Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D Modulating, Condensing, Forced Draft, Hot Water Boiler 1,500,000 BTU/H Input Applicable for Serial Numbers: G-11-1938 and above. Benchmark 1.5LN Low NOx Boiler USER MANUAL Installation, Operation, and Maintenance Benchmark 1.5LN Low NOx Boiler Revised: 05/09/2012 PR2: 05/09/12 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D Technical Support: (Mon–Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com Disclaimer The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D Table of Contents CHAPTER 1 SAFETY PRECAUTIONS ............................................................................. 9 1.1 WARNINGS & CAUTIONS .................................................................................... 9 1.2 EMERGENCY SHUTDOWN ............................................................................... 10 1.3 PROLONGED SHUTDOWN ...........................................................
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D 2.10.12 FAULT RELAY (13)........................................................................................... 26 2.11 AUXILIARY RELAY CONTACTS (14) ............................................................... 26 2.12 FLUE GAS VENT INSTALLATION .................................................................... 26 2.13 COMBUSTION AIR .................................................................................
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D 5.3.1 Setting the Setpoint .................................................................................................. 54 5.4 REMOTE SETPOINT MODES ............................................................................ 55 5.4.1 Remote Setpoint Field Wiring ................................................................................. 55 5.4.2 Remote Setpoint Startup .........................................
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 8 TROUBLESHOOTING GUIDE ................................................................... 83 8.1 INTRODUCTION ................................................................................................. 83 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................... 93 CHAPTER 9 RS232 COMMUNICATION ......................................................................... 97 9.1 INTRODUCTION ...
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D Foreword The AERCO Benchmark 1.5LN 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. The Benchmark 1.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D (This page left intentionally blank) Page 8 of 152 AERCO International, Inc. • 100 Oritani Dr.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 1: SAFETY PRECAUTIONS CHAPTER 1: SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 1: SAFETY PRECAUTIONS front panel door) must be installed at all times, except during maintenance and servicing. CAUTIONS Must be observed to prevent equipment damage or loss of operating effectiveness. CAUTION Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be rinsed thoroughly with clean water after leak checks have been completed.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D • • • • • CHAPTER 1: SAFETY PRECAUTIONS IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements: Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts. Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual CHAPTER 1: SAFETY PRECAUTIONS GF-120 OMM-0041_0D 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 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: 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION CHAPTER 2: INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark 1.5 Boiler. Brief descriptions are also provided for each available mode of operation. Detailed procedures for implementing these modes are provided in Chapter 5. 2.2 RECEIVING THE UNIT Each Benchmark 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION 2.4 SITE PREPARATION. Ensure that the site selected for installation of the Benchmark 1.5 Boiler includes: • Access to AC Input Power at 120 VAC, 1-Phase, 60 Hz @ 20 • Access to Natural Gas line at a minimum pressure of 4 inches W.C. 2.4.1 Installation Clearances The unit must be installed with the prescribed clearances for service as shown in Figure 2-1.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION 2.4.2 Setting the Unit The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate drainage. If anchoring the unit, refer to the dimensional drawings in Appendix F for anchor locations. Two lifting tabs are provided at the top of the heat exchanger. Figure 2-2 shows the location of the tab on the top-left side.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 2: INSTALLATION 2.5 SUPPLY AND RETURN PIPING The Benchmark 1.5 Boiler utilizes 3” 150# flanges for the water system supply and return piping connections. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-3. Refer to Appendix F, Drawing AP-A-832 for additional dimensional data.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION NOTE There are two slightly different types of condensate traps that may be used in your configuration; an older style without built-in adapter, and a newer style with a built-in adapter (see Figure 2-5). Installation is the same (1/4” threads are inside built-in adapter on newer style). Refer to Figure 2-5 and install the trap as follows: 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION NOTE All gas piping must be arranged so that it does not interfere with removal of any covers, inhibit service/maintenance, or restrict access between the unit and walls, or another unit. A 1-1/2 inch gas inlet connection is located on the rear of the unit as shown in Figure 2-3.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION NATURAL GAS SUPPLY 1-1/2” MANUAL GAS SHUTOFF VALVE GAS PRESSURE REGULATOR (REQUIRED FOR MASSACHUSETTS INSTALALTIONS ONLY) DIRT TRAP Figure 2-6: Manual Gas Shut-Off Valve Location 2.7.4 IRI Gas Train Kit The IRI gas train is an optional gas train configuration which is required in some areas for code compliance or for insurance purposes. The IRI gas train is factory pre-piped and wired.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 2: INSTALLATION TERMINAL BLOCK UPPER RIGHT CORNER OF FRONT PANEL Figure 2-7: AC Input Terminal Block Location 2.8.1 Electrical Power Requirements The AERCO Benchmark 1.5 Boiler accepts 120 VAC, single-phase, 60 Hz @ 20 A. The Power Box contains a terminal block as shown in Figure 2-8. In addition, a wiring diagram showing the required AC power connections is provided on the front cover of the Power Box.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 1.5 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.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION 2.9.3 Boiler Management System Mode NOTE BMS Model 168 can utilize either pulse width modulation (PWM) or RS485 Modbus signaling to the Boiler. BMS II Model 5R5-384 can utilize only RS485 signaling to the Boiler. When using an AERCO Boiler Management System (BMS), the field wiring is connected between the BMS Panel and each Boiler’s I/O Box terminal strip (Figure 2-10).
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION Figure 2-10. I/O Box Terminal Locations and Functions 2.10 I/O BOX CONNECTIONS The types of input and output signals and devices to be connected to the I/O Box terminals shown in Figure 2-10 are described in the following paragraphs. NOTE Older I/O PCBs are wired the same as new ones, even if silkscreen designations may slightly differ.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION ungrounded. When mounting the sensor, it must be located on the North side of the building where an average outside air temperature is expected. The sensor must be shielded from direct sunlight as well as impingement by the elements. If a shield is used, it must allow for free air circulation. 2.10.2 AIR TEMP.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION IMPORTANT DO NOT USE the mA OUT output to remotely monitor Setpoint, Outlet Temp or Fire Rate Out. 2.10.6 mA OUT (6) These terminals provide a 4 to 20 mA output to the VFD (if so equipped) to control the rotational speed of the blower. This function is enabled in the Configuration Menu (Chapter 3, Table 3-4). 2.10.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual CHAPTER 2: INSTALLATION GF-120 OMM-0041_0D from 0 to 120 seconds. This option is locate in the Configuration Menu (Chapter 3, Table 3-4). 2.10.12 FAULT RELAY (13) The fault relay is a single pole double throw (SPDT) relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 2: INSTALLATION The AERCO Benchmark 1.5 Boiler is UL listed for 100% sealed combustion. It can also be installed using room air, provided there is an adequate supply. (See paragraph 2.13.3 for more information concerning sealed combustion air).
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual CHAPTER 2: INSTALLATION • 10 A Resistive @ 277 VAC/28 VDC • 1/3 HP N/O @ 120/240 VAC • 1/6 HP N/C @ 120/240 VAC GF-120 OMM-0041_0D • 480 VA Pilot Duty @ 240-277 VAC If pump/valve load exceeds the above contact ratings, use a separate contact relay. See Diagrams 2-1a and 2-1b. To identify if the boiler is equipped with the BMK Pump Relay Option (part no. 69102), look for the label and relay as shown in Figure 2-12.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 1.5 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. Operation prior to initial startup by factory trained personnel will void the equipment warranty.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION 2 1 3 4 12 5 11 6 10 7 8 9 Figure 3-1: Control Panel Front View Page 30 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION Table 3-1: Operating Controls, Indicators and Displays ITEM NO. 1 CONTROL, INDICATOR OR DISPLAY LED Status Indicators FUNCTION 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.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION Table 3-1: Operating Controls, Indicators and Displays (Continued) ITEM NO. 10 CONTROL, INDICATOR OR DISPLAY MENU Keypad FUNCTION Consists of 6 keys which provide the following functions for the Control Panel Menus: MENU Steps through the main menu categories shown in Figure 32. The Menu categories wrap around in the order shown.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION 3.3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of five major menu categories which are applicable to this manual. These categories are shown in Figure 3-2. Each of the menus shown, contain options which permit operating parameters to be viewed or changed.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION OPERATING LEVEL 1 PWD SETUP CONFIGURATION TUNING LEVEL 2 PWD COMBUSTION CAL CALIBRATION (NOT USED IN THIS O & M) DIAGNOSTICS (NOT USED IN THIS O & M) Figure 3-2: Control Panel Menu Structure NOTE The following paragraphs provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION 3.5 SETUP MENU The Setup Menu (Table 3-3) permits the operator to enter the unit password (159) which is required to change the menu options. To prevent unauthorized use, the password will time-out after 1 hour. Therefore, the correct password must be reentered when required.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION 3.6 CONFIGURATION MENU The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint (Setpt) temperature regardless of whether the valid password has been entered. Setpt is required for operation in the Constant Setpoint mode. The remaining options in this menu require the valid password to be entered, prior to changing existing entries.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION Table 3-4: Configuration Menu (Continued) Aux Start On Dly 0 sec. Failsafe Mode *Analog Output (See CAUTION at end of Table 3-4 ) Low Fire Timer 120 sec. 0 sec. Shutdown or Constant Setpt Shutdown Off, Setpoint, Outlet Temp, Valve Position 4-20 mA, Valve Position 0-10V *Valve Position 0-10V 2 sec. Setpt Limiting 600 sec. 2 sec.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION Table 3-6: Combustion Cal Menu Menu Item Display CAL Voltage 16% Available Choices or Limits Minimum Maximum .25 8.20 Default 1.80v CAL Voltage 30% .25 8.20 3.20v CAL Voltage 45% .25 8.20 3.70v CAL Voltage 60% .25 8.20 3.80 CAL Voltage 80% .25 8.20 4.60 CAL Voltage 100% .25 8.20 6.00 SET Valve Position 0% 100% 0% Blower Output Monitor Blower Output Voltage .
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION MANUAL GAS SHUT-OFF VALVE TO AIR/FUEL VALVE SSO GAS INLET Figure 3-3: SSOV Location 4. Next, the blower proof switch on the Air/Fuel Valve (Figure 3-5) closes. The display will show Purging and indicate the elapsed time of the purge cycle in seconds. 5.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION AIR IN TO BLOWER DIAL (DETAIL “A”) STEPPER MOTOR 100 DETAIL “A” Figure 3-4: Air/Fuel Valve In Purge Position BLOWER PROOF SWITCH AIR/FUEL VALVE OUTLET TO BLOWER Figure 3-5: Blower Proof Switch Page 40 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION AIR IN TO BLOWER DIAL (DETAIL “A”) STEPPER MOTOR 25 DETAIL “A” Figure 3-6: Air/Fuel Valve In Ignition Position 6. Up to 7 seconds will be allowed for ignition to be detected. The igniter relay will be turned off one second after flame is detected. 7. After 2 seconds of continuous flame, Flame Proven will be displayed and the flame strength will be indicated.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 3: CONTROL PANEL OPERATION Table 3-7: Relationship Between Air/Fuel Valve Position and Energy Input For Unit Running On Natural Gas Page 42 of 152 Air/Fuel Valve Position (% Open) Energy Input (BTU/Hr) Boiler Energy Input (% of Full Capacity) 0% 10% 16% (Stop Level) 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 0 75,000 0 0 5.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP 4.2.1 Required Tools & Instrumentation The following tools and instrumentation are necessary to perform combustion calibration of the unit: • Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1PPM. • 16 inch W.C. manometer or equivalent gauge and plastic tubing.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP Install the 16” W.C. manometer(s) as described in the following steps: 1. Turn off the main gas supply upstream of the unit. 2. Remove the top panel and left or right side panel from the boiler to access the gas train components. 3. Perform the RSI regulator Safe Test as described in paragraph 4.3. If test shows a successful RSI ignition, proceed to the next step.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP 1. Close the main gas supply shut-off valve upstream of the unit. 2. Refer to Figure 4.1 and CLOSE the following valves in the unit’s gas train: • RSI gas valve • RSI Bleed-off Valve • Manual shut-off valve to Air/Fuel Valve. 3. OPEN the main gas supply upstream of the unit. 4. Turn ON electrical power to the system. 5. Slowly OPEN the RSI Gas Valve. 6.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP 4.4 NATURAL GAS COMBUSTION CALIBRATION The Benchmark 1.5LN Boiler is combustion calibrated at the factory prior to shipping. However, 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. Factory Test Data sheets are shipped with each unit.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 4: INITIAL START-UP 11. Increase the valve open position to 100% and verify that the gas pressure downstream of the SSOV remains at 3” W.C. Readjust pressure if necessary. 12. With the valve position at 100%, insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer to settle. 13.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at air/fuel valve positions of 80%, 60%, 45%, 30% and 16% as described in the following steps.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 4: INITIAL START-UP 29. Press the down ▼ arrow key until CAL Voltage 60% is displayed. 30. Press the CHANGE key. CAL Voltage 60% will begin to flash. 31. The oxygen level at the 60% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 4: INITIAL START-UP 45. Press the ▼ arrow key until CAL Voltage 30% is displayed. 46. Press the CHANGE key. CAL Voltage 30% will begin to flash. 47. The oxygen level at the 30% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 4: INITIAL START-UP 2. Disconnect AC power from the unit. 3. Shut off the gas supply to the unit. 4. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound. 5. Remove the combustion analyzer probe from the vent hole. Replace the NPT plug in the vent hole using a suitable pipe joint compound. 6. Replace the unit’s side panels and front door. 4.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION 5.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The following paragraphs in this Chapter provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation. All temperature related parameters are at their factory default values which work well in most applications.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION NOTE A design engineer typically provides design temperature and supply header temperature data. outdoor air 4. Once the design outdoor air temperature is chosen, go across the chart to the desired supply header temperature for the design temperature chosen in step 3. 5. Next, go up that column to the Reset Ratio row to find the corresponding reset ratio. 6.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION 5.4 REMOTE SETPOINT MODES The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal within the following ranges: • 4-20 mA/1-5 Vdc • 0-20 mA/0-5 Vdc The factory default setting for the Remote Setpoint mode is 4 - 20 mA/1 - 5 Vdc.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION multiple units, each unit’s wiring must conform to the above. 5.4.2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when the external signal is present. To operate the unit in the Manual mode, press the AUTO/MAN switch.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION signal leads from the source to the unit’s I/O Box. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION (boilers 9 through 40) and the RS485 COMM terminals in the I/O Box on the front of the boilers. Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the proper polarity for the B.M.S. (PWM) IN and/or RS485 COMM wiring connections. Shields should be terminated only at the BMS and the boiler end must be left floating. Each unit’s wiring must conform to the above. 5.6.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 5: MODE OF OPERATION 5.7.2 Combination Control System Setup and Startup Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode, remote signal type and setpoint. The setpoint is adjustable from 40°F to 240°F.
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Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 6.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustionrelated safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed.
Benchmark 1.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 6. The unit should shut down and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 4.7” W.C. The FAULT indicator should also start flashing. 7. Reduce the gas pressure back to 3.0” W.C. 8. Press the CLEAR button on the Control Box to clear the fault. 9. The fault message should clear and the FAULT indicator should go off. The unit should restart. 10.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 5. The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature. SEE DETAIL “A” FRONT VIEW ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH DETAIL “A” Figure 6-2: Temperature Limit Switch Setting 6.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2-9) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the unit in the event that an interlock is opened.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 8. Once flame is proven, close the manual gas valve located between the SSOV (Figure 6-3) and the Air/Fuel Valve. 9. The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps: (a) The unit will execute a shutdown purge cycle for a period of 15 seconds and display WAIT FAULT PURGE.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 6.8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-3. 1. Disable the blower output drive voltage as follows: (a) Press the MENU key until CONFIGUR-ATION MENU is displayed. (b) Press the ▲ arrow key until the ANA-LOG OUTPUT function is displayed, then press the CHANGE key.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 4. Remove the cover from the SSOV by loosening the screw shown in Figure 6-4. Lift off the cover to access the terminal wiring connections. 5. Disconnect wire #148 from the SSOV to “open” the proof of closure switch circuit. 6. The unit should fault and display SSOV SWITCH OPEN. 7. Replace wire #148 and press the CLEAR button. 8. Set the ON/OFF switch to ON to start the unit. 9.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING 6.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: 1. Set the unit’s ON/OFF switch to the OFF position. 2. Place the unit in Manual Mode and set the valve position between 25% and 30%. 3.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 6: SAFETY DEVICE TESTING STEPPER MOTOR DIAL TO BLOWER 170 16 2 171 IGNITION POSITION SWITCH 17 9 AIR IN PURGE POSITION SWITCH 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 70 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 7-1. See Appendix I for a complete CSD-1 inspection check list.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 7.2 IGNITER-INJECTOR The igniter-injector (part no. 58023) is located on the burner plate at the top of the boiler. In addition to providing the ignition spark required to light the burner, the igniter-injector also contains a gas injector tube which connects to the staged ignition assembly.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE COMPRESSION FITTING & ELBOW STAGED IGNITION ASSEMBLY IGNITORINJECTOR FLAME DETECTOR FLAME DETECTOR GASKET INDEXING WASHERS (QTY = 0-3 AS REQ’D) BURNER PLATE Figure 7-2 Igniter-Injector & Flame Detector Mounting Details 5. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end wrench. 6. Check the igniter-injector for evidence of erosion or carbon build-up.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 8. Reinstall the igniter-injector in the burner plate. Torque to 15 ft-lbs. Do not over tighten. 9. Connect the staged ignition assembly to the gas injector tube of the igniter-injector by securing the compression nut to the elbow of the staged ignition assembly. 10. Reconnect the igniter-injector cable. 11. Reinstall the side and top panels on the unit. 7.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 4. Remove the pipe plug from the 1/4” NPT port on the outlet side of the RSI regulator and insert a NPT-to-barbed adapter fitting (see Figure 7-4). 5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16” W.C. manometer. 6.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 10. Look into the observation port in the top head and ensure that you observe the orange glow of the RSI flame during the ignition trial period. NOTE If you don’t see the orange glow, contact AERCO technical support to ascertain the problem. If you DO see it, proceed to the next step. 11. If the manometer reading is less than 3.0” w.c.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE Figure 7-4: RSI Manometer Installation Location 7.5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1, require that these tests be performed on a scheduled basis. Test schedules must conform to local jurisdictions.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 2. Remove the side and top panels from the unit. 3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure 7-4.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 14. Remove the four (4) 5/16-18 hex head screws securing the blower to the burner plate (Figure 7-5). 15. Remove the blower and air/fuel valve from the burner plate by lifting straight up. Also, remove the blower gasket. 16. Remove the eight (8) 3/8-16 nuts from the burner flange (Figure 7-4) using a 9/16” wrench. NOTE The burner assembly is heavy, weighing approximately 25 pounds. 17.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 7.7 CONDENSATE DRAIN TRAP The Benchmark 1.5 Boiler contains a condensate trap as shown in Chapter 2, Figure 2-5. The trap is located external to the unit and attached to the drain pipe from the exhaust manifold. This trap should be inspected and, if necessary, cleaned to ensure proper operation.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be taken out of service for an extended period of time (one year or more), the following instructions must be followed. 1. Set ON/OFF switch on the front panel to the OFF position to shut down the boiler’s operating controls. 2. Disconnect AC power from the unit. 3.
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Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 8: TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 1.5 Boiler. 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.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES 1. Blower stopped running due to thermal or current overload 2. Blocked Blower inlet or inlet ductwork 3. Blocked Blower proof switch 4. Blocked blocked-air inlet switch 5. Defective Blower proof switch 6. Defective blocked-air inlet switch AIRFLOW FAULT DURING IGNITION 7. Loose temperature to AUX connection in I/O Box 8.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE FAULT INDICATION TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. Blower not running or running too slow 2. Defective Air Flow Switch 3. Blocked Air flow Switch AIRFLOW FAULT DURING PURGE 4. Blocked Blower inlet or inlet ductwork. 5. No voltage to switch from control box. 6. PROBABLE CAUSES from 3 to 16 for AIRFLOW FAULT DURING IGNITION applies for this fault 1.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual FAULT INDICATION DELAYED INTERLOCK OPEN DIRECT DRIVE SIGNAL FAULT TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. Delayed Interlock Jumper not installed or removed. 2. Device proving switch hooked to interlocks is not closed 1. Direct drive signal is not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring. 2. Signal is not isolated (floating). 3.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION FAULT INDICATION 9. FLAME LOSS DURING IGN (continued) Unstable gas pressure. 10. Carbon or other debris on Burner. 11. Staged ignition solenoid valves don’t open. 12. Clogged staged ignition piece. 1. Worn Flame Detector or cracked ceramic. 2. Defective Regulator. FLAME LOSS DURING RUN 3.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual FAULT INDICATION TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. Incorrect supply gas pressure. 2. Defective SSOV Actuator. HIGH GAS PRESSURE 3. Defective High Gas Pressure Switch 4. Gas pressure snubber not installed. 1. Faulty Water temperature switch. 6. Boiler Management System PID or other settings not correctly setup. 7.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE FAULT INDICATION IGN BOARD COMM FAULT TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. Communication fault has occurred between the PMC board and Ignition/Stepper (IGST) board 1. Press CLEAR button and restart unit. If fault persists, contact qualified Service Personnel. 1. Air/Fuel Valve not rotating 1. Start the unit.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual FAULT INDICATION INTERLOCK OPEN LINE VOLTAGE OUT OF PHASE LOW GAS PRESSURE LOW WATER LEVEL TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. Interlock jumper not installed or removed 2. Energy Management System does not have boiler enabled. 3. Device proving switch hooked to interlocks is not closed. 1. Line and Neutral switched in AC Power Box. 2. Incorrect power supply transformer wiring. 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE FAULT INDICATION TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 2. Defective or shorted switch. PRG SWTCH CLOSED DURING IGNITION (continued) 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board 1. Defective purge switch. 2. No voltage present at switch. PRG SWTCH OPEN DURING PURGE 3. Switch wired incorrectly. 4.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual FAULT INDICATION RESIDUAL FLAME SSOV FAULT DURING PURGE SSOV FAULT DURING RUN TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. SSOV not fully closed. 1. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator. Close gas shut-off valve downstream of SSOV.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE FAULT INDICATION STEPPER MOTOR FAILURE (continued) 8.2 TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 2. Air/Fuel Valve unplugged. 3. Loose wiring connection to the stepper motor. 4. Defective Air/Fuel Valve stepper motor. 5. Defective Power Supply Board or fuse 6. Defective IGST Board 2. Check that the Air/Fuel Valve is connected to the Control Box. 3. .
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D Figure 8-1: High Gas Pressure Switch & Snubber Locations BLOWER AIR/FUEL VALVE BURNER PLATE IGNITORINJECTOR BURNER FLAME DETECTOR STAGED IGNITION SOLENOID #1 Figure 8-2: Staged Ignition Solenoid Location PR2: 05/01/11 AERCO International, Inc. • 100 Oritani Dr.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D CHAPTER 7: MAINTENANCE DAMPING ORIFICE SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT Figure 8-3: Damping Orifice Location PR2: 05/09/12 AERCO International, Inc. • 100 Oritani Dr.
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Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 9: RS232 COMMUNICATION 9.1 INTRODUCTION The RS232 port on the front panel of the C-More Control Box (Figure 3-1) can be interfaced to a laptop computer or other suitable terminal using a RS232 adapter cable. RS232 communication can be accomplished using any “Dumb Terminal” emulation, such as “Hyper Terminal” which is included with Microsoft Windows.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 9: RS232 COMMUNICATION 5. To view the available menus in the top-down sequence shown in Figure 3-2, enter M . The Menu title and first 10 options will be displayed. 6. When viewing menus containing more than 10 options, enter N to display the remaining options. 7. Shortcut keys are also available to go directly to a specific menu. These shortcut keys are: m0 m1 m2 m3 m4 m5 8.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 9: RS232 COMMUNICATION 9.4.2 Operation Time Log The Operation Time Log consists of a string of ASCII records stored in non-volatile memory within the C-More Control Panel. Events such as power-up, ignition and turn-off are time stamped. Data logged while the unit is running are run-length encoded. Data is logged or the run-length incremented every 30 seconds.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D CHAPTER 9: RS232 COMMUNICATION Table 9-3.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX A: OMM-0041_0D MENU ITEM DESCRIPTIONS Table A-1: 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. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX A: OMM-0041_0D MENU ITEM DESCRIPTIONS Table A-1: Boiler Menu Item Descriptions 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. Language Permits selection of English, Spanish or French for displayed messages. Default is English.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX A: MENU ITEM DESCRIPTIONS Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) 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. Default is disabled.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX A: OMM-0041_0D MENU ITEM DESCRIPTIONS Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH. Setting range is from 0 to 100.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX A: MENU ITEM DESCRIPTIONS Table A-1: Boiler Menu Item Descriptions 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%.
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Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX B: GF-120 OMM-0041_0D STARTUP, STATUS AND FAULT MESSAGES Table B-1: Startup and Status Messages MESSAGE DEMAND DELAY XX sec DISABLED HH:MM pm, pm MM/DD/YY FLAME PROVEN IGNITION TRIAL XX sec PURGING XX sec STANDBY WAIT WARMUP XX sec PR2: 05/01/11 DESCRIPTION Displayed if Demand Delay is active. Displayed if ON/OFF switch is set to OFF. The display also shows the time (am or pm) and date that the unit was disabled.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES Table B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge, or air inlet is blocked. AIRFLOW FAULT DURING IGN The Blower Proof Switch opened during ignition. AIRFLOW FAULT DURING RUN The Blower Proof Switch opened during run. DELAYED INTERLOCK OPEN The Delayed Interlock is open.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES Table B-2: Fault Messages (Continued) FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX C: GF-120 OMM-0041_0D SENSOR TEMPERATURE RESISTANCE TABLE C-1: Temperature Sensor Resistance Voltage Chart (Balco) PR2: 05/01/11 TEMP (°F) RES (OHMS) VOLTS* -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 779.0 797.5 816.3 835.4 854.8 874.6 894.7 915.1 935.9 956.9 978.3 1000.0 1022.0 1044.4 1067.0 1090.0 1113.3 1137.0 1160.9 1185.2 1209.5 1234.7 1260.0 1285.6 1311.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX D: OMM-0041_0D INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1: Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F -20F 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX D: OMM-0041_0D INDOOR/OUTDOOR RESET RATIO CHARTS Table D-3: Header Temperature for a Building Reference Temperature of 65F Air Temp 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHARTS Table D-5: Header Temperature for a Building Reference Temperature of 75F Air Temp 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX D: OMM-0041_0D INDOOR/OUTDOOR RESET RATIO CHARTS Table D-7. Header Temperature for a Building Reference Temperature of 90F Air Temp 90F 85F 80F 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX E: BOILER DEFAULT SETTINGS Table E-1: Boiler Default Settings (Continued) MENU & OPTION FACTORY DEFAULT Configuration Menu --Continued Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min Page 116 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PR2: 05/01/11 GF-120 OMM-0041_0D PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
210 160 240 TEST PRESS. (PSIG) Page 118 of 152 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 1-1/2" NPT DRAIN CONN. 3"-150# FLG'D COLD WATER INLET CONN. 5-15/16 (15.1) 3 (7.6) 51-7/8 (131.8) 4" CONCRETE PAD - SET UNIT FLUSH AT REAR 55-1/2 (141.0) 3/4" NPT GAS VENT CONN. FOR "IRI" GAS TRAIN OPTION" ONLY 1-1/2" NPT NATURAL GAS INLET CONN. 8-1/8 (20.6) 22-15/16 (58.2) THIS AREA TO BE ACCESSIBLE FOR MAINTENANCE. 45-3/4 (116.2) 36-1/4 (92.1) 5-11/16 (14.
NOTES: PR2: 05/09/12 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 1) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 2) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS) FRONT INTERNATIONAL, INC. NORTHVALE, NJ 07647 Page 119 of 152 *NOT TO SCALE* DRWN BY:SJD DATE:10/12/07 REV SD - A - 730 A BENCHMARK 1.5 LOW NOx GAS FIRED BOILER ANCHOR BOLT LOCATION AERCO REAR OMM-0041_0D GF-120 Benchmark 1.
Page 120 of 152 AERCO International, Inc. • 100 Oritani Dr.
PR2: 05/09/12 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 79" 18" 1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING 2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS: LEFT & RIGHT SIDES: 24" FRONT: 24" REAR: 42" * CEILING HIEGHT: 101" INSTALLATION CLEARANCES: 44.5" SIDE VIEW 101" 24" FRONT 24" INTERNATIONAL, INC. NORTHVALE, NJ 07647 Page 121 of 152 *NOT TO SCALE* DRWN BY:SJD DATE:10/12/07 REV SD - A - 731 A BENCHMARK 1.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 122 of 152 AERCO International, Inc. • 100 Oritani Dr.
GF-120 OMM-0041_0D PR2: 05/09/12 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 124 of 152 AERCO International, Inc. • 100 Oritani Dr.
GF-120 OMM-0041_0D PR2: 05/09/12 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 126 of 152 AERCO International, Inc. • 100 Oritani Dr.
GF-120 OMM-0041_0D PR2: 05/09/12 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 128 of 152 AERCO International, Inc. • 100 Oritani Dr.
GF-120 OMM-0041_0D PR2: 05/09/12 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 130 of 152 AERCO International, Inc. • 100 Oritani Dr.
GF-120 OMM-0041_0D PR2: 05/09/12 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 132 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX G: PR2: 05/01/11 GF-120 OMM-0041_0D PIPING DRAWINGS AERCO International, Inc. • 100 Oritani Dr.
DRIP TRAP GAS SUPPLY 1-1/2" NPT DRAIN CONN. DIAPHRAGM TYPE EXPANSION TANK SYSTEM PUMP * CONDENSATE DRAIN TRAP AIR SEPARATOR AUTOMATIC AIR VENT P&T Page 134 of 152 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 05/09/12 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED.
PR2: 05/09/12 NOTES: DRIP TRAP GAS SUPPLY SYSTEM PUMP AUTOMATIC AIR VENT P&T AIR SEPARATOR * CONDENSATE DRAIN TRAP 1-1/2" NPT DRAIN CONN. DIAPHRAGM TYPE EXPANSION TANK CHECK VALVE (TYP.) RELIEF VALVE (TYP.) P&T AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 135 of 152 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.
DRIP TRAP GAS SUPPLY AUTOMATIC AIR VENT P&T AIR SEPARATOR * CONDENSATE DRAIN TRAP 1-1/2" NPT DRAIN CONN. SYSTEM PUMP P&T P&T RELIEF VALVE (TYP.) Page 136 of 152 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 05/09/12 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 DATE 102307 DWN.BY JK NTS SCALE APPD. DATE SD-A-739 BENCHMARK 1.5 MIL.
PR2: 05/09/12 NOTES: DRIP TRAP GAS SUPPLY CHECK VALVE (TYP.) 1-1/2" NPT DRAIN CONN. P&T AUTOMATIC AIR VENT AIR SEPARATOR * CONDENSATE DRAIN TRAP SYSTEM PUMP P&T P&T AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 137 of 152 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG.
P&T MOTORIZED GLOBE VALVE P&T Page 138 of 152 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 05/09/12 FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PANELS AND COVERS. ALL PIPING AND 5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED. ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE BE 6" AWAY FROM SIDE PANELS. INTERNATIONAL, INC. NORTHVALE, NJ 07647 DWN.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX H: PR2: 05/01/11 GF-120 OMM-0041_0D WIRING SCHEMATICS AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX H: GF-120 OMM-0041_0D WIRING SCHEMATICS (This page intentionally blank) Page 140 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.
Benchmark 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D APPENDIX H: CONTROL BOX CONNECTORS 19-PIN CONNECTOR 4 3 135 138 192 140 1 16 15 14 13 12 11 10 9 WATER LEVEL PROBE 7 6 5 4 3 9 8 6 7 152 5 150 153 151 153 151 4 3 2 7 1 6 5 4 133 148 146 147 145 149 3 A STEPPING MOTOR 5K B 53 152 C SSOV 10K HIGH GAS PRESS. SW. LOW GAS PRESS. SW.
Benchmark 1.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D 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.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D APPENDIX J: BENCHMARK CONTROL PANEL FEATURES Figure J-1: Control Panel Exploded View PR2: 05/01/11 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D P3 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) P1 A/F VALVE HARNESS CONNECTOR (16 PIN) P2 GAS TRAIN HARNESS CONNECTOR (9 PIN) P5 SHELL HARNESS CONNECTOR (19 PIN) P4 INTERLOCK HARNESS CONNECTOR (16 PIN) TO INPUT/OUTPUT (I/O) BOX P6 APPENDIX J: BENCHMARK CONTROL PANEL FEATURES Figure J-2: Control Panel Rear Panel PR2: 05/09/12 AERCO International, Inc.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual APPENDIX J: BENCHMARK CONTROL PANEL FEATURES GF-120 OMM-0041_0D (This page intentionally blank) Page 148 of 152 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual APPENDIX K: OMM-0041_0D RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix F for the locations of the recommended and optional spare parts listed in the following Tables.
Benchmark 1.5LN Low NOx Boiler GF-120 Operation and Maintenance Manual OMM-0041_0D STANDARD WARRANTY: Benchmark Gas-Fired Hydronic Boiler STANDARD WARRANTY: Benchmark Gas-Fired Hydronic Boiler PRESSURE VESSEL/HEAT EXCHANGER: 10 YEARS FROM SHIPMENT The pressure vessel/heat exchanger shall carry a 10-year prorated, limited warranty from shipment against any failure due to condensate corrosion, thermal stress, mechanical defects or workmanship.
GF-120 Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual OMM-0041_0D STANDARD WARRANTY: Benchmark Gas-Fired Hydronic Boiler (Continued) CONDITIONS OF WARRANTY Should an AERCO gas-fired Hydronic boiler fail for any of the above reasons within the specified time period from the date of original shipment(s), AERCO shall, at its option, modify, repair or exchange the defective item.
Benchmark 1.5LN Low NOx Boiler Operation and Maintenance Manual GF-120 OMM-0041_0D © AERCO International, Inc., 2011 PR2: 05/01/11 AERCO International, Inc. • 100 Oritani Dr.
