Benchmark 1500DF - 2000DF Boilers Installation, Operation & Maintenance Manual (IOMM) Natural Gas Modulating & Condensing Hot Water Boiler Models: • BMK 1500DF • BMK 2000DF Applicable to Serial Numbers: G-14-0304 and Above USER MANUAL Installation, Operation and Maintenance BENCHMARK 1500DF / 2000DF DUAL FUEL Gas-Fired Boilers Release Date: 04/01/2014 OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers Installation, Operation & Maintenance Manual (IOMM) 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 1500DF - 2000DF Boilers Installation, Operation & Maintenance Manual (IOMM) TABLE OF CONTENTS FOREWORD ......................................................................................................................................... 7 CHAPTER 1. SAFETY PRECAUTIONS ......................................................................................... 11 1.1 WARNINGS & CAUTIONS ..............................................................................................................
Benchmark 1500DF - 2000DF Boilers Installation, Operation & Maintenance Manual (IOMM) 3.5 SETUP MENU ....................................................................................................................................... 41 3.6 CONFIGURATION MENU .................................................................................................................... 42 3.7 TUNING MENU .................................................................................................................
Benchmark 1500DF - 2000DF Boilers Installation, Operation & Maintenance Manual (IOMM) 6.6.2 Delayed Interlock Test ....................................................................................................................................83 6.7 FLAME FAULT TESTS ......................................................................................................................... 83 6.8 AIR FLOW FAULT TESTS .........................................................................................
Benchmark 1500DF - 2000DF Boilers Installation, Operation & Maintenance Manual (IOMM) APPENDIX E: APPENDIX F: APPENDIX G: APPENDIX H: APPENDIX I: APPENDIX J: APPENDIX K: APPENDIX L: RECOMMENDED PERIODIC TESTING ............................................................ 153 INDOOR/OUTDOOR RESET RATIO CHARTS ............................................... 155 DIMENSIONAL AND CLEARANCE DRAWINGS ............................................. 159 PART DRAWINGS ..................................................
Benchmark 1500DF - 2000DF Boilers 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. The turn down ratios for these boilers is 20:1.
Benchmark 1500DF - 2000DF Boilers FORWARD Phrases, Abbreviations and Acronyms Phrase, Abbreviation or Acronym Meaning A (Amp) Ampere ACS AERCO Control System ADDR Address AGND Analog Ground ALRM Alarm ASME American Society of Mechanical Engineers AUX Auxiliary BAS Building Automation System, often used interchangeably with EMS (see below) Baud Rate Symbol rate, or simply the number of distinct symbol changes (signaling events) transmitted per second.
Benchmark 1500DF - 2000DF Boilers FORWARD Phrases, Abbreviations and Acronyms – Continued Phrase, Abbreviation or Acronym Meaning IGST Board Ignition/Stepper Board contained in C-More Control Box INTLK (INTL’K) Interlock I/O Input/Output I/O Box Input/Output (I/O) Box currently used on Benchmark, Innovation and KC1000 Series products IP Internet Protocol IRI Industrial Risk Insurers. A now discontinued code used to define gas trains containing two SSOVs and a solenoid operated vent valve.
Benchmark 1500DF - 2000DF Boilers FORWARD Phrases, Abbreviations and Acronyms – Continued Phrase, Abbreviation or Acronym SSOV Safety Shut Off Valve TEMP (Temp) Temperature Terminating Resistor A resistor placed at each end of a daisy-chain or multi-drop network in order to prevent reflections that may cause invalid data in the communication uA Microamp (0.
Benchmark 1500DF - 2000DF Boilers 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 1500DF - 2000DF Boilers CHAPTER 1 – SAFETY PRECAUTIONS WARNING A THREE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL SUPPLY LINE OF THE UNIT. THE SWITCH MUST BE INSTALLED IN AN EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO UNIT SHEET METAL ENCLOSURES. 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 1500DF - 2000DF Boilers CHAPTER 1 – SAFETY PRECAUTIONS 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 1 – SAFETY PRECAUTIONS 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 1500DF - 2000DF Boilers 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 Boiler Model BMK 1500 and BMK 2000. 2.2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for these BMK models is approximately 1800 pounds. The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 2.4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark 1500/2000 Boiler includes: • Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps • Access to Natural Gas line at a minimum pressure of 8 inches W.C. at gas flow for 1,500,000 BTU/hr energy input for the BMK 1500 OR 2,000,000 BTU/hr energy input for the BMK 2000. 2.4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS. CAUTION While packaged in the shipping container, the unit must be moved by pallet jack or forklift from the FRONT ONLY. FOR MASSACHUSSETTS ONLY: For Massachusetts installations, the unit must be installed by a plumber or gas-fitter licensed within the Commonwealth of Massachusetts.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION LIFTING LUGS (3 POSITIONS) 1” PROPANE INLET 2” NATURAL GAS INLET Figure 2-2: Boiler Lifting Provisions In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. All piping must include ample provisions for expansion.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 2.5 SUPPLY AND RETURN PIPING The Benchmark Boiler utilizes 4” 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION are allowed in the discharge line. In multiple unit installations the discharge lines must not be manifolded together. Each must be individually run to a suitable discharge location. PRESSURE RELIEF VALVE 4” HOT BOILER WATER OUTLET Figure 2-4: P&T Relief Valve Location 2.7 CONDENSATE DRAIN & PIPING The Benchmark Boiler is designed to condense water vapor from the flue products.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION While observing the above guidelines, install the condensate trap as follows: Condensate Trap Installation 1. Connect the condensate trap inlet to the exhaust manifold drain connection by inserting the drain port directly into the trap adaptor inlet, and then tightening the inlet thumbscrew, as shown in Figure 2-6. The inlet features two integral O-rings to prevent leakage. 2. At the condensate trap outlet, install a 3/4” NPT nipple. 3.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 2.8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS. CAUTION Many of the soaps used for gas pipe leak testing are corrosive to metals. Therefore, piping must be rinsed thoroughly with clean water after leak checks have been completed.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 2.8.3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions (see sections 2.8.3.1 and 2.8.3.2, below). Regulators must conform to the following specifications: • NATURAL GAS: The external natural gas regulator must be capable of regulating 100,000 – 2,120,000 BTU/HR of natural gas while maintaining a gas pressure of 8.0” W.C. minimum to the unit.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION NOTE 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. 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION WIRE CONDUITS POWER BREAKER TRANSFORMER 24V POWER SUPPLY 12V POWER SUPPLY FUSE BLOCKS (2) TERMINAL BLOCKS Figure 2-9: Power Box Internal Components With the exception of the transformer shown in Figure 2-9, all of the components in the Power Box are mounted on a DIN rail.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION Figure 2-10: Power Box Cover Labels – 120VAC Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER. A three-pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet metal enclosures of the unit.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION TERMINAL STRIPS I/O PCB BOARD Figure 2-11: Input/Output (I/O) Box Location NOTE Use Figure 2-12 to determine the functions of the I/O PCB connections. Do not use the silkscreened labels on the PCB itself, as these may not match the function names. There is a diagram of the connection functions on the cover of the I/O Box as well. CAUTION DO NOT make any connections to the I/O Box terminals labeled “NOT USED”.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 2.10.2 COMBUSTION AIR Terminal The COMBUSTIAN AIR terminal is used to monitor the combustion air temperature sensor. This input is always enabled and is a “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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION • When 0-10VDC is selected, the voltage output is used by the controller to modulate the combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.10.11). • If On Board Boiler Sequencing Technology (BST) is enabled, the Analog Output terminals are used to drive the isolation valve, open and closed.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION • If BST is NOT implemented, the second use is typically in conjunction with the AUXILIARY RELAY CONTACTS described in section 2.10.14. This interlock circuit is located in the purge section of the start string. It can be connected to the proving device (end switch, flow switch etc.) of an auxiliary piece of equipment started by the unit’s auxiliary relay.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION For Massachusetts installations, the following companies provide vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts. Contact information is as follows: Selkirk Corporation - Heatfab Division 130 Industrial Blvd. Turners Falls, MA 01376 Phone: 1-800-772-0739 www.heat-fab.com Watertown Supply 33Grove St. Watertown, MA 02472 Phone: (617) 924-2840 http://www.watertownsupply.com/ M. A.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION 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. 2.
Benchmark 1500DF - 2000DF Boilers CHAPTER 2 – INSTALLATION Figure 2-14: Sequencing Valve Installed 3. Remove the jumper wire from the Molex connector and then plug it into the sequencing valve’s connector. Page 34 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION CHAPTER 3. OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 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 may void the equipment warranty.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION 2 3 1 *4 12 5 11 6 7 10 8 9 Figure 3-1: Control Panel Front View *NOTE If there is a requirement to use the RS232 port (Item 4) on the CMore controller front panel, contact AERCO to purchase the RS232 Adaptor Cable (P/N 124675), which is designed for this purpose. This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial-toUSB adaptor for use in modern computer USB ports.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION LED Status Indicators Four Status LEDs indicate the current operating status as follows: 1 COMM Lights when RS-232 communication is occurring MANUAL Lights when the valve position (fire rate) is being controlled using the front panel keypad. This mode of operation is for service technician use only.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays – Continued CONTROL, INDICATOR OR DISPLAY ITEM NO. FUNCTION MENU Keypad Six (6) keys which provide the following functions for the Control Panel Menus: 10 MENU Steps through the main menu categories shown in Figure 3-2. The Menu categories wrap around in the order shown. BACK Allows you to go back to the previous menu level without changing any information.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – 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. The menus are protected by a password levels to prevent unauthorized use.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION * Only if BST is enabled (see Chapter 10) Figure 3-2: Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. Page 40 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION 3.4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3-2. This menu is “Read-Only” and does not allow personnel to change or adjust any displayed items. Since this menu is “Read-Only”, it can be viewed at any time without entering a password. Pressing the ▲ arrow key to display the menu items in the order listed (Top-Down).
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Table 3-3: Setup Menu Menu Item Display Passsword Language Time Date Unit of Temp Comm Address Baud Rate Upload Timer Unit Alpha Unit Serial # Unit Year C-More Year C-More Serial # C-More Alpha IP Address Software Available Choices or Limits Minimum Maximum 0 9999 English 12:00 am 11:59 pm 01/01/00 12/31/99 Fahrenheit or Celsius 0 127 2400, 4800, 9600, 19.2K 0 A Z 0000 9999 0 99 0 99 0 9999 A Z Ver 0.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Table 3-4: Configuration Menu Menu Item Display Internal Setpt Unit Type Unit Size (Only the unit sizes available for the Unit Type will be displayed) Fuel Type Available Choices or Limits Minimum Maximum Lo Temp Limit Hi Temp Limit Outdoor Sensor 130°F KC Boiler, KC Boiler LN, BMK Boiler Std, BMK Boiler LN, BMK Blr Std Dual, BMK Blr LN, KC Water Heater, KC Wtr Heater LN, Innovation WH, BMK Blr LN Dual BMK Boiler LN 750 MBH, 800 MBH 1000 MB
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Table 3-4: Configuration Menu - Continued Menu Item Display Max Valve Position Available Choices or Limits Minimum Maximum 40% 100% Default 100% Pump Delay Timer 0 min. 30 min. 0 min. Aux Start On Dly 0 sec. 120 sec. 0 sec. Failsafe Mode Low Fire Timer Shutdown or Constant Setpt 2 sec. Shutdown 600 sec. 2 sec.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION 3.8 COMBUSTION CAL MENU The Combustion Cal (Calibration) Menu is protected by the level 2 password (6817) which must be entered to view or change the menu items shown in Table 3-6. These menu items are used to vary the speed of the unit’s blower motor based on air temperature and air density at prescribed Air/Fuel Valve positions (% open).
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION The Items contained in group 1 (BST Monitor Items) are ALWAYS displayed within the menu, as these items are critical for proper system operation. Therefore, the BST Monitor Items Header itself is NOT displayed. The Items contained in groups 2-5 are NOT DISPLAYED unless that particular item group has been enabled from the C-More keypad.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Menu Item Display Available Choices or Limits Default Minimum Maximum BST Setpt Lo Limit BST Setpt HI Limit 130°F Setback Start 12:00am 11:59pm 12.00am Setback End 12:00am 11:59pm 12.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION Available Choices or Limits Menu Item Display Maximum 1 9 5 Degrees Points Degrees 0 9999 sec 0 Err Threshold SSD Temp Format Default Minimum BST Upld Timer 3.10 START SEQUENCE When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge safety switches to ensure they are closed.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION NATURAL GAS INLET PROPANE INLET TO AIR/FUEL VALVE MANUAL SHUTOFF VALVE NATURAL GAS SSOV NATURAL GAS HIGH GAS PRESSURE SWITCH NATURAL GAS LOW GAS PRESSURE SWITCH PROPANE SSOV PROPANE HIGH GAS PRESSURE SWITCH PROPANE LOW GAS PRESSURE SWITCH Figure 3-3: BMK 1500DF/2000DF: SSOV Location 3. With all required safety device switches closed, a purge cycle will be initiated and the following events will occur: a.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION c. The VALVE POSITION bargraph will show 100%. TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN Figure 3-4: Air/Fuel Valve In Purge Position 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION (b) The “Spark Cycle Time” item in the Factory menu can be set to either 0 Sec, 2 Sec or 7 Sec to define the duration of the Spark Element Cleaning Cycle. This cycle turns on the spark transformer to produce a spark (with no gas flowing) to clean the spark element of moisture or carbon buildup. For the duration of this cycle, the C-More will display the “CLEANING IGNITER” message.
Benchmark 1500DF - 2000DF Boilers CHAPTER 3 – OPERATION 3.11 START/STOP LEVELS The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows and should not require adjustment: Natural Gas Start Level: Stop Level: Propane Gas BMK 1500 BMK 2000 BMK 1500 BMK 2000 24% 16% 24% 16% 24% 18% 24% 16% Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP CHAPTER 4. INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark boiler consists of the following: • • • • Complete installation (Chapter 2) Set proper controls and limits (Chapter 3) Perform combustion calibration (Chapter 4) Test safety devices (Chapter 6) All applicable installation procedures in Chapter 2 must be fully completed prior to performing the initial start-up of the unit.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP • 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. • 1/4 inch NPT-to-barbed fittings for use with gas supply manometer or gauge. • Small and large flat blade screwdrivers. • Tube of silicone adhesive 4.2.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP Install the 16” W.C. manometer(s) as described in the following steps: Installing Gas Supply Manometer 1. Turn off the main gas supply upstream of the unit. 2. Remove the top panel and front panel from the boiler to access the gas train components. 3. To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration (section 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP 4.3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated at the factory prior to shipping. This gas pressure must be within the following ranges for each model of boiler at full fire: Table 4-1: Nominal Gas Pressure – NATURAL GAS BMK Boiler Model Nominal Gas Pressure BMK 1500DF 3.5” W.C. ±0.2” W.C. BMK 2000DF 6.3” W.C. ±0.2” W.C.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP NATURAL GAS Combustion Calibration – Continued 13. Compare the oxygen readings on the combustion analyzer to the on-board O2 sensor value displayed in the Operating Menu of the C-More Control Panel. If the values differ by more than ±1.5% and your combustion analyzer is correctly calibrated, the on-board O2 sensor may be defective and need to be replaced. 14. Compare the measured oxygen level to the oxygen range shown below.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP NATURAL GAS Combustion Calibration – Continued 25. The oxygen level at the 80% valve position should be as shown below. Also, ensure that the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the following values: Combustion Calibration Readings – 80% valve Position Valve Position Oxygen (O2) % Nitrogen Oxide (NOx) Carbon Monoxide (CO) 80% 5.4% ± 0.5% ≤50 ppm <150 ppm 26.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP BRASS HEX HEAD (Remove to access the 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-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP 4.4 PROPANE COMBUSTION CALIBRATION If the boiler is currently running Natural Gas, complete the instructions in section 4.5.1 to switch the boiler fuel source from NATURAL GAS to PROPANE Gas. The Benchmark boiler is combustion calibrated at the factory prior to shipping.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP PROPANE Combustion Calibration – Continued 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 reading to stabilize. 13. Compare the oxygen readings on the combustion analyzer to the on-board O2 sensor value displayed in the Operating Menu of the C-More Control Panel. If the values differ by more than ±1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP PROPANE Combustion Calibration – Continued 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. 25. The oxygen level at the 80% valve position should be as shown below.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP 4.5 DUAL-FUEL SWITCHOVER INSTRUCTIONS 4.5.1 Switchover from NATURAL GAS to PROPANE To switch from Natural Gas to Propane Gas operation, proceed as follows: Switchover from NATURAL GAS to PROPANE 1. Set the ON/OFF switch on the C-More Controller to the OFF position. 2. Close the external Natural Gas supply valves. 3. Open the external Propane Gas supply valves. 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP C-MORE CONTROLER DUAL FUEL CUTOVER SWITCH FRONT VIEW Figure 4-6: Duel Fuel Switch Location 4.5.2 Switchover from PROPANE to NATURAL GAS To switch from Propane to Natural Gas, proceed as follows: Switchover from PROPANE to NATURAL GAS 1. Set the ON/OFF switch on the C-More Controller to the OFF position. 2. Close the external Propane Gas supply valves. 3. Open the external Natural Gas supply valves. 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP Switchover from PROPANE to NATURAL GAS – Continued 15. Using the ▲ and ▼ arrow keys, scroll through the Configuration Menu and stop at Fuel Type. 16. Press the CHANGE key. Fuel Type will begin to flash. 17. Press the ▼ arrow key. Natural Gas will be displayed. 18. Press the ENTER key to store the Natural Gas Fuel type. 19. Replace the front door panel previously removed from the boiler. 20.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP DIGITAL OVER-TEMPERATURE ALARM SWITCH ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH FUEL SELECTOR SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 4-5: Over-Temperature Limit Switch Locations 4.7.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP Perform the following steps to check or adjust the digital alarm switch settings: Digital Alarm Settings 1. Set the ON/OFF to the ON position. 2. Press the SET button on the Digital Alarm Switch. SP will appear in the display. 3. Press the SET button again. The current over-temperature limit value stored in memory will be displayed. (default = 210°F). 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 4 – INITIAL START-UP (This Page Is Intentionally Blank) Page 68 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers CHAPTER 5 – MODE OF OPERATION CHAPTER 5. MODE OF OPERATION 5.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The following sections 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 1500DF - 2000DF Boilers CHAPTER 5 – MODE OF OPERATION Indoor/Outdoor Startup 1. Refer to the Indoor/Outdoor reset ratio charts in Appendix F. 2. Choose the chart corresponding to the desired Building Reference Temperature. 3. Go down the left column of the chart to the coldest design outdoor air temperature expected in your area. 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.
Benchmark 1500DF - 2000DF Boilers 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 1500DF - 2000DF Boilers CHAPTER 5 – MODE OF OPERATION 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. The REMOTE LED will go off and the MANUAL LED will light. To change back to the Remote Setpoint mode, simply press the AUTO/MAN switch.
Benchmark 1500DF - 2000DF Boilers CHAPTER 5 – MODE OF OPERATION 5.5.1 Direct Drive Field Wiring The only wiring connections necessary for Direct Drive mode are connection of the remote 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 5 – MODE OF OPERATION 5.6.2 ACS Setup and Startup This mode of operation is factory preset and the ACS controls the firing rate (air/fuel valve % open position). There are no setup instructions for each individual unit. To operate the unit in manual mode, press the AUTO/MAN switch. The REMOTE LED will go off and the MANUAL LED will light To change back to the ACS mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off.
Benchmark 1500DF - 2000DF Boilers CHAPTER 5 – MODE OF OPERATION will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boilers are not able to satisfy the domestic hot water demand. When the combo units are satisfying the domestic load, they are in the constant setpoint mode of operation. When the combo units switch over to space heating, their mode of operation changes to follow the ACS command.
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Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING 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 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.2 LOW GAS PRESSURE FAULT TEST The instructions below apply to both the BMK 1500DF and BMK 2000DF and to both the NATURAL GAS and PROPANE gas trains.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING Low Gas Pressure Fault Test – Continued 7. The unit should shut down and display a GAS PRESSURE fault message at approximately 2.6” W.C.. 8. Fully open the external manual gas shut-off valve and press the CLEAR button on the Control Box. 9. The fault message should clear and the FAULT indicator should go off. The unit should restart. 10. Upon test completion, close the ball valve and remove the manometer.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING High Gas Pressure Test 1. Ensure that the appropriate high gas pressure leak detection ball valve (Natural Gas or Propane) is closed (see Figure 6-1b). Note that there are two Natural Gas leak detection ball valves (for high and low pressure) but only one on the Propane gas train. 2. Remove the 1/4“ plug from the leak detection ball valve shown in Figure 6-1b. 3. Install a 0 – 16” W.C. manometer (or W.C.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING Low Water Level Fault – Continued 7. Close the drain and pressure relief valve used in draining the unit. 8. Open the water shut-off valve in the return piping to the unit. 9. Open the water supply shut-off valve to the unit to refill. 10. After the shell is full, press the LOW WATER LEVEL RESET button to reset the low water cutoff. 11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message. 12.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING 9. OVER TEMPERATURE LIMIT DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON FUEL SELECTION SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 6-2: Temperature Limit Switch Location 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.6.2 Delayed Interlock Test Delayed Interlock Test 1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals. 2. Start the unit in the Manual Mode at a valve position between 25% and 30%. 3. If there is a jumper across the DELAYED INTL’K IN terminals, remove one side of the jumper. If the interlock is connected to a proving switch of an external device, disconnect one of the wires leading to the proving switch. 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING IGNITER/INJECTOR ASSEMBLY NATURAL GAS INLET BLOWER PLENUM BLOWER PROPANE INLET A/F VALVE PLENUM HEAT EXCHANGER BLOWER PROOF SWITCH MANUAL SHUT-OFF VALVE AIR/FUEL VALVE NATURAL GAS SSOV BLOCKED INLET SWITCH AIR FILTER PROPANE GAS SSOV Figure 6-3: Bare Boiler – Partial View (BMK 1500DF/2000DF) Page 84 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers 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. 6.8.1 Blower Proof Switch Test Blower Proof Switch Test 1. Disable the blower output drive voltage as follows: (a) Press the MENU key until CONFIGURATION MENU is displayed. (b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed, then press the CHANGE key.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING Blocked Inlet Switch Test – Continued WARNING THE BLOWER SUCTION IS VERY STRONG AND CAN PULL NEARBY OBJECTS INTO THE BLOWER’S FAN BLADES. DO ALLOW ANYTHING TO BE PULLED INTO THE BLOWER. DO NOT WEAR ANYTHING THAT COULD GET CAUGHT AND PULL YOU INTO THE BLOWER. 3. Turn off the gas supply ball valve to the boiler and then complete the following steps: (a) Use jumper wires to jump out the Low Gas Pressure Switch and the Blower Proof Switch.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING AIR INLET PRIMARY WATER INLET EXHAST MANIFOLD ANALYZER PORT DRAIN VALVE CONDENSATE DRAIN Figure 6-4: Boiler Rear View Showing Air Inlet Location 6.9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6-1 contains the proof of closure switch. The proof of closure switch circuit is checked as follows: SSOV Proof of Closure Switch 1. Set the unit’s ON/OFF switch to the OFF position. 2.
Benchmark 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING SSOV ACTUATOR COVER ACTUATOR COVER SCREW Figure 6-5: SSOV Actuator Cover Location 6.10 PURGE SWITCH OPEN DURING PURGE The Purge Switch (and Ignition Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Purge Switch Open During Purge 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set the valve position between 25% and 30%. 2.
Benchmark 1500DF - 2000DF Boilers 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: Ignition Switch Open During Ignition 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 1500DF - 2000DF Boilers CHAPTER 6 – SAFETY DEVICE TESTING TO BLOWER 169 170 Ignition Position Switch VALVE POSITION DIAL 171 172 AIR/FUEL VALVE SWITCH WIRING BREAKOUT Purge Position Switch AIR IN Figure 6-7: 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 90 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE 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. For a complete inspection check list see ASME CSD1 chart.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE 7.2 IGNITER-INJECTOR The igniter-injector (part no. 66026) 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.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE Igniter-Injector Maintenance Procedures – Continued 4. Refer to the partial exploded view in Figure 7-2. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly. Disconnect the staged ignition assembly from the igniter-injector. 5. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end wrench. 6.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE IGNITER-INJECTOR MAINTENANCE PROCEDURES – Continued NOTE If a replacement igniter-injector (part no. 66026) is being installed, a compression nut containing a built-in ferrule will be included with the replacement part. If needed, 3 indexing washers are also included These washers may be needed to properly position the gas injector tube of the igniter-injector within the 120° angle range shown in Figure 7-3.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE Flame Detector Maintenance – Continued 3. Disconnect the flame detector lead wire. 4. Remove the two (2) screws securing the flame detector to the plate (Figure 7-2). The flame detector is secured to the burner plate with one #10-32 screw and one #8-32 screw. 5. Remove the flame detector and gasket from the burner plate. 6. Thoroughly inspect the flame detector. If eroded, the detector should be replaced.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE 7.6 BURNER ASSEMBLY INSPECTION The burner assembly is located at the top of the unit's heat exchanger. The burner assembly may be hot. Therefore, allow the unit to cool sufficiently before removing the burner assembly.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedures (Cont.) 11. Remove the eight (8) 3/8-16 nuts, using a 9/16” wrench, attaching the blower plenum to the burner beneath (see Figure 7-4a & 7-4b). 12. Remove the blower plenum from between the blower and the burner and set aside for later reassembly. O2 sensor and flame observation port remain assembled to the plenum flange. NOTE The burner assembly is heavy, weighing approximately 65 lbs. 13.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedure (Cont.) BLOWER PLENUM IGNITERINJECTOR ASSEMBLY 5/16” x 1-3/4” BOLTS, 5/16” WASHERS & NYLOCK NUTS (4 each) BLOWER A/F VALVE PLENUM 3/8”-16 HEX NUTS (8 each) AIR/FUEL VALVE FILTER BURNER PLATE 1/2” NUTS & BOLTS (4 each) AIR FILTER GAS TRAIN Figure 7-4a: Burner Assembly Mounting Details Page 98 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedure – Continued 5/16” x 1-3/4” BOLTS, 5/16” WASHERS & NYLOCK NUTS (4 each) BLOWER 3/8”-16 HEX NUTS (8 each) A/F VALVE PLENUM BLOWER PROOF SWITCH NATURAL GAS INLET AIR/FUEL VALVE PROPANE INLET BLOCKED INLET SWITCH MANUAL SHUT-OFF VALVE AIR FILTER Figure 7-4b: Burner Assembly Mounting Details IMPORTANT! NOTE The LOWER RELEASE GASKET (P/N 81186) features four tabs around its periphery.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE 7.7 CONDENSATE DRAIN TRAP Benchmark boilers 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 cleaned in accordance with the maintenance schedule shown in Table 7-1 to ensure proper operation. To inspect and clean the trap, proceed as follows: Condensate Drain Trap Maintenance Procedure 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE 7.8 AIR FILTER CLEANING & REPLACEMENT The Benchmark boiler is equipped with an air filter (part no. 88014) which should be cleaned and re-oiled every 12 months and replaced every 24 months. The air filter is located at the inlet of the air fuel valve at the top of the boiler as shown in Figure 7-7. To inspect/replace the air filter, proceed as follows: Air Filter Cleaning & Replacement Procedures 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 7 – MAINTENANCE 7.9 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. Shutting Boiler Down for Extended Period 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. Close the water supply and return valves to isolate boiler. 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE 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 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.
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Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING FAULT INDICATION AIRFLOW FAULT DURING IGNITION PROBABLE CAUSES 1. Blower stopped running due to thermal or current overload. 2. Blocked Blower inlet or inlet air filter. 3. Blockage in Blower Proof switch. 4. Blockage in Blocked Inlet switch. 5. Defective Blower Proof switch. 6. Defective Blocked Inlet switch. 7. Loose temperature to AUX connection in I/O Box. 8. Defective temperature sensor.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION AIRFLOW FAULT DURING PURGE PROBABLE CAUSES 1. Blower not running or running too slow. 2. Defective Blocked Inlet switch. 3. Blockage in air filter or Blocked Inlet switch. 4. Blocked blower inlet or inlet ductwork. 5. No voltage to Blocked Inlet switch from C-More Control Box. 6.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION DELAYED INTERLOCK OPEN PROBABLE CAUSES 1. Delayed Interlock Jumper not 1. Check to insure jumper is properly installed across the delayed 2. Device proving switch hooked to 2. If there are 2 external wires on these terminals, check to see if properly installed or missing. interlocks is not closed.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) PROBABLE CAUSES 6. Carbon or other debris on Burner. 7. Staged ignition solenoid valve doesn’t open. 8. Clogged staged ignition piece. 1. Worn Flame Detector or cracked ceramic. 2. Defective Regulator. FLAME LOSS DURING RUN 3. Poor combustion calibration. 4. Debris on burner. 5. Blocked condensate drain. HEAT DEMAND FAILURE HIGH EXHAUST TEMPERATURE 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 1. Incorrect supply gas pressure. HIGH GAS PRESSURE 2. Defective SSOV Actuator. 3. Defective High Gas Pressure Switch. HIGH WATER TEMP SWITCH OPEN 1. Faulty Water temperature switch. 2. Incorrect PID settings. 3. Faulty shell temperature sensor. 4. Unit in Manual mode. 5. Unit setpoint is greater than Over Temperature Switch setpoint. 6.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION IGN SWTCH CLOSED DURING PURGE PROBABLE CAUSES 1. Air/Fuel Valve not rotating. 2. Defective or shorted switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse. 5. Defective IGST Board. IGN SWTCH OPEN DURING IGNITION 1. Air/Fuel Valve not rotating to ignition position. 2. Defective ignition switch. 3. Defective Power Supply Board or fuse. 4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION INTERLOCK OPEN PROBABLE CAUSES 1. Interlock jumper not installed or removed. 2. Energy Management System does not have unit 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. Incorrect supply gas pressure. LINE VOLTAGE OUT OF PHASE LOW GAS PRESSURE 2.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) PROBABLE CAUSES 2. Defective or shorted switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse. 5. Defective IGST Board. PRG SWTCH OPEN DURING PURGE 1. Defective purge switch. 2. No voltage present at switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board. OUTDOOR TEMP SENSOR FAULT 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION RECIRC PUMP FAILURE 1. Internal recirculation pump failed. 1. Replace recirculation pump. REMOTE SETPT SIGNAL FAULT 1. Remote setpoint signal not present: 1. Check I/O Box to ensure signal is hooked up. Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring. 2.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION SSOV SWITCH OPEN PROBABLE CAUSES 1. Actuator not allowing for full closure of gas valve. 2. SSOV powered when it should not be. 3. Defective Switch or Actuator. 4. Incorrectly wired switch. STEPPER MOTOR FAILURE 1. Air/Fuel Valve out of calibration. 2. Air/Fuel Valve unplugged. 3. Loose wiring connection to the stepper motor. 4. Defective Air/Fuel Valve stepper motor.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 8-2: BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT Hard Light-Off PROBABLE CAUSES 1. Clogged/damaged Gas Injector on Igniter-Injector (Figure 8-1). 2. Defective Staged Ignition Solenoid (Figure 8-1). Fluctuating Gas Pressure 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE STAGED IGNITION SOLENOID BLOWER PLENUM INJECTORIGNITOR ASSY WITH INDEXING (CLOCKING) WASHERS (0-3 as needed) FLAME OBSERVATION PORT O2 SENSOR & WASHER FLAME DETECTOR & GASKET BURNER PLATE FLANGE Figure 8-1: Igniter-Injector & Flame Detector Mounting Details DAMPING ORIFICE BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw).
Benchmark 1500DF - 2000DF Boilers CHAPTER 9 – RS232 COMMUNICATION CHAPTER 9. RS-232 COMMUNICATION 9.1 INTRODUCTION The RS-232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line, Fault and Sensor log displays. NOTE The information in this chapter does not apply when implementing BST.
Benchmark 1500DF - 2000DF Boilers CHAPTER 9 – RS232 COMMUNICATION flow control), you can use the Serial Configuration panel (right image in Figure 9-1) by selecting “Serial” in the left navigation pane. Now, to connect to the remote server, simply click the Open button at the bottom of the dialog box. A new terminal window will pop up and ask you to log in.
Benchmark 1500DF - 2000DF Boilers CHAPTER 9 – RS232 COMMUNICATION Running a Command on a Remote Machine Using PuTTY – Continued 5. You are now ready to execute this command on the remote machine, simply click the Open button at the bottom of the dialog. 6. You will have to provide an account name and password in the terminal window to complete the process. 9.
Benchmark 1500DF - 2000DF Boilers CHAPTER 9 – RS232 COMMUNICATION MENU PROCESSING UTILIZING RS-232 COMMUNICATION – Continued NOTE The Level 1 password (159) must be entered to change options in the Setup, Configuration and Tuning Menus. The Level 2 password (6817) must be entered to view or change options in the Calibration and Diagnostics Menus. With the exception of the password entry, all other keyboard entries can be made using either upper or lower case. 5.
Benchmark 1500DF - 2000DF Boilers CHAPTER 9 – RS232 COMMUNICATION 9.4.1 Fault Log The C-More Control Panel logs the last 20 faults (0 – 19) starting with the most recent (#0). They can be viewed in the front panel display or via the RS-232 port. The Fault Log cannot be cleared. If the Fault Log already contains 10 faults, the earliest fault is overwritten when a new fault occurs. A sample Fault Log display is shown in Table 9-1. Table 9-1: Sample Fault Log Display No.
Benchmark 1500DF - 2000DF Boilers CHAPTER 9 – RS232 COMMUNICATION NOTE The Sensor (S) Log can store up to 1200 records. Therefore, to view the most recently logged record, enter “S” followed by 0 (zero) and then press Enter (i.e. S0 ). To view earlier records in reverse chronological order, enter S and press Enter. To go back 200 or 700 records, enter S200 or S700, etc. and press Enter. 9.4.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.1 INTRODUCTION The C-More on-board Boiler Sequencing Technology system (BST) is an integrated 8 boiler control system designed into the C-More controller. The BST has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 8 boilers while achieving maximum operational efficiency.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.2 AERCO BST Quick Start Chart Select the single option that suites your installation and then complete the instructions in the corresponding sub-sections of section 10.3 BST Implementation Instructions. Constant Setpoint (choose option 1 or 2) Option 1 – Direct Wired Header Complete section 10.3.1 OR Option 2 – Modbus Header Complete section 10.3.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3 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” in the I/O Box.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.2 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. 2.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor NOTE: Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1 - Direct Wired Header Sensor Wiring 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 3 – Continued Step 3 - Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu and set the BST Mode item to BST Slave (for now). On MASTER only: 3. Go to the BST Setpoint item and enter the Failsafe Setpoint. 4. Go to the BST Setup Menu item and set to Enabled. 5. Go to the BST Setpoint Mode item and select Outdoor Reset. 6.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor NOTE: Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1 - Modbus Header Sensor Wiring 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 4 – Continued • There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded. Temp Sensor PN 61043 Modbus Transmitter I/O Box Step 3 - Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu and set the BST Mode item to BST Slave (for now).
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 420ma Setpoint Drive NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: Direct Wired Header Sensor Wiring 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive NOTE: Both Header Sensor AND the ProtoNode SSD Device must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: Direct Wired Header Sensor Wiring 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: MODbus Header Sensor 1.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 7 – Continued Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu and set the BST Mode item to BST Slave (for now). On MASTER only: 3. Go to the BST Setpoint item and enter the Failsafe Setpoint. 4. Go to the BST Setup Menu item and set to Enabled. 5. Go to the BST Setpoint Mode item and select Remote Setpoint. 6.
Benchmark 1500DF - 2000DF Boilers CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive NOTE! Both Header Sensor AND ProtoNode SSD Device must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: MODbus Header Sensor 1.
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Benchmark 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint Inlet Water Temp 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 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows Level 1 or Level 2 password to be entered. Entering the Level 1 Password (159) allows options in the Setup, Configuration and Tuning Menus to be modified. Entering the Level 2 Password (6817) allows options in the Calibration and Diagnostics Menus to be changed or activated, in addition to all Level 1 Menu options.
Benchmark 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set (40°F to 240°F). Default is 130°F. Unit Size Sets unit size from 600 MBH to 6000 MBH depending on the Unit Type.
Benchmark 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Aux Start On Dly Specifies the amount of time to wait (0 to 120 sec.) between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the boiler. Default is 0 sec. Failsafe Mode Allows the Failsafe mode to be set to either Constant Setpoint or Shutdown. Default is Shutdown.
Benchmark 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Deadband High Deadband Low Deadband High and Deadband Low settings create an “Outlet Temperature” Zone in which no Valve Position corrections will be attempted. The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint + Deadband High and Active Setpoint – Deadband Low.
Benchmark 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%.
Benchmark 1500DF - 2000DF Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION COMBUSTION CAL MENU NOTE: The Level 2 Password (6817) must be entered to view the options in the Combustion Cal Menu. This Menu is used during the Combustion Calibration procedures described in Chapter 4 of this Manual.
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Benchmark 1500DF - 2000DF Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Appendix B: STARTUP, STATUS & DISPLAY MESSAGES Table B-1: Startup And Status Messages MESSAGE DESCRIPTION DEMAND DELAY XX sec DISABLED HH:MM pm, pm MM/DD/YY 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. FLAME PROVEN IGNITION TRIAL XX sec Displayed after flame has been detected for a period of 2 seconds.
Benchmark 1500DF - 2000DF Boilers APPENDIX B – STARTUP, STATUS & DISPLAY 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 1500DF - 2000DF Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages – Continued FAULT MESSAGE LOW WATER LEVEL FAULT DESCRIPTION The Low Water Cutoff board is indicating low water level. NETWORK COMM FAULT O2 % OUT OF RANGE The RS-485 network information is not present or is corrupted. The O2 % has gone below 3% or above 8%. OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range.
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Benchmark 1500DF - 2000DF Boilers APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART Appendix C: SENSOR RESISTANCE/VOLTAGE CHART Temperature Sensor Resistance Voltage Chart (Balco) OMM-0098_0A GF-144 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 1311.4 1337.
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Benchmark 1500DF - 2000DF Boilers APPENDIX D – BOILER DEFAULT SETTINGS Appendix D: BOILER DEFAULT SETTINGS Appendix D: Boiler Default Settings MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130°F Unit Type BMK Boiler LN Unit Size 1500 MBH or 2000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal (If Mode = Remote Setpoint, Direct Drive or Combination) 4 –
Benchmark 1500DF - 2000DF Boilers APPENDIX D – BOILER DEFAULT SETTINGS Appendix D: Boiler Default Settings MENU & OPTION FACTORY DEFAULT Configuration Menu (Cont.) Setpt Limit Band (If Setpt Limiting = Enabled) 5°F 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 152 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX E – RECOMMENDED PERIODIC TESTING Appendix E: RECOMMENDED PERIODIC TESTING WARNING 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. The owner or user of an automatic boiler system should set up a formal system of periodic preventive maintenance and testing.
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Benchmark 1500DF - 2000DF Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Appendix F: INDOOR/OUTDOOR RESET RATIO CHARTS Table F-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 1500DF - 2000DF Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-3: Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1500DF - 2000DF Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-5: Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air Temp 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1500DF - 2000DF Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-7: Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air Temp 90F 85F 80F 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 1500DF - 2000DF Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix G: DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-936 rev A OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-995 rev A Page 160 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-898 rev C OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
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Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS Appendix H: PART DRAWINGS Benchmark 1500DF – 2000DF Part List Item# Qty Part # EXHAUST MANIFOLD 1 1 39187 2 1 81165 3 6 9-22 Description MANIFOLD: EXHAUST MANIFOLD: SEAL PIPE PLUG: 1/4" NPT: STEEL GAS TRAIN 4 1 5 1 6 1 7 1 22198 22201 63019 97005-2 97005-6 97005-5 BMK 1500DF/2000DF GAS TRAIN ASSY BMK 1500DF/2000DF DBB GAS TRAIN ASSY GAS TRAIN HARNESS FLEX HOSE 12” on Gas Train 22201 FLEX HOSE 24” on Gas Train 22198 HOSE, FLEXIBLE G
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS Benchmark 1500DF – 2000DF Part List – Continued Item# Qty Part # Description Item# Qty Part # Description SHEET METAL/PANEL ASSEMBLY OTHER ACCESSORIES & PARTS 72 1 37117 BACK PANEL: LEFT 87 1 73 74 1 2 37118 35029 BACK PANEL RIGHT TOP RAIL 88 89 1 1 SEE TABLE A SEE TABLE A 123540 75 76 77 78 79 80 81 82 1 1 1 2 4 1 1 2 1 1 25068 25078 72068 59179 59133 37119 37120 30117 74031 74033 ASSEMBLY: FRONT FRAME ASSEMBLY: F
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 OMM-0098_0A GF-144 Benchmark 1500DF – 2000DF Part List 02/01/2014 Whole Boiler 29313-3 – 29337-3 Sheet 3 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS 9 Benchmark 1500/2000 Burner-Air/Fuel Valve Assembly P/N 24378 & 24388 See full part lists below AERCO International, Inc. Blauvelt, NY 10913 Page 166 of 196 04/01/2014 Benchmark 1500DF – 2000DF Part List 02/01/2014 Whole Boiler 29313-3 – 29337-3 Sheet 4 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS NATURAL GAS Gas Train P/N 22188-1 7 4 PROPANE Gas Train P/N 22197 6 PARTIALLY EXPLODED VIEW Benchmark 1500DF/2000DF DUAL FUEL Gas Train P/N 22198 Consists of: - 22188-1 NATURAL GAS Gas Train - 22197 PROPANE Gas train Full gas train part lists are shown below AERCO International, Inc. Blauvelt, NY 10913 OMM-0098_0A GF-144 Benchmark 1500DF – 2000DF Part List 02/01/2014 Whole Boiler 29313-3 – 29337-3 Sheet 5 of 7 AERCO International, Inc.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS NATURAL GAS Gas Train P/N 22199-1 6 4 7 PARTIALLY EXPLODED VIEW 7 Benchmark 1500DF/2000DF DUAL FUEL DBB Gas Train P/N 22201 Consists of: - 22299-1 NATURAL GAS Gas Train - 22200 PROPANE Gas train AERCO International, Inc. Blauvelt, NY 10913 Page 168 of 196 04/01/2014 PROPANE Gas Train P/N 22200 Benchmark 1500DF – 2000DF Part List 02/01/2014 Whole Boiler 29313-3 – 29337-3 Sheet 6 of 8 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 OMM-0098_0A GF-144 Benchmark 1500DF – 2000DF Part List 02/01/2014 Whole Boiler 29313-3 – 29337-3 Sheet 7 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS 97 Power I/O Box P/N # 24386 54 29 31 AERCO International, Inc. Blauvelt, NY 10913 Page 170 of 196 04/01/2014 Benchmark 1500DF – 2000DF Part List 02/01/2014 Whole Boiler 29313-3 – 29337-3 Sheet 8 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS Benchmark 1500DF – 2000DF Natural Gas Gas Train – p/n 22188-1 rev A Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 1 1 1 1 2 5 1 1 2 1 3 3 1 2 2 1 1 Part # Description 123542 93069 94060-3 94060-8 94060-3.50 94060-2 99014 99015 69005 12951-2 9-43 92077 9-22 99017 123536 124083 124088 94060-6.5 FLANGE 2" 125# 2"NPT BUSHING: REDUCING 1-1/2" TO 2" NPT NIPPLE: 1-1/2" NPT X 3.00" LG NIPPLE: 1-1/2 NPT X 8.00 LG NIPPLE: 1-1/2 NPT X 3.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS Benchmark 1500DF – 2000DF PROPANE Gas Train – p/n 22197 rev A Item Qty Part # Description Item 1 2 3 4 5 6 7 8 9 10 11 1 1 2 2 1 1 2 1 1 1 2 VALVE: SSOV 1" NPT ACTUATOR: SSOV W/ REGULATOR BUSHING: REDUCING 1/4" X 1/8" NPT BUSHING: CONTROL BOX PRESSURE SWITCH: 2.6" W.C. FALL N.O. HIGH GAS PRESSURE SWITCH 4.7" W.C. NIPPLE: HEX 1/4" NPT X 3/8" NPT DAMPING ORIFICE: SSOV PIPE PLUG: 1/4" NPT: STEEL NIPPLE: 1" NPT TBE X 2.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 – 2000 Burner Assembly, p/n 24378 – 24388 rev A Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 1 1 1 1 1 1 10 1 5 2 1 1 1 1 1 1 Part # 69078 43090 24220-3 24220-10 46042 46044 81057 43095 55025 59138 9-21 123535 124008 61024 124979 93230 61002-5 60011-2 Description BLOWER: AMETEK 12.
Benchmark 1500DF - 2000DF Boilers APPENDIX H – PART DRAWINGS 14 2 5 16 13 7 11 9 15 27 21 9 10 20 26 12 32 19 33 31 29 28 30 24 27 22 23 18 25 17 AERCO International, Inc. Blauvelt, NY 10913 Page 174 of 196 04/01/2014 Benchmark 1500 – 2000 Burner Assembly 10/18/2013 24378 – 24388 rev A Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX I – WIRING DIAGRAMS Appendix I: WIRING DIAGRAMS Drawing Number 68064 rev B page 1 of 2 OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
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Benchmark 1500DF - 2000DF Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68064 rev B page 2 of 2 OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
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Benchmark 1500DF - 2000DF Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number: 68068 rev B page 1 of 2 OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
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Benchmark 1500DF - 2000DF Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68068 rev B page 2 of 2 OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
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Benchmark 1500DF - 2000DF Boilers APPENDIX J – PIPING DRAWINGS Appendix J: PIPING DRAWINGS Drawing Number: SD-A-989 rev A OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-990 rev A Page 184 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-991 rev A OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-992 rev A Page 186 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-993 rev A OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-994 rev A Page 188 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers APPENDIX K – C-MORE CONTROL PANEL VIEWS Appendix K: C-MORE CONTROL PANEL VIEWS CONNECTOR BOARD P/N 124366 LOW WATER CUTOFF BOARD P/N 124363 PMC BOARD P/N 124364 DISPLAY BOARD P/N 124365 GREEN LED P/N 124948 ENCLOSURE P/N 124951 ROCKER SWITCH P/N 124947 POWER SUPPLY BOARD P/N 124362 V.F.D.
Benchmark 1500DF - 2000DF Boilers 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 K – C-MORE CONTROL PANEL VIEWS Figure K-2: Benchmark Control Panel Rear View Page 190 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 1500DF - 2000DF Boilers APPENDIX L – RECOMMENDED SPARES Appendix L: RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix H for the locations of the recommended and optional spare parts listed in the following Tables.
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Benchmark 1500DF - 2000DF Boilers WARRANTY LIMITED WARRANTY: BENCHMARK 750 - 6000 GAS-FIRED BOILER PRESSURE VESSEL/HEAT EXCHANGER: 10 YEAR NON-PRORATED FROM SHIPMENT The pressure vessel/heat exchanger shall carry a 10 year non-prorated, limited warranty from date of shipment against any condensate corrosion, thermal stress failure, mechanical defects or workmanship. Operation of the boiler using contaminated air will void the warranty.
Benchmark 1500DF - 2000DF Boilers WARRANTY (Continued) Warranty coverage for all components and equipment mentioned in said warranty are not valid unless the water heater is started up by a factory certified SST (Service, Start-Up and Troubleshooting) Technician and an AERCO start-up sheet is completed. This warranty coverage is only applicable within the United States, Canada and Mexico.
Benchmark 1500DF - 2000DF Boilers NOTES: OMM-0098_0A GF-144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 1500DF - 2000DF Boilers Change Log: Date Description Changed By 04/01/2014 Rev A: Initial release Chris Blair © AERCO International, Inc., 2014 Page 196 of 196 04/01/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
