Aerco Benchmark 1500 User Manual
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Aerco Benchmark 1500 User Manual

Gas-fired boilers
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Benchmark 1500 - 2000 Boilers
Installation, Operation & Maintenance Manual (IOMM)
USER MANUAL
Natural Gas Modulating
Installation, Operation and Maintenance
& Condensing Hot Water
Boiler Models:
BENCHMARK
• BMK 1500
1500 / 2000
• BMK 2000
Gas-Fired Boilers
Applicable to Serial Numbers:
G-14-0304 and Above
Latest Update: 03/20/2014
OMM-0097_0D
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 188
GF-142
Ph.: 800-526-0288

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  • Page 1 • BMK 1500 1500 / 2000 • BMK 2000 Gas-Fired Boilers Applicable to Serial Numbers: G-14-0304 and Above Latest Update: 03/20/2014 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 188 GF-142 Ph.: 800-526-0288...
  • 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. AERCO International is not liable for errors appearing in this manual.

  • Page 3: Table Of Contents

    3.2 CONTROL PANEL DESCRIPTION ...................... 33 3.3 CONTROL PANEL MENUS ........................37 3.3.1 Menu Processing Procedure ........................... 37 3.4 OPERATING MENU ..........................39 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 188 GF-142 Ph.: 800-526-0288...
  • Page 4 6.6.2 Delayed Interlock Test ............................ 76 6.7 FLAME FAULT TESTS ......................... 77 6.8 AIR FLOW FAULT TESTS ........................79 6.8.1 Blower Proof Switch Test ..........................79 Page 4 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 5 APPENDIX E: RECOMMENDED PERIODIC TESTING ............145 APPENDIX F: INDOOR/OUTDOOR RESET RATIO CHARTS ..........147 APPENDIX G: DIMENSIONAL AND CLEARANCE DRAWINGS ..........151 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 5 of 188 GF-142 Ph.: 800-526-0288...
  • Page 6 APPENDIX I: WIRING DIAGRAMS ..................... 167 APPENDIX J: PIPING DRAWINGS ....................175 APPENDIX K: C-MORE CONTROL PANEL VIEWS ..............181 APPENDIX L: RECOMMENDED SPARES ................... 183 Page 6 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 7: Foreword

    FORWARD FOREWORD The AERCO Benchmark (BMK) 1500 and 2000 MBH boilers are modulating and condensing units. They represent 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 8 British Thermal Unit. A unit of energy approximately equal to the heat required to raise 1 pound of water 1° F. Combustion Control Panel C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Carbon Monoxide...
  • Page 9 A standard for serial, half-duplex (HDX) transmission of data based on (or EIA-485) the RS-485 Standard RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 188 GF-142 Ph.: 800-526-0288...
  • 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.) Page 10 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • 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. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers.

  • 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 the unit. The installer must identify the emergency shut-off device.
  • Page 13 248 CMR 5.08(2)(a)1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 13 of 188 GF-142 Ph.: 800-526-0288...
  • Page 14 ____________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] Page 14 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 15: Chapter 2. Installation

    2.4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark 1500/2000 Boiler includes: OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 16: Installation Clearances

    The Benchmark Model 1500 and 2000 are packaged in an enclosure having identical exterior dimensions. The unit must be installed with the prescribed clearances for service as shown in Figure 2-1a. 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.

  • 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 188 GF-142 Ph.: 800-526-0288...
  • Page 18 Combination Mode Boilers in advance and place them in the proper physical location. Refer to Chapter 5 for information on Combination Mode Boilers. Page 18 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 19: Supply And Return Piping

    In multiple unit installations the discharge lines must not be manifolded together. Each must be individually run to a suitable discharge location. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 188 GF-142...

  • Page 20: Condensate Drain & Piping

    • The base of the condensate trap must be supported to ensure that it is level (horizontal). • The trap must be removable for routine maintenance. Page 20 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 21: Condensate Trap Installation

    (8” MAXIMUM) EXHAUST UNDER THE FLOOR MANIFOLD CONDENSATE DRAIN DRAIN PORT ASSEMBLY. Figure 2-6: Sample Condensate Trap Installation (Right Side View) OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 21 of 188 GF-142 Ph.: 800-526-0288...

  • Page 22: Gas Supply Piping

    Benchmark 1500 MBH and 2000 MBH units contain a 2 inch NPT gas inlet connection on the top of the unit, as shown in Figure 2-2 and 2-3.

  • Page 23: External Gas Supply Regulator

    It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above. However, AERCO offers for sale an appropriate regulator, which may be ordered at the time of unit purchase or separately. Contact AERCO for more information. OMM-0097_0D AERCO International, Inc.

  • Page 24: Ac Electrical Power Wiring

    CHAPTER 2 – INSTALLATION 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 on the front of the unit. Remove the front panel to access the Power Box, which is mounted in the upper right corner of the unit as shown in Figure 2-8.

  • Page 25: Electrical Power Requirements

    2.9.1 Electrical Power Requirements The Benchmark 1500 and Benchmark 2000 models are available in one voltage configuration: • 120 VAC, Single-Phase, 60 Hz @ 20 Amps The Power Box contains terminal blocks as shown in Figure 2-9. In addition, a label showing the required AC power connections is provided on the front cover of the Power Box as shown in Figure 2-10.

  • Page 26: Field Control Wiring

    DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage. Page 26 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

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

    Figure 2-12: I/O Box Terminal Strips 2.10.1 Outdoor Air In (OUT) & Air Sensor Common (COM) The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO P/N GM-123525) as required primarily for the Indoor/Outdoor reset mode of operation. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature.

  • Page 28: Combustion Air Terminal

    “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 29: Comm (+, Gnd, & -)

    2.10.9 RS-485 Comm (+, GND, & -) The RS-485 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 (RS- 485) communication. 2.10.10 RS-232 Comm (TxD & RxD) The RS-232 communication terminals permit a laptop computer or other suitable terminal to be connected to the boiler.

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

    Figure 2-12 to locate the 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 Air

    In a ducted combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run. See the AERCO Benchmark Venting and Combustion Air Guide, GF-2050. When using the unit in a ducted combustion air configuration, each unit must have a minimum 8 inch diameter connection at the unit.
  • 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. Page 32 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 33 of 188 GF-142 Ph.: 800-526-0288...
  • Page 34 Serial-to- USB adaptor for use in modern computer USB ports. Page 34 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 35 Low Water Level alarm. TEST/RESET Switches Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 35 of 188 GF-142 Ph.: 800-526-0288...
  • Page 36 20 segment red LED bargraph continuously shows the VALVE POSITION Air/Fuel Valve position in 5% increments from 0 to 100% Bargraph Page 36 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 37 of 188 GF-142 Ph.: 800-526-0288...
  • Page 38 Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. Page 38 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 39 of 188 GF-142 Ph.: 800-526-0288...

  • Page 40: Configuration Menu

    Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. Page 40 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 41 *NOTE The Bldg Ref Temp and Reset Ratio Menu Items are only displayed when the Outdoor Sensor is set to “Enabled”. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 188 GF-142 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? Page 42 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 43: Combustion Cal Menu

    These displayed item groups are displayed in UPPER CASE letters, and are bounded by an asterisk * in order to readily identify them within the item list. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 43 of 188 GF-142...
  • Page 44 Remote Intlk Use Boiler Shutdown System Shutdown Shutdown On-Outlet One Boiler Mode On-Avg Temp Temp 1 Blr Threshold Setpoint Setback Disable Enable Disable Page 44 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 45 60°F Disabled Enabled Disabled *BST COMM MENU* Comm Address BST Min Addr BST Max Addr SSD Address SSD Poll Control 1000 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 45 of 188 GF-142 Ph.: 800-526-0288...

  • Page 46: Start Sequence

    The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for SSOV location. Page 46 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...
  • 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 47 of 188 GF-142 Ph.: 800-526-0288...
  • Page 48 The Dial on the Air/Fuel Valve (Figure 3-6) will read between 25 and 35 to indicate that the valve is in the low fire position. Page 48 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...
  • 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 188 GF-142 Ph.: 800-526-0288...

  • Page 50: Start/Stop Levels

    (% of Full Capacity) (% Open) 16% (Stop Level) 100,000 6.7% 143,000 388,000 759,000 1,069,000 1,283,000 1,476,000 1,675,000 1,833,000 100% 2,000,000 100% Page 50 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 51: Chapter 4. Initial Start-Up

    Safety Device 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 at: AERCO International, Inc. 100 Oritani Drive...

  • Page 52: Required Tools & Instrumentation

    LEAK DETECTION BALL VALVE (Install manometer here for Combustion Calibration) Figure 4-1: BMK 1500/2000: 1/4 Inch Gas Plug Location for Combustion Calibration Page 52 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 53: Accessing The Analyzer Probe Port

    PRIMARY HOT WATER INLET DRAIN VALVE EXHAST MANIFOLD ANALYZER PORT CONDENSATE DRAIN Figure 4-2: Analyzer Probe Port Location (Right Side Partial View) OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 53 of 188 GF-142 Ph.: 800-526-0288...

  • Page 54: Natural Gas Combustion Calibration

    Recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU content, gas supply piping and supply regulators. Combustion Calibration Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
  • Page 55 23. Next, press the down (▼) arrow key until CAL Voltage 80% is displayed. 24. Press the CHANGE key and observe that CAL Voltage 80% is flashing. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 55 of 188 GF-142...
  • Page 56 60% down to 16% after making a change to the idle screw (TAC valve). 30. This completes the BMK 1500 Natural Gas combustion calibration procedures. Page 56 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...
  • Page 57 Gas Pressure Adjustment Screw). Figure 4-3: Gas Pressure Adjustment Screw Location TAC VALVE IDLE SCREW Figure 4-4: TAC Valve Adjust (Idle Screw) OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 57 of 188 GF-142 Ph.: 800-526-0288...
  • Page 58 Combustion Calibration Readings – 100% valve Position Valve Position Oxygen (O Nitrogen Oxide (NOx) Carbon Monoxide (CO) 100% 5.0% - 6.0% ≤20 ppm <100 ppm Page 58 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 59 Pressing the ▲ arrow key increases the oxygen level and pressing the down ▼ arrow key decreases the oxygen level. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 188 GF-142 Ph.: 800-526-0288...

  • Page 60: Reassembly

    6. Replace all previously removed sheet metal enclosures on the unit. 7. This concludes reassembly of the unit after combustion calibration. Page 60 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 61: Over-Temperature Limit Switches

    Figure 4-6 and Table 4-1. Alarm Limit Control Figure 4-6: Digital Over-Temperature Alarm Switch Front Panel OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 61 of 188 GF-142 Ph.: 800-526-0288...
  • Page 62 Alarm Switch. 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. 7. Press the SET button again to enter the code. The first parameter label (SP) will appear in the display.

  • Page 63: Chapter 5. Mode Of Operation

    Startup in the Indoor/Outdoor Reset Mode is accomplished as follows: NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 63 of 188 GF-142 Ph.: 800-526-0288...

  • Page 64: Constant Setpoint Mode

    Select desired setpoint using ▲ and ▼ arrow keys (40°F to 240°F) Refer to section 3.3 for detailed instructions on changing menu options. Page 64 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 65: Remote Setpoint Modes

    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 66: Remote Setpoint Startup

    If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information. Page 66 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 67: Direct Drive Field Wiring

    485 signaling to the boiler. Installations with 1 to 8 boilers can use BST (see Chapter 10). 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.

  • Page 68: Acs Setup And Startup

    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...

  • Page 69: Combination Control System Field Wiring

    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 D.
  • Page 70 Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION (This Page Is Intentionally Blank) Page 70 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 71: Chapter 6. Safety Device Testing

    230 OR 460, 120 AND 24 VOLTS AC. POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT RESULT ELECTRICAL SHOCK. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 71 of 188 GF-142 Ph.: 800-526-0288...

  • Page 72: Low Gas Pressure Fault Test

    10. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4“ plug removed in step 1. Page 72 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 73: High Gas Pressure Test

    12. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4“ plug removed in step 1. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 73 of 188 GF-142 Ph.: 800-526-0288...

  • Page 74: Low Water Level Fault Test

    11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message. 12. Set the ON/OFF switch to the ON position. The unit is now ready for operation. Page 74 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 75: Water Temperature Fault Test

    LIMIT DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON MANUAL TEMPERATURE LIMIT SWITCH Figure 6-2: Temperature Limit Switch Location OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 75 of 188 GF-142 Ph.: 800-526-0288...

  • Page 76: 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. Page 76 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 77: Flame Fault Tests

    9. The unit should shut down and Lockout, flashing FLDR in the display. 10. Open the valve previously closed in step 8. 11. Press the CLEAR button. The unit should restart and fire. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 77 of 188 GF-142 Ph.: 800-526-0288...
  • Page 78 SWITCH AIR/FUEL VALVE MANUAL SHUT-OFF VALVE SSOV BLOCKED INLET SWITCH FILTER TRAIN Figure 6-3: Bare Boiler – Partial View (BMK 1500/2000) Page 78 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 79: 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. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 79 of 188 GF-142...
  • Page 80 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. Page 80 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 81: 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. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 81 of 188 GF-142...

  • Page 82: Purge Switch Open During Purge

    5. The unit should begin its start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE. 6. Replace the wire on the Purge Switch and depress the CLEAR button. The unit should restart. Page 82 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 83: Ignition Switch Open During Ignition

    BLOWER 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 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 83 of 188 GF-142 Ph.: 800-526-0288...

  • Page 84: 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. Page 84 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 85: Chapter 7. Maintenance

    Replace Gaskets Replace Gaskets Air Filter (59138) Clean Replace 15 mins. * Only performed after initial 6 month period after initial startup. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 85 of 188 GF-142 Ph.: 800-526-0288...

  • Page 86: Igniter-Injector

    This will disengage the shroud from the four (4) pins in the side panels. Disconnect the cable from the igniter-injector (Figure 7-1). Page 86 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...
  • Page 87 Chapter 4 for combustion calibration procedures. Prior to reinstalling the igniter-injector, a high temperature, conductive, anti-seize com- pound must be applied to the threads. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 87 of 188 GF-142 Ph.: 800-526-0288...

  • Page 88: Flame Detector

    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. Page 88 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 89: O 2 Sensor

    The results of the tests should be recorded in a log book. See Chapter 6- Safety Device Testing Procedures. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 188 GF-142 Ph.: 800-526-0288...

  • Page 90: Burner Assembly Inspection

    Loosen and remove the four 5/16x1-3/4” bolts, washers, and nuts from the burner plenum where it is attached to the blower (see Figure 7-4a & 7-4b). Page 90 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...
  • Page 91 Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 188 GF-142 Ph.: 800-526-0288...
  • Page 92 (8 each) AIR/FUEL PLATE VALVE FILTER 1/2” NUTS & BOLTS (4 each) FILTER GAS TRAIN Figure 7-4a: Burner Assembly Mounting Details Page 92 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 93 81166 – MIDDLE BURNER GASKET 81186 – LOWER RELEASE GASKET BARE BURNER INSTALLED IN HEAT EXCHANGER ASSY. Figure 7-5: Bare Burner and Replacement Gaskets Location OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 93 of 188 GF-142 Ph.: 800-526-0288...

  • Page 94: Condensate Drain Trap

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

  • Page 95: Air Filter Cleaning & Replacement

    Replace the top shroud on the unit and return boiler to service use. AIR/FUEL VALVE AIR FILTER MANUAL HOSE CLAMP SHUT-OFF VALVE FILTER TRAIN Figure 7-7: Air Filter Location OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 95 of 188 GF-142 Ph.: 800-526-0288...

  • Page 96: 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. Page 96 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 97: Chapter 8. Troubleshooting Guide

    This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 1500 MBH and 2000 MBH boilers. The troubleshooting procedures contained herein are presented in tabular form on the following pages. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action.
  • Page 98 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE (This page left intentionally blank) Page 98 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 99 Air/Fuel Valve dial. Check igniter-injector for soot or erosion of electrode. Check Hard light. injector solenoid valve to insure proper open/close operation. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 99 of 188 GF-142 Ph.: 800-526-0288...
  • Page 100 Probable causes from 3 to 16 for See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW AIRFLOW FAULT DURING FAULT DURING IGNITION. IGNITION applies for this fault. Page 100 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 101 If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 101 of 188 GF-142 Ph.: 800-526-0288...
  • Page 102 Carboned heat exchanger due to If exhaust temperature is greater than 200 F, check incorrect combustion calibration. combustion calibration. Calibrate or repair as necessary. Page 102 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 103 Press CLEAR button and restart unit. If fault persists, contact IGN BOARD between the PMC board and qualified Service Personnel. COMM FAULT Ignition/Stepper (IGST) board. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 103 of 188 GF-142 Ph.: 800-526-0288...
  • Page 104 Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. Page 104 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 105 Air/Fuel Valve calibration. If calibration is okay, the problem may be in the Air/Fuel Valve or the Control Box. Refer fault to qualified service personnel. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 105 of 188 GF-142 Ph.: 800-526-0288...
  • Page 106 Check Combustion Analyzer and recalibrate the boiler. Blocked inlet air duct or louver. Unblock air inlet and measure open area for combustion air to the room. Page 106 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 107 Check SSOV power wiring. Hot and Neutral reversed at SSOV. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 188 GF-142 Ph.: 800-526-0288...
  • Page 108 Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. Page 108 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 109: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 80% Valve Position in Control Box are outdated. are Rev. E or higher. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 109 of 188 GF-142 Ph.: 800-526-0288...
  • Page 110 DAMPING ORIFICE BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). Figure 8-2: SSOV Actuator with Gas Pressure Adjustment Page 110 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 111: Chapter 9. Rs-232 Communication

    (if your computer has more than one) and what speed (baud rate) to use when transferring data. For further configuration options (data bits, stop bits, parity, OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 188 GF-142...

  • Page 112: Running A Command On A Remote Machine Using Putty

    Figure 9-2: PuTTY GUI: Basic SSH Options for Running Remote Commands Into the textbox titled, Remote command type the full command line you wish to have executed on the remote machine. Page 112 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 113: Communication Setup

    At the prompt, enter the valid RS-232 password (jaguar) in lower case letters and press Enter. “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 114: Data Logging

    Descriptions of these data logs are provided in the following sections. The procedure for accessing specific data logs is described in section 9.3 step 10. Page 114 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 115: Fault Log

    Run, Direct Drive 1/15/02 1:21pm Ignition 1/15/02 1:20pm Off, Switch 1/15/02 12:30pm Run, Manual 1/15/02 11:55am Ignition 1/15/02 11:55am Power-up 1/15/02 11:50am OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 188 GF-142 Ph.: 800-526-0288...

  • Page 116: Sensor Log

    OPEN OPEN OPEN OPEN OPEN 1/15/02 5:16pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:11pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:06pm Page 116 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 117: Chapter 10. Boiler Sequencing Technology

    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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 117 of 188 GF-142 Ph.: 800-526-0288...

  • Page 118: 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 Page 118 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 119: 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 120: 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 121: 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 122 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. Page 122 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 123: 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 124 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. Page 124 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 125: Option 5 - Remote Setpoint With 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 126: 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 127: 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 128 When ALL C-More units have been configured: 10. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. Page 128 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288...

  • Page 129: 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 130 Benchmark 1500 - 2000 Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY (This Page Is Intentionally Blank) Page 130 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 131: 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 131 of 188 GF-142 Ph.: 800-526-0288...
  • Page 132 Std, BMK Blr Std Dual, BMK Boiler LN, BMK Blr LN Dual, KC Water Heater, KC Wtr Heater LN, Innovation WH Page 132 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 133 Specifies the amount of time (0 to 30 min.) to keep the pump running after the unit turns off. Default is zero. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 133 of 188 GF-142 Ph.: 800-526-0288...
  • Page 134 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) Page 134 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 135 Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature. Span is 40% to 100%, Default is 60%. OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 135 of 188 GF-142 Ph.: 800-526-0288...
  • Page 136 Warmup PID Timer Range = 1-240 Default = 20 Reset Defaults? Allows Tuning Menu options to be reset to their Factory Default values. Page 136 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

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

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 137 of 188 GF-142 Ph.: 800-526-0288...
  • Page 138 The RS-485 network information is not present or is FAULT corrupted. % OUT OF RANGE % has gone below 3% or above 8%. Page 138 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 139 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 139 of 188 GF-142 Ph.: 800-526-0288...
  • Page 140 Benchmark 1500 - 2000 Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES This Page Is Intentionally Blank Page 140 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

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

    2.39 1185.2 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 141 of 188 GF-142 Ph.: 800-526-0288...
  • Page 142 Benchmark 1500 - 2000 Boilers APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART This Page Is Intentionally Blank Page 142 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 143: Appendix D: Boiler Default Settings

    Aux Start On Dly 0 sec Failsafe Mode Shutdown Valve Position 0-10V Analog Output CAUTION: DO NOT Change Lo Fire Timer 2 sec OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 143 of 188 GF-142 Ph.: 800-526-0288...
  • Page 144 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 Page 144 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 145: 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-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 145 of 188 GF-142 Ph.: 800-526-0288...
  • Page 146 Benchmark 1500 - 2000 Boilers APPENDIX E – RECOMMENDED PERIODIC TESTING This Page Is Intentionally Blank Page 146 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 147: Appendix F: Indoor/Outdoor Reset Ratio Charts

    Temp -10F -15F -20F Table F-2: Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp -10F -15F -20F OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 147 of 188 GF-142 Ph.: 800-526-0288...
  • Page 148 Table F-3: Header Temperature for a Building Reference Temperature of 65F RESET RATIO Temp Table F-4: Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F Page 148 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 149 Table F-5: Header Temperature for a Building Reference Temperature of 75F RESET RATIO Temp -10F -15F Table F-6: Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 149 of 188 GF-142 Ph.: 800-526-0288...
  • Page 150 APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-7: Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp Page 150 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 151: Appendix G: Dimensional And Clearance Drawings

    Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix G: DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-936 rev A OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 151 of 188 GF-142 Ph.: 800-526-0288...
  • Page 152 Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-995 rev A Page 152 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 153 Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-898 rev C OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 153 of 188 GF-142 Ph.: 800-526-0288...
  • Page 154 Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS This Page Is Intentionally Blank Page 154 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 155: Appendix H: Part Drawings

     Not shown on drawing AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 1 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 155 of 188 GF-142 Ph.: 800-526-0288...
  • Page 156 58023 AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 2 of 7 Whole Boiler 29313-1 – 29337-1 Page 156 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 157 APPENDIX H – PART DRAWINGS AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 3 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 157 of 188 GF-142 Ph.: 800-526-0288...
  • Page 158 See full part lists below AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 4 of 7 Whole Boiler 29313-1 – 29337-1 Page 158 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 159 See full part lists below AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 5 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 159 of 188 GF-142 Ph.: 800-526-0288...
  • Page 160 APPENDIX H – PART DRAWINGS AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 6 of 7 Whole Boiler 29313-1 – 29337-1 Page 160 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 161 PARTIAL FRONT VIEW AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 7 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 161 of 188 GF-142 Ph.: 800-526-0288...
  • Page 162 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 - 2000 Standard Gas Train – p/n 22188 rev B Item Qty Part # Description Item Part # Description 123542 FLANGE 2" 125# 2"NPT 18 63109 GAS TRAIN HARNESS 93069 BUSHING: REDUCING 1-1/2"...
  • Page 163 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500/2000 DBB Gas Train – p/n 22199 rev A Item Qty Part # Description Item Part # Description 123542 FLANGE 2" 125# 2"NPT 124142 VALVE: SSOV: DOUBLE BODY: 2" NPT BUSHING: REDUCING 1-1/2"...
  • Page 164 APPENDIX H – PART DRAWINGS AERCO 10/31/2013 Benchmark 1500/2000 DBB Gas Train International, Inc. Blauvelt, NY 10913 Sheet 2 of 2 22199 rev A Page 164 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 165 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 – 2000 Burner Assembly, p/n 24378 – 24388 rev A Item Qty Part # Description Item Part # Description 69078 BLOWER: AMETEK 12.3" 81100 GASKET: BLOWER 12.3" 43090...
  • Page 166 10/18/2013 Benchmark 1500 – 2000 Burner Assembly International, Inc. Blauvelt, NY 10913 Sheet 2 of 1 24378 – 24388 rev A Page 166 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 167: Appendix I: Wiring Diagrams

    Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Appendix I: WIRING DIAGRAMS Drawing Number 68050 rev B page 1 of 2 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 167 of 188 GF-142 Ph.: 800-526-0288...
  • Page 168 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) Page 168 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 169 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68050 rev B page 2 of 2 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 169 of 188 GF-142 Ph.: 800-526-0288...
  • Page 170 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) Page 170 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 171 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68071 rev B page 1 of 2 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 171 of 188 GF-142 Ph.: 800-526-0288...
  • Page 172 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) Page 172 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 173 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68071 rev B page 2 of 2 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 173 of 188 GF-142 Ph.: 800-526-0288...
  • Page 174 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This Page Is Intentionally Blank) Page 174 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 175: Appendix J: Piping Drawings

    Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Appendix J: PIPING DRAWINGS Drawing Number: SD-A-989 rev A OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 175 of 188 GF-142 Ph.: 800-526-0288...
  • Page 176 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-990 rev A Page 176 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 177 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-991 rev A OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 177 of 188 GF-142 Ph.: 800-526-0288...
  • Page 178 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-992 rev A Page 178 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 179 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-993 rev A OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 179 of 188 GF-142 Ph.: 800-526-0288...
  • Page 180 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-994 rev A Page 180 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 181: Appendix K: C-More Control Panel Views

    P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 BENCHMARK CONTROL PANEL EXPLODED VIEW Figure K-1: Benchmark Control Panel Exploded View OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 181 of 188 GF-142 Ph.: 800-526-0288...
  • Page 182 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure K-2: Benchmark Control Panel Rear View Page 182 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

  • Page 183: Appendix L: Recommended Spares

    Table L-3: Optional Spare Parts DESCRIPTION PART NUMBER C-More Control Box 181197 BMK 1500: 46042 Burner BMK 2000: 46044 Sensor 61026 OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 183 of 188 GF-142 Ph.: 800-526-0288...
  • Page 184 Benchmark 1500 - 2000 Boilers APPENDIX L – RECOMMENDED SPARES This page left intentionally blank Page 184 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...
  • Page 185 Benchmark 1500 - 2000 Boilers NOTES: OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 187 of 188 GF-142 Ph.: 800-526-0288...
  • Page 186 Sensor. PIR-934-37: Modified Blocked Inlet Switch Test instructions, section 6.8.2. PIR-1005: Changed Maintenance Kit part numbers © AERCO International, Inc., 2014 Page 188 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D Ph.: 800-526-0288 GF-142...

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