A.

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  • Page 1 Instruction GF-116 AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions Benchmark 3.0LN Series Gas Fired Low NOx Boiler System Condensing, Modulating Forced Draft, Hot Water Boiler 3,000,000 BTU/H Input Applicable for Serial Numbers G-06-1069 and above REVISED JANUARY, 2009 Printed in U.S.A.
  • Page 2 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. AERCO International is not liable...

  • Page 3: Table Of Contents

    CONTENTS GF-116 - AERCO BENCHMARK 3.0LN GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions FOREWORD Chapter 1 – SAFETY PRECAUTIONS Para. Subject Page Para. Subject Page Warnings & Cautions Prolonged Shutdown Emergency Shutdown Chapter 2 – INSTALLATION Para. Subject Page Para.
  • Page 4 CONTENTS Chapter 5 – MODE OF OPERATION Para. Subject Page Para. Subject Page Introduction Boiler Management System Indoor/Outdoor Reset Mode (BMS) Constant Setpoint Mode Combination Control System Remote Setpoint Mode (CCS) Direct Drive Modes Chapter 6 – SAFETY DEVICE TESTING PROCEDURES Para.
  • Page 5 CONTENTS APPENDICES Subject Page Subject Page Boiler Menu Item Descriptions Piping Drawings Startup, Status and Fault Wiring Schematics Messages Recommended Periodic Testing Temperature Sensor Resistance Checklist Chart Benchmark Control Panel Views Indoor/Outdoor Reset Ratio Natural Gas Combustion Charts Calibration Procedure for Unit Boiler Default Settings Serial Nos.
  • Page 7 FOREWORD Foreword The AERCO Benchmark 3.0LN Boiler is a modulating unit. It represents a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.

  • Page 9: Warnings & Cautions

    LEAKS. precautions included in these instructions. addition to all the requirements included in this WARNING! AERCO Instruction Manual, the installation of FLUIDS UNDER PRESSURE MAY units MUST conform with local building codes, CAUSE INJURY TO PERSONNEL or, in the absence of local codes, ANSI Z223.1...

  • Page 10: Emergency Shutdown

    IMPORTANT turn off the electrical power supply to the The Installer must identify and indicate AERCO boiler and close the manual gas valve the location of the emergency shutdown located upstream the unit. The installer is to manual gas valve to operating personnel.

  • Page 11: Introduction

    This Chapter provides the descriptions and • Spare Spark Igniter procedures necessary to unpack, inspect and • Spare Flame Detector install the AERCO Benchmark 3.0 Boiler. Brief descriptions are also provided for each available • ASME Pressure Relief Valve mode of operation. Detailed procedures for •...
  • Page 12 INSTALLATION Figure 2-1 Benchmark 3.0 Boiler Clearances WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS FLAMMABLE VAPORS OR LIQUIDS CAUTION While packaged shipping container, the boiler must be moved by pallet jack or forklift from the FRONT ONLY.

  • Page 13: Supply And Return Piping

    INSTALLATION 2.4.3 Removal of Support Rod Prior to installation of water supply and return piping, the 24” threaded rod shown in Figure 2-3 must be removed. This rod is installed prior to shipment from the factory to prevent damage to the insulated metal flex hose on the hot water supply outlet of the boiler.

  • Page 14: Condensate Trap Installation

    INSTALLATION NOTE The condensate trap described in the following steps can be installed on the EXHAUST MANIFOLD floor behind the unit as shown in Figure 2- 6. There will be sufficient downward slope from the drain pipe to the trap inlet to drain the condensate by gravity.

  • Page 15: Gas Supply Piping

    2.7 GAS SUPPLY PIPING 2.7.1 Gas Supply Specification Benchmark 3.0 The gas supply input specifications to the unit The AERCO Gas Components for Natural Gas are as follows: and Supply Design Guide, GF-3030 must be consulted prior to designing or installing any gas The maximum static pressure to the unit must supply piping.

  • Page 16: Ac Electrical Power Wiring

    INSTALLATION 2.8.1 Electrical Power Requirements 2.7.3 IRI Gas Train Kit The AERCO Benchmark 3.0 Boiler is available The IRI gas train is an optional gas train in two different AC power configurations: configuration which is required in some areas for code compliance or for insurance purposes.
  • Page 17 INSTALLATION 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 3.0 Boiler is available in several different modes of operation. While each unit is factory configured and wired for its intended mode, some additional field wiring may be required to complete the installation. This wiring is typically connected to the Input/Output (I/O) Box located on the lower portion of the unit front panel (Figure 2-10) behind the removable front...
  • Page 18 RS485 COMM terminals on the I/O Box terminal strip. Polarity must be maintained and the shield CAUTION must be connected only at the AERCO BMS. The boiler end of the shield must be left floating. DO NOT make any connections to the...
  • Page 19 AUX SENSOR IN and SENSOR These terminals provide a 4 to 20 mA output to COMMON terminals and must be similar to the VFD to control the rotational speed of the AERCO BALCO wire sensor Part No. 12449. A blower. This function...
  • Page 20 U/L listed, position. positive pressure, watertight vent materials as specified in AERCO’s GF-3050, must be used for safety and code compliance. Since the unit is 2.10.9.2 DELAYED INTERLOCK IN capable of discharging low temperature exhaust...
  • Page 21 2.13.3 Sealed Combustion The AERCO Benchmark 3.0 Boiler is UL listed The AERCO Benchmark 3.0 Boiler is UL listed for 100% sealed combustion. It can also be 100%-sealed combustion.

  • Page 23: Introduction

    CONTROL PANEL OPERATING PROCEDURES CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 3.0 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 24 CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION LED Status Indicators Four Status LEDs indicate the current operating status as follows: COMM Lights when RS-232 communication is occurring MANUAL Lights when the unit is being controlled using the front panel keypad.
  • Page 25 CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays – Continued ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION MENU Keypad Consists of 6 keys which provide the following functions for the Control Panel Menus: MENU Steps through the main menu categories shown in Figure 3- 2.

  • Page 26: Control Panel Menus

    CONTROL PANEL OPERATING PROCEDURES around after the first or last available option 3.3 CONTROL PANEL MENUS is reached. The Control Panel incorporates an extensive 6. To change the value or setting of a menu structure which permits the operator to set displayed menu option, press the CHANGE up, and configure the unit.
  • Page 27 CONTROL PANEL OPERATING PROCEDURES time-out after 1 hour. Therefore, the correct 3.4 OPERATING MENU password must be reentered when required. In The Operating Menu displays a number of key addition to permitting password entries, the operating parameters for the unit as listed in Setup Menu is also used to enter date and time, Table 3-2.
  • Page 28 CONTROL PANEL OPERATING PROCEDURES 3.6 CONFIGURATION MENU NOTE The Configuration Menu shown in Table 3-4 The Configuration Menu settings shown in permits adjustment of the Internal Setpoint Table 3-4 are Factory-Set in accordance (Setpt) temperature regardless of whether the with the requirements specified for each valid password has been entered.
  • Page 29 CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Default Failsafe Mode Shutdown or Constant Setpt Shutdown *mA Output Setpoint, Outlet Temp, *Fire Rate (See CAUTION) Fire Rate Out, Off Low Fire Timer 2 sec.
  • Page 30 CONTROL PANEL OPERATING PROCEDURES DIAL (DETAIL “A”) STEPPER MOTOR DETAIL “A” Figure 3-4. Air/Fuel Valve In Purge Position Figure 3-3. SSOV Locations With all required safety device switches closed, a purge cycle will be initiated and the following events will occur: (a) The Blower relay energizes and turns on blower.
  • Page 31 CONTROL PANEL OPERATING PROCEDURES 5. Upon completion of the purge cycle, the DIAL Control Box initiates an ignition cycle and (DETAIL “A”) the following events occur: (a) The Air/Fuel Valve rotates to the low- fire ignition position and closes the ignition switch.
  • Page 33 • Small and large flat blade screwdrivers. An AERCO Gas Fired Startup Sheet, included • Tube of silicone adhesive with each Benchmark Boiler, must be completed for each unit for warranty validation and a copy 4.2.2 Installing Gas Supply Manometer...
  • Page 34 BTU content, gas supply piping and supply regulators. Factory Test Data sheets are shipped with each unit. These sheets must be Figure 4-1. filled out and returned to AERCO for proper 1/8 Inch Gas Plug Location Warranty Validation. It is important to perform the following procedure as outlined.
  • Page 35 INITIAL START-UP 5. Set the unit to the Manual Mode by pressing 11. Raise the firing rate to 100% and verify that the AUTO/MAN key. A flashing Manual Fire the gas pressure downstream of SSOV No. Rate message will be displayed with the 1 remains at 1.8”...
  • Page 36 INITIAL START-UP Figure 4-5 VFD Controls and Displays 17. Press the M (Menu) programming key on the VFD. 18. Using the up (▲) arrow key, select VFD parameter 65. The selected parameter will appear in the left part of the display and the frequency (Hz) will appear in the right part of the display.
  • Page 37 INITIAL START-UP 22. Once the oxygen level is within the specified NOTE range at 70%, lower the firing rate to 50% At a 14% fire rate, if parameter 61 is and select VFD parameter 64. The oxygen above 326, the VFD software will use 326 level at the 50% firing rate should be as default.
  • Page 38 INITIAL START-UP 4.5 OVER-TEMPERATURE LIMIT SWITCHES The unit contains both automatic and manual reset over-temperature limit switches. These switches are mounted on a plate attached to the boiler shell as shown in Figure 4-6. The switches can be accessed by removing the left side panels of the unit.

  • Page 39: Mode Of Operation

    MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5.1 INTRODUCTION 5.2.3 Outdoor Air Temperature Sensor Installation The Benchmark 3.0 Boiler is capable of being operated in any one of six different modes. The The outdoor air temperature sensor must be following paragraphs in this Chapter provide mounted on the North side of the building in an descriptions of each of these operating modes.
  • Page 40 The unit is factory preset with settings PMC Board located in the Control Panel that work well in most applications. Prior to Assembly. Contact your local AERCO changing any temperature-related parameters, representative for details. other than the setpoint, it is suggested that an AERCO representative be contacted.
  • Page 41 4-20 mA/1-5 Vdc applications. It is suggested that an AERCO representative be contacted, prior to changing 0-20 mA/0-5 Vdc any temperature related function settings. For...
  • Page 42 RS485 This mode of operation is factory preset and the Modbus signaling to the Boiler. BMS II AERCO BMS controls the firing rate. There are Model 5R5-384 can utilize only RS485 no setup instructions for each individual unit. signaling to the Boiler.
  • Page 43 When the boiler is switched to BMS mode, the switch over to space heating, their mode of AERCO BMS controls the firing rate. There are operation changes to the BMS mode. For more no setup requirements to the boiler(s) in this information concerning the operation of the mode.

  • Page 45: Chapter 6 Safety Device Testing

    SAFETY DEVICE TESTING CHAPTER 6 SAFETY DEVICE TESTING 4. Place the unit in Manual Mode and adjust 6.1 TESTING OF SAFETY DEVICES the firing rate between 25 and 30%. Periodic safety device testing is required to 5. While the unit is firing, slowly close the ensure that the control system and safety external manual gas shut-off valve.
  • Page 46 SAFETY DEVICE TESTING unit should not start. If the unit does start, 6.3 HIGH GAS PRESSURE TEST shut the unit off immediately and refer fault to qualified service personnel. To simulate a high gas pressure fault, refer to Figure 6-1 and proceed as follows: 7.
  • Page 47 SAFETY DEVICE TESTING that a device such as a pump, gas booster, or louver is operational. 6.6.1 REMOTE INTERLOCK 1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals. 2. Start the unit in the Manual Mode and set the firing rate between 25% and 30%.
  • Page 48 SAFETY DEVICE TESTING 6.8 AIR FLOW FAULT TESTS 3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV) These tests check the operation of the Blower and the Air/Fuel Valve (see Figure 6-3). Proof Switch and Blocked Inlet Switch shown in Figure 6-3.
  • Page 49 SAFETY DEVICE TESTING 8. Set the ON/OFF switch to ON to start the 6.11 IGNITION SWITCH OPEN DURING unit. IGNITION The Ignition Switch (and the Purge Switch) is 9. Remove the wire again when the unit located on the Air/Fuel Valve. To check the reaches the purge cycle and PURGING is switch, proceed as follows: displayed.

  • Page 50: Safety Device Testing

    SAFETY DEVICE TESTING Figure 6-6 Air/Fuel Valve Purge and Ignition Switch Locations 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.

  • Page 51: Chapter 7 Maintenance

    MAINTENANCE CHAPTER 7 MAINTENANCE 5. The igniter is gapped at 1/8-inch. If there is a 7.1 MAINTENANCE SCHEDULE substantial erosion of the spark gap or The unit requires regular routine maintenance to ground electrode, the igniter should be keep up efficiency and reliability. For best replaced.
  • Page 52 MAINTENANCE Table 7-1 - Maintenance Schedule Labor PARAGRAPH ITEM 6 Mos. 12 Mos. 24 Mos. Time Spark *Inspect Inspect Replace 15 mins. Igniter Flame *Inspect Inspect Replace 15 mins. Detector Combustion *Check Check 1 hr. Calibration Testing of See CSD-1 Safety Chart in 20 mins.
  • Page 53 MAINTENANCE 9. Remove the grounding screw. 7.5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating 10. If there is an extension ring around the and safety devices should be performed to burner, remove it. ensure that they are operating as designed. 11.
  • Page 54 MAINTENANCE 7.7 CONDENSATE DRAIN TRAPS Benchmark Boiler contains condensate traps as shown in Figure 2-5. One trap is located external to the unit and attached to the drain pipe from the connecting manifold. The other trap is an integral part of the exhaust manifold.
  • Page 55 MAINTENANCE 7.9 PLACING THE BOILER BACK IN FLUE UNIT SERVICE AFTER A PROLONGED FRAME SHUTDOWN BOLTS After a prolonged shutdown (one year or more), the following procedures must be followed: EXHAUST MANIFOLD 1. Review installation requirements included in Chapter 2. 2.

  • Page 57: Troubleshooting

    Troubleshooting Tables, contact your local AERCO Representative. 1. Observe the fault messages displayed in the Control Box display. 2. Refer to the Fault Indication column in Troubleshooting Table 8-1 which follows and locate the Fault that best describes the...
  • Page 58 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT 1. Blower stopped running due to thermal 1. Check combustion blower for signs of excessive heat or high DURING IGNITION or current overload current drain that may trip thermal or current overload devices. 2.
  • Page 59 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT 1. Blower not running or running too slow 1. Start the unit. If the blower does not run check the blower solid DURING PURGE state relay for input and output voltage. If the relay is okay, check the blower.
  • Page 60 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED 1. Delayed Interlock Jumper not 1. Check for a jumper properly installed across the delayed INTERLOCK OPEN installed or removed. interlock terminals in the I/O box. 2.
  • Page 61 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 7. Defective Differential Pressure 7. Check gas pressure readings using gauge or manometer into Regulator and out of the Air/Fuel Valve to ensure gas is getting to the burner.
  • Page 62 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 3. Defective High Gas Pressure Switch 3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. Replace the switch if it does not show continuity.
  • Page 63 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED 1. Air/Fuel Valve not rotating 1. Start the unit. The Air/Fuel Valve should rotate to the purge DURING PURGE (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration.
  • Page 64 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 3. Device proving switch hooked to 3. Check that proving switch for any device hooked to the interlock interlocks is not closed. circuit is closing and that the device is operational. LINE VOLTAGE 1.
  • Page 65 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION PRG SWTCH OPEN 1. Defective purge switch. 1. If the air-fuel valve does rotate, check the purge switch for DURING PURGE continuity when closing. Replace switch if continuity does not exist.
  • Page 66 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Defective Flame Detector 2. Replace Flame Detector. SSOV FAULT See SSOV SWITCH OPEN DURING PURGE SSOV FAULT 1. SSOV switch closed for 15 seconds 1. Replace or adjust microswitch in SSOV actuator. If fault during run.
  • Page 67 TROUBLESHOOTING 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. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Hard Light-Off 1.
  • Page 68 TROUBLESHOOTING Figure 8-2 Staged Ignition Solenoid Location Figure 8-1 High Pressure Gas Switch & Snubber Locations Figure 8-3 Damping Orifice Location...
  • Page 69 TROUBLESHOOTING Table 8-3 BMK 3.0 LN (3.3 KΩ) Temperature Sensor and Temperature Transmitter Outputs TEMP Volts TEMP Volts TEMP Resistance TEMP Resistance ºF outputs ºF outputs ºC ºC UA33 UA33 UA33 UA33 111177 0.289 82.4 2915 6.16 58443 0.523 84.2 2787 6.31 32814...

  • Page 71: Operating Menu

    APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode.

  • Page 72: Setup Menu

    APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be entered. Once the valid password (159) is entered, options in the Setup, Configuration and Tuning Menus can be modified.
  • Page 73 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Reset Ratio Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode. Reset Ratio is adjustable from 0.1 to 9.9. Default is 1.2. Outdoor Sensor Allows outdoor sensor function to be enabled or disabled.

  • Page 74: Tuning Menu

    APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%.
  • Page 75 APPENDIX B APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DISABLED Displayed if ON/OFF switch is set to OFF. The display also HH:MM pm MM/DD/YY shows the time and date that the unit was disabled. STANDBY Displayed when ON/OFF switch is in the ON position, but there is no demand for heat.
  • Page 76 APPENDIX B TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION HIGH WATER TEMP The High Water Temperature Limit Switch is open. SWITCH OPEN LOW WATER The Water Level Control board is indicating low water level. LEVEL LOW GAS The Low Gas Pressure Limit Switch is open. PRESSURE HIGH GAS The High Gas Pressure Limit Switch is open.
  • Page 77 APPENDIX B TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION RESIDUAL The Flame signal was seen for more than 60 seconds during FLAME standby. HEAT DEMAND The Heat Demand Relays on the Ignition board failed to FAILURE activate when commanded. A communication fault has occurred between the PMC board IGN BOARD COMM FAULT...

  • Page 79: Temperature Sensor Resistance Chart

    APPENDIX C TEMPERATURE SENSOR RESISTANCE CHART (BALCO) TEMPERATURE SENSOR AERCO PART NO. 123449 R = RESISTANCE (OHMS) T = TEMPERATURE (°F) R=.00161T^2+1.961T+854.841 TEMP (°F) RES. (OHMS) 779.0 797.5 816.3 835.4 854.8 874.6 894.7 915.1 935.9 956.9 978.3 1000.0 1022.0 1044.4 1067.0...
  • Page 81 APPENDIX D APPENDIX D. - INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1. Header Temperature for a Building Reference Temperature of 50F RESET RATIO Temp -10F -15F -20F Table D-2. Header Temperature for a Building Reference Temperatrure of 60F RESET RATIO Temp -10F -15F -20F...
  • Page 82 APPENDIX D Table D-3. Header Temperature for a Building Reference Temperature of 65F RESET RATIO Temp Table D-4. Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F...
  • Page 83 APPENDIX D Table D-5. Header Temperature for a Building Reference Temperature of 75F RESET RATIO Temp -10F -15F Table D-6. Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F...
  • Page 84 APPENDIX D Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp...
  • Page 85 APPENDIX E BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password Language English Unit of Temp Fahrenheit Comm Address Baud Rate 9600 Configuration Menu Internal Setpt 130°F Unit Type Boiler Unit Size 3.0 MBTU Boiler Mode Constant Setpoint Remote Signal 4 –...
  • Page 87 APPENDIX F...
  • Page 88 APPENDIX F...
  • Page 89 APPENDIX F...
  • Page 90 APPENDIX F...
  • Page 91 APPENDIX F...
  • Page 92 APPENDIX F...
  • Page 93 81057 BLOWER GASKET 96006 6" 90 DEG ELBOW 96009 6" DIAM. x 4" LG DUCT W/POR 96008 6" DIAM. x 4" LG DUCT AERCO INTERNATIONAL, INC. 123990 REDUCER OFFSET COVER NORTHVALE, NJ 07647 123583 CLAMP HOSE SAE #96 BENCHMARK 3.0 LOW NOx...
  • Page 94 TWO (2) REQUIRED FOR DUAL FUEL BMK3.0 LN 123540 (8) SEE DRAWING AP-A-826 FOR DUAL FUEL DETAILS EXT. MANUAL SHUT-OFF VALVE 91030 1" DRAIN HOSE, 60" LG 12820-11 1-1/2" NPT BALL VALVE AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 59043 CONDENSATE FLOAT BENCHMARK 3.0 LOW NOx 24060 COND.
  • Page 95 APPENDIX F AERCO INTERNATIONAL, INC. DETAIL A NORTHVALE, NJ 07647 SCALE 1 : 10 BENCHMARK 3.0 LOW NOx BOILER PARTS LIST PL - A - 150 DRAWN BY (SHEET 3 OF 7) DATE 12/02/08...
  • Page 96 APPENDIX F SECTION B-B SCALE 1 : 18 AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 3.0 LOW NOx BOILER PARTS LIST PL - A - 150 DRAWN BY (SHEET 4 OF 7) DATE 12/02/08 F-10...
  • Page 97 APPENDIX F DETAIL B: SEE DETAIL C DETAIL C: FUEL SELECTOR SWITCH (DUAL FUEL ONLY) FM GAS TRAIN (NON DUAL FUEL) AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 3.0 LOW NOx BOILER PARTS LIST PL - A - 150 DRWN BY...
  • Page 98 APPENDIX F AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 3.0 LOW NOx BOILER PARTS LIST PL - A - 150 DRWN BY SD (SHEET 6 OF 7 DATE 12/02/08 F-12...
  • Page 99 APPENDIX F AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 3.0 LOW NOx BOILER PARTS LIST PL - A - 150 DRWN BY SD (SHEET 7 OF 7 DATE 12/02/08 F-13...
  • Page 101 APPENDIX G...
  • Page 102 APPENDIX G...
  • Page 103 APPENDIX G...
  • Page 104 APPENDIX G...
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  • Page 107 APPENDIX H...
  • Page 108 APPENDIX H...
  • Page 109 APPENDIX H...
  • Page 110 APPENDIX H...
  • Page 111 APPENDIX I RECOMMENDED PERIODIC TESTING CHECK LIST WARNING NOTE: Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage.
  • Page 113 APPENDIX J BENCHMARK CONTROL PANEL EXPLODED VIEW...
  • Page 114 APPENDIX J BENCHMARK CONTROL PANEL REAR VIEW...
  • Page 115 APPENDIX K APPENDIX K NATURAL GAS COMBUSTION CALIBRATION PROCEDURE FOR UNIT SERIAL NUMBERS BELOW G-07-1901...
  • Page 116 BTU content, gas supply piping and supply regulators. Factory 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.
  • Page 117 APPENDIX K 14. If necessary, adjust the iris air damper 16. Locate the Variable Frequency Drive (VFD) shown in Figure K-2 until the oxygen level is behind the front door of the unit. Refer to the within the range specified in Table K-1. VFD operating controls shown in Figure K-3.

  • Page 118: Unit Reassembly

    APPENDIX K 21. If the oxygen level is not within the specified 26. Finally, reduce the firing rate to 14% and range, adjust the level using the up (▲) and select VFD parameter 15. The oxygen level down (▼) arrow keys on the VFD. Using the at the 14% firing rate should be as shown in up (▲) arrow key will increase oxygen level the following tabular listing:...

  • Page 119: Standard Warranty

    Any claim relating to the product must be filed with AERCO not later than 14 days after the event-giving rise to such claim. Any claims relating to this product shall be limited to the sale price of the product at the time of sale. The sale of the product is specifically conditioned upon acceptance of these terms.
  • Page 120 AERCO shall have the option of having the item returned, FOB its factory, or to make field replacements at the point of installation. In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges.

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Benchmark 3.0ln series

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