Instruction No.

GF-116

AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

Installation, Operation & Maintenance Instructions

Benchmark 3.0LN Series Gas Fired Low NOx Boiler System

Condensing, Modulating Forced Draft, Hot Water Boiler 3,000,000 BTU/H Input
Applicable for Serial Numbers G-10-1031 and above

Printed in U.S.A.

REVISED JUNE 15, 2010

Telephone Support
Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday):

1-800-526-0288

The information contained in this installation, operation and maintenance manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material.

AERCO International, Inc. 159 Paris Avenue Northvale, NJ 07647-0128 www.aerco,com

© AERCO International, Inc., 2010

CONTENTS GF-116 - AERCO BENCHMARK 3.0LN GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions
FOREWORD A

Chapter 1 – SAFETY PRECAUTIONS
Para. 1-1 1-2 Subject Warnings & Cautions Emergency Shutdown Page 1-1 1-2 Para. 1-3 Subject Prolonged Shutdown

1-1
Page 1-2

Chapter 2 – INSTALLATION

2-1

Para. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Subject Introduction Receiving the Unit Unpacking Site Preparation Supply and Return Piping Condensate Drains Gas Supply Piping AC Electrical Power Wiring

Page 2-1 2-1 2-1 2-1 2-3 2-3 2-5 2-6

Para. 2.9 2.10 2.11 2.12 2.13

Subject Modes of Operation and Field Control Wiring I/O Box Connections Auxiliary Relay Contacts Flue Gas Vent Installation Combustion Air

Page 2-7 2-9 2-11 2-11 2-11

Chapter 3 – CONTROL PANEL OPERATING PROCEDURES
Para. 3.1 3.2 3.3 3.4 3.5 Subject Introduction Control Panel Description Control Panel Menus Operating Menu Setup Menu Page 3-1 3-1 3-4 3-5 3-5 Para. 3.6 3.7 3.8 3.9 3.10 Subject Configuration Menu Tuning Menu Combustion Cal Menu Start Sequence Start/Stop Levels

3-1
Page 3-6 3-8 3-8 3-8 3-10

Chapter 4 – INITIAL START-UP
Para. 4.1 4.2 4.3 Subject Initial Startup Requirements Tools and Instruments for Combustion Calibration Natural Gas Combustion Calibration Page 4-1 4-1 4-2 Para. 4.4 4.5 Subject Unit Reassembly Over-Temperature Limit Switch

4-1
Page 4-6 4-6

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6 Subject Maintenance Schedule Ignitor-Injector Flame Detector Combustion Calibration Safety Device Testing Burner Assembly Inspection Page 7-1 7-1 7-2 7-3 7-3 7-3 Para. 6.8 6.12 Subject Air Flow Fault Test SSOV Proof of Closure Switch Purge Switch Open During Purge Ignition Switch Open During Ignition Safety Pressure Relief Valve Test 6-1 Page 6-4 6-4 6-5 6-5 6-6 Chapter 7 – MAINTENANCE REQUIREMENTS Para.11 6.3 5.7 7.5 Subject Introduction Indoor/Outdoor Reset Mode Constant Setpoint Mode Remote Setpoint Mode Direct Drive Modes Page 5-1 5-1 5-2 5-2 5-3 Para.1 Subject Introduction Page 8-1 Para. 6.5 6.8 7. 8.1 6. Subject 8-1 Page ii . 7.9 6.3 7.2 7. 7.2 6.1 7.5 7.6 6.4 7.1 5.9 Subject Condensate Drain Trap Shutting the Boiler Down For An Extended Period of Time Placing The Boiler Back In Service After A Prolonged Shutdown 7-1 Page 7-4 7-6 7-6 Chapter 8 – TROUBLESHOOTING GUIDE Para.CONTENTS Chapter 5 – MODE OF OPERATION Para.7 Subject Boiler Management System (BMS) Combination Control System (CCS) 5-1 Page 5-4 5-5 Chapter 6 – SAFETY DEVICE TESTING PROCEDURES Para.2 5. 5. 5.4 6.7 Subject Testing of Safety Devices Low Gas Pressure Fault Test High Gas Pressure Test Low Water Level Fault Test Water Temperature Fault Test Interlock Tests Flame Fault Test Page 6-1 6-1 6-2 6-2 6-2 6-3 6-3 Para.6 5.4 5.10 6.3 6.

9-3 9-4 Subject Menu Processing Utilizing RS232 Communication Data Logging 9-1 Page 9-1 9-2 APPENDICES App A B C D E F Subject Boiler Menu Item Descriptions Startup.RS232 COMMUNICATION Para.CONTENTS Chapter 9 . 9.1 9-2 Subject Introduction RS232 Communication Setup Page 9-1 9-1 Para. Status and Fault Messages Temperature Sensor Resistance Chart Indoor/Outdoor Reset Ratio Charts Boiler Default Settings Dimensional and Part Drawings Page A-1 B-1 C-1 D-1 E-1 F-1 J K App G H I Subject Piping Drawings Wiring Schematics Recommended Periodic Testing Checklist Benchmark Control Panel Views Recommended Spare Parts Page G-1 H-1 I-1 J-1 K-1 WARRANTIES W-1 iii .

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Designed for application in any closed loop hydronic system.1 Whether used in singular or modular arrangements.0 offers the maximum flexibility in venting with minimum installation space requirements. to 2. as well as. the Benchmark 3. When installed and operated in accordance with this Instruction Manual. the Benchmark 3. the Benchmark's modulating capability relates energy input directly to fluctuating system loads. The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration.000 BTU/hr. with its 15:1 turn down ratio and condensing capability.FOREWORD Foreword The AERCO Benchmark 3. conventional heating systems. to 3.000 BTU/hr. NAME: ORGANIZATION: ADDRESS: TELEPHONE: INSTALLATION DATE: _____________________________________________ A . The output of the boiler is a function of the unit’s firing rate and return water temperature. It represents a true industry advance that meets the needs of today's energy and environmental concerns. contact your local sales representative or AERCO INTERNATIONAL.000. Output ranges from 198. provides extremely high efficiencies and makes it ideally suited for modern low temperature. The Benchmark 3.0. depending on operating conditions.0 operates at inputs ranging from 200. The Benchmark 3.900. For service or parts.0 Boiler complies with the NOx emission standards outlined in: • South Coast Air Quality Management District (SCAQMD).. Rule 1146.0LN Boiler is a modulating unit.000 BTU/hr.000 BTU/hr.

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Where applicable. In addition to all the requirements included in this AERCO Instruction Manual. CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING MAINTENANCE. CAUTION! Many soaps used for gas pipe leak testing are corrosive to metals. WARNING! ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS EQUIPMENT. CAUTIONS! Must be observed to prevent equipment damage or loss of operating effectiveness.SAFETY PRECAUTIONS CHAPTER 1 1. which should be carefully followed in all cases.1 (National Fuel Gas Code Publication No. 1-1 . or. EXCEPT DURING MAINTENANCE AND SERVICING. WARNING! BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE UNIT. the installation must conform to CSD-1. Authorities having jurisdiction should be consulted before installations are made. observe all safety regulations. in the absence of local codes. FLAMES. Where ASME CSD-1 is required by local jurisdiction. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions. at all times. IMPORTANT This Instruction Manual is an integral part of the product and must be maintained in legible condition. SAFETY PRECAUTIONS WARNING! DO NOT USE MATCHES. the installation of units MUST conform with local building codes. BE SURE TO SHUT OFF ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES. CANDLES. WARNING! THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A POSITIVE PRESSURE AND THEREFORE MUST BE COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES. WARNINGS! MUST BE OBSERVED TO PREVENT SERIOUS INJURY. and applicable Provincial regulations for the class.1 WARNINGS & CAUTIONS Installers and operating personnel MUST. The piping must be rinsed thoroughly with clean water after leak checks have been completed. CAUTION! DO NOT use this boiler if any part has been under water. the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment. It must be given to the user by the installer and kept in a safe place for future reference. NFPA54). THEREFORE THE COVER ON THE UNIT’S POWER BOX (LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED AT ALL TIMES. CGA B149. OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS. SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT. WARNING! FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED. Call a qualified service technician to inspect and replace any part that has been under water. ANSI Z223.

It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. the complete gas train and all connections must be leak tested using a non-corrosive soap. INSTALLATION OF CARBON MONOXIDE DETECTORS. the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling. In addition. At the time of installation of the side wall horizontal vented gas fueled equipment. 1-2 .3 PROLONGED SHUTDOWN After prolonged shutdown. the following requirements shall be satisfied: 1. If side-wall venting is used. including but not limited to decks and porches. the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. building or structure served by the side wall horizontal vented gas fueled equipment. turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit. a backflow preventer must be installed upstream of the Fill/Makeup Valve. If a glycol solution is used as anti-freeze protection. close the manual gas shutoff valve (Figure 1-1) located external to the unit. to verify all systemoperating parameters. If there is an emergency. building or structure used in whole or in part for residential purposes. including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting. The installer must identify the emergency shut-off device. the installation must conform to the following requirements extracted from 248 CMR 5. MANUAL GAS SHUTOFF VALVE 1. it is recommended that the startup procedures in Chapter 4 and the safety device test procedures in Chapter 6 of this manual be performed. Prior to unit operation. The vent termination must be located a minimum of 4 feet above grade level. IMPORTANT The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.SAFETY PRECAUTIONS 1. VALVE OPEN VALVE CLOSED Figure 1-1 Manual Gas Shutoff Valve 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.08 (2): (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases.GAS EQUIPMENT VENTING SYSTEM PROVIDED. (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5. APPROVED CARBON MONOXIDE DETECTORS. the owner shall have a period of thirty (30) days to comply with the above requirements.08 (2) – Continued a. upon inspection. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless. and 2.08 (2)] 1-3 . (c) MANUFACTURER REQUIREMENTS . and 2. the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.SAFETY PRECAUTIONS Extracted Information From 248 CMR 5. the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 1. a battery operated carbon monoxide detector with an alarm shall be installed. provided. KEEP CLEAR OF ALL OBSTRUCTIONS". (e) A copy of all installation instructions for the Product Approved side wall horizontally vented gas fueled equipment and all the venting instructions. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board. Detailed instructions for the installation of the venting system design or the venting system components. phone number or manufacturer’s address where the venting system installation instructions can be obtained. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. and the instructions for that system shall include a parts list and detailed installation instructions. the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5. _______________________________ [End of Extracted Information From 248 CMR 5. 4. parts lists and/or design instructions for the venting system shall remain with the appliance or equipment at the completion of the installation. in print size no less than one-half (1/2) inch in size. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment. 3. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling. (d) MANUFACTURER REQUIREMENTS . The "special venting systems" shall be Product Approved by the Board. however. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. but identifies "special venting systems". building or structure used in whole or in part for residential purposes. that during said thirty (30) day period. In the event that the requirements of this subdivision can not be met at the time of completion of installation. 2. and 2. the following requirements shall be satisfied by the manufacturer: 1. The sign shall read. The identification of each "special venting system" shall include the listing of either the website. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic. INSPECTION.08(2)(a)1 through 4: 1.08(2)(a)1 through 4. b. "GAS VENT DIRECTLY BELOW. A complete parts list for the venting system design or venting system.GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

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inspect and install the AERCO Benchmark 3. or inhibit service or maintenance of the unit. packed within the boiler shipping container. The freight carrier should be notified immediately if any damage is detected. (IRI). The shipping weight is approximately 2. 2-1 .3 UNPACKING Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials A close inspection of the unit should be made to ensure that there is no evidence of damage not indicated by the Tip-N-Tell indicator. The available power configurations are: • • 208 VAC. Any standard or optional accessories shipped loose should be identified and stored in a safe place until ready for installation or use. if Local Building Codes require additional clearances. Detailed procedures for implementing these modes are provided in Chapter 5. 2. 60 Hz @ 15 A NOTE AERCO is not responsible for lost or damaged freight.C.0 System is shipped as a single crated unit.INSTALLATION CHAPTER 2 2. Ensure that the site selected for installation of the Benchmark 3.1 Installation Clearances The unit must be installed with the prescribed clearances for service as shown in Figure 2-1. optional accessories may be packed separately. The unit should be completely inspected for evidence of shipping damage and shipment completeness at the time of receipt from the carrier and before the bill of lading is signed. Each unit has a Tip-N-Tell indicator on the outside of the crate. This indicates if the unit has been turned on its side during shipment.4. water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels. Any other visual damage to the packaging materials should also be made clear to the delivering carrier.(FM) or 4. • Access to Natural Gas line at a minimum static pressure of 3. 2. 60 Hz @ 20 A 460 VAC.0 Boiler includes: • Access to AC Input Power corresponding to the ordered power configuration. The following accessories come standard with each unit and are either packed separately within the unit’s packing container or are factory installed on the boiler: All gas piping. 3-Phase.0 Boiler. are listed below.170 pounds. 3-Phase. Note the information on the carrier’s paperwork and request a freight claim and inspection by a claims adjuster before proceeding. Brief descriptions are also provided for each available mode of operation. do not sign for the shipment.5” W. The minimum clearance dimensions.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack.0” W. required by AERCO.4 SITE PREPARATION. these codes shall supersede AERCO’s requirements.2 RECEIVING THE UNIT Each Benchmark 3. However.C. or may be installed on the boiler. The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage. Minimum acceptable clearances required are: • Sides: • Front : • Rear: • Top: 24 inches 24 inches 43 inches 18 inches 2. 2. If the Tip-N-Tell indicator is tripped. INSTALLATION • Pressure/Temperature Gauge • Spare Ignitor-Injector • Spare Flame Detector • ASME Pressure Relief Valve • Condensate Drain Trap & Adapter ` • 2” Gas Supply Shutoff Valve When ordered. Maximum static pressure must not exceed 2 psi.

If anchoring the unit. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. Tabs 1 and 3 are used only when removing or replacing the unit’s primary heat exchanger. the boiler must be moved by pallet jack or forklift from the FRONT ONLY. refer to the dimensional drawings in Appendix F for anchor locations.0 Boiler Clearances WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS. LIFTING TAB 1 LIFTING TAB 2 LIFTING TAB 3 FOR MASSACHUSETTS ONLY For Massachusetts installations. USE ONLY TABS 1 AND 2 SHOWN IN FIGURE 2-2 TO MOVE THE ENTIRE UNIT. it is important to identify the Combination Mode Boilers in advance and place them in the proper physical location. the boiler must be installed by a plumber or gas fitter who is licensed within the Commonwealth of Massachusetts. A total of 3 lifting tabs are provided at the top of the primary heat exchanger as shown in Figure 2-2. the installation must comply with all requirements specified in Chapter 1 (Safety Precautions). Refer to Chapter 5 for information on Combination Mode Boilers. pages 1-2 & 1-3.4. In addition. .INSTALLATION Figure 2-1 Benchmark 3. If installing a Combination Control Panel (CCP) system. Remove the front top panel from the unit to provide access to the lifting tabs. it is important to plan the position of each unit in advance. However.2 Setting the Unit The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate drainage. 2. 2-2 PRIMARY HEAT EXCHANGER Figure 2-2 Lifting Lug Locations In multiple unit installations. Remove the four (4) lag screws securing the unit to the shipping skid. BURNER ASSEMBLY CAUTION While packaged in the shipping container. Lift the unit off the shipping skid and position it on the 4 inch to 6 inch housekeeping concrete pad (required) in the desired location. All piping must include ample provisions for expansion.

FAILURE TO PROPERLY POSITION THIS HOSE MAY CAUSE INEFFECTIVE AIR ELIMINATION RESULTING IN ELEVATED TEMPERATURES THAT COULD COMPROMISE THE TOP HEAD GASKET. 3. Therefore. BOILER SUPPLY 4" – 150# FLANGED CONNECTION EXHAUST MANIFOLD BOILER RETURN 4" – 150# FLANGED CONNECTION OUTLET FLANGE SHELL DRAIN VALVE 2" GAS INLET CONNECTION INSULATED FLEX HOSE (SEE IMPORTANT NOTE BELOW) EXHAUST MANIFOLD REAR VIEW PARTIAL TOP VIEW . the installation must have provisions for suitable condensate drainage or collection. hex nut and coupling nut from the boiler. The drain pipe located on the connecting manifold must be connected to a second condensate trap which is packed separately within the unit’s shipping container. When condensate collects in the exhaust manifold.4 Removal of Strap and Packing Material From Heat Exchanger Prior to connecting the external gas supply or electrical power to the unit. Refer to Appendix F.INSTALLATION 2. The drain at the bottom of the exhaust manifold also includes a condensate trap containing a float assembly. thereby allowing it to discharge through the drain opening.0 Boiler utilizes 4” 150# flanges for the water system supply and return piping connections. this rod must be removed as follows: 1. Refer to Figure 2-3 and back off the hex nut on the outlet side of the flex hose. This rod is installed prior to shipment from the factory to prevent damage to the insulated metal flex hose on the hot water supply outlet of the boiler. This material is located in the area of the ignitor-injector and staged ignition solenoid on the burner assembly 2-3 .6 CONDENSATE DRAINS The Benchmark 3. IMPORTANT THE INSULATED FLEX HOSE SHOWN IN FIGURE 2-3 MUST BE LEVEL OR SLOPING UPWARD AS IT EXITS THE BOILER.4. 5/8-11 x 24" LONG THREADED ROD 5/8-11 HEX NUT 5/8-11 COUPLING NUT This can be easily accomplished by removing the top panel nearest to the front of the unit. disconnect the coupling nut from the flange stud. 2. 2. Next. In order to install the water supply piping. Two condensate drain connections are provided on the rear of the unit as shown in Figure 2-5. the 24” threaded rod shown in Figure 2-3 must be removed.REAR Figure 2-3 Location of Threaded Support Rod Figure 2-4 Supply and Return Locations 2.4. One drain connection is located on the exhaust manifold and the other is located on the connecting manifold. Drawing AP-A-811 for additional dimensional data. Completely remove the threaded rod.5 SUPPLY AND RETURN PIPING The Benchmark 3. the float rises.3 Removal of Support Rod Prior to installation of water supply and return piping. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-4. the strap and packing material must be removed from the top of the primary heat exchanger.0 Boiler is designed to condense water vapor from the flue products. 2.

View A – A and install as follows: 1. 3. 2. 91030) to the drain on the exhaust manifold and secure it in place with a hose clamp. Attach another 3/4” NPT nipple (not supplied) to the condensate trap outlet on the lower part of the trap. Connect the condensate trap and adaptor to the connecting manifold drain pipe.6. 6. This condensate trap (part no. If a floor drain is not available. 5. 4. 24060) is supplied with the unit along with a trap adapter and a 3/4” NPT x 5” long nipple. Place a suitable support under the condensate trap to maintain the trap in the level position.2 Connecting Manifold Condensate Drain The connecting manifold drain pipe shown in Figure 2-5. 2. Apply Teflon tape to the threads of the 3/4” x 5” long nipple provided with the boiler. associated fittings and drain lines must be removable for routine maintenance. Route the hose to a nearby floor drain. Attach the 3/4” NPT nipple between the condensate trap inlet and the trap adaptor (Figure 2-6). polypropylene hose to the outlet side of the condensate trap and route it to a nearby floor drain. Ensure that the condensate trap inlet is level with or below the connecting manifold drain pipe. If desired. Ensure that the outlet hose from the trap slopes away (down) from the trap. Refer to Figure 2-6 and install the trap as follows: EXHAUST MANIFOLD A NOTE CONDENSATE TRAP DRAIN SHELL DRAIN VALVE A B CONNECTING MANIFOLD The condensate trap described in the following steps can be installed on the floor behind the unit as shown in Figure 26. a Tee fitting may be used to connect the two drain hoses from the exhaust manifold and the outlet side of the of the condensate trap attached to the connecting manifold. Position the trap so it is level and then tighten the thumb screw on the adaptor. The maximum condensate flow rate is 20 GPH. View B – B must be connected to a separate condensate drain trap external to the unit. HOSE TO FLOOR DRAIN DRAIN VALVE CONNECTING MANIFOLD TO CONDENSATE TRAP CONDENSATE DRAIN PIPE VIEW “A . Connect a length of 1 inch I. The condensate drain trap. 1.6.B” Figure 2-5 Condensate Drain Connection Location 2.D.D.INSTALLATION The procedures to install and connect both of the condensate drains are provided in paragraphs 2. 2-4 .1 and 2. a condensate pump can be used to remove the condensate to drain.6.D.1 Exhaust Manifold Condensate Drain Refer to Figure 2-5.A” VIEW “B .6. DRAIN B REAR VIEW UNIT FRAME SHELL EXHAUST MANIFOLD UNIT FRAME CONDENSATE TRAP DRAIN HOSE CLAMP 1" I. hose (part no. Connect a length of 1” I. 2.2.

C. CANDLES.C.7.0 Gas Components and Supply Design Guide. CAUTION Many soaps used for gas pipe leak testing are corrosive to metals. A 2 inch gas inlet connection is located on the rear of the unit as shown in Figure 2-4.7. 2.5” W. Consult the local gas utility for detailed requirements concerning venting of the the supply gas regulator. NOTE All gas piping must be arranged so that it does not interfere with removal of any covers. isolate the unit from the gas supply piping. Therefore. The gas supply input specifications to the unit for Natural Gas are as follows: The maximum static pressure to the unit must not exceed 2 psi. for FM or 4.3 applies only to bolier installations within the Commonwealth of Massachusetts. Any excess must be wiped off to prevent clogging of components. should be used.3 External Gas Supply Regulator For Massachusetts installations. piping must be rinsed thoroughly with clean water after leak checks have been completed. HOSE 3/4" NPT NIPPLES DRAIN PIPE 2. all pipes should be deburred and internally cleared of any scale. 2.0” for IRI gas trains.2 Manual Gas Shutoff Valve A manual shut-off valve must be installed in the gas supply line upstream of the Boiler as shown in Figure 2-7. or restrict access between the unit and walls. Prior to installation. approved for use with natural gas. Maximum allowable gas pressure to the Boiler is 2 psi WARNING NEVER USE MATCHES.D. CAUTION A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.INSTALLATION A suitable piping compound.7 GAS SUPPLY PIPING The AERCO Benchmark 3.C. FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.C. ceiling or walls only and must not be supported by the unit.000 BTU/HR of natural gas while maintaining a gas pressure to the boiler of 3. a mandatory external gas supply regulator must be positioned as shown in Figure 2-7.1 Gas Supply Specification Figure 2-6 Condensate Trap Installation 2. for IRI gas trains.0” W.7. or another unit. The gas piping used must meet all applicable codes. CONDENSATE TRAP CONNECTING MANIFOLD ADAPTOR CLAMP TO FLOOR DRAIN 1" I. metal chips or other foreign particles. The gas supply pressure to the unit must be of sufficient capacity to provide 3000 cfh while maintaining the gas pressure at 3. Piping must be supported from the floor.7. To avoid unit damage when pressure testing gas piping.5” W. At no time should the gas pressure applied to the unit exceed 2 psi. Do Not install any flexible connectors or unapproved gas fittings. NOTE Paragraph 2. for FM or 4. The gas supply regulator must be properly vented to outdoors. NOTE The external regulator must be capable of regulating 3. inhibit service/maintenance. GF-3030 must be consulted prior to designing or installing any gas supply piping. 2-5 .00. Leak test all external piping thoroughly using a soap and water solution or suitable equivalent.

For electrical power wiring diagrams. 2-6 . 2.1 Electrical Power Requirements The AERCO Benchmark 3. See Appendix F. Remove the front door of the unit to access the Power Box mounted directly above the Control Box. All electrical connections should be made in accordance with the National Electrical Code and/or with any applicable local codes. A means for disconnecting AC power from the unit (such as a service switch) must be installed near the unit for normal operation and maintenance. GF-3060. External AC power connections are made to the unit inside the Power Box on the front panel of the unit. (GF-3060).0 Electrical Power Wiring Guide. inhibit service/maintenance. Loosen the four Power Box cover screws and remove cover to access the AC terminal connections inside the Power Box (Figure 2-8).8 AC ELECTRICAL POWER WIRING The AERCO Benchmark 3. NOTE All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers. A wiring diagram showing the required AC power connections is provided on the front cover of the Power Box.0 Electrical Power Wiring Guide.0 Boiler must be connected to a dedicated electrical circuit. Drawing AP-A-803 for details.8.0 Boiler is available in two different AC power configurations: • 208 VAC/3-Phase/60 @20 amps • 460 VAC/3-Phase/60 Hz @ 15 amps Each of the power configurations utilize a Power Box with a terminal block that matches the configuration ordered. 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. Each Benchmark 3. The two different terminal block configurations are shown in Figure 2-9. see the AERCO Benchmark 3. must be consulted prior to connecting any AC power wiring to the unit. The IRI gas train is factory pre-piped and wired.INSTALLATION TERMINAL BLOCK NATURAL GAS SUPPLY 2" MANUAL SHUTOFF VALVE UPPER RIGHT CORNER OF FRONT PANEL MANDATORY REGULATOR FOR MASSACHUSSETTS INSTALLATIONS ONLY DIRT TRAP Figure 2-8 AC Input Terminal Block Location Figure 2-7 Manual Gas Shut-Off Valve Location 2. or prevent access between the unit and walls or another unit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BENCHMARK BOILER.

Figure 2-10.9.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 3.9. Additional information concerning field wiring is provided in paragraphs 2. some additional field wiring may be required to complete the installation. loosen the four cover screws and remove the cover. 3 Phase 460 VAC. Refer to Chapter 5 for detailed information on the available modes of operation 2-7 .0 Boiler is available in several different modes of operation. and their wiring requirements. 3 PHASE TERMINAL STRIPS GND GND NEU L3 L3 L2 L2 L1 L1 208 VAC. are provided in the following paragraphs. This wiring is typically connected to the Input/Output (I/O) Box located on the lower portion of the unit front panel (Figure 2-10) behind the removable front door. 3 PHASE 460 VAC. 3 Phase Figure 2-9 AC Terminal Block Configurations LOWER RIGHT CORNER OF FRONT PANEL 2. All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided. Input/Output (I/O) Box Location Refer to the wiring diagram provided on the cover of the I/O Box (Figure 2-11) when making all wiring connections.INSTALLATION 208 VAC. While each unit is factory configured and wired for its intended mode. Brief descriptions of each mode of operation. To access the I/O Box terminal strips shown in Figure 2-10.1 through 2.9.

See para. Refer to paragraph 2. The sensor MUST BE wired to the I/O Box wiring terminals (see Figure 2-11). When using an AERCO Boiler Management System (BMS). For PWM signaling.9. NOT USED 0 – 10V AGND NC COM NO NOT USED RELAY CONTACTS: 120 VAC. For RS485 Modus signaling.10).0 Boiler can accept several types of signal formats from an Energy Management System (EMS). refer to GF108M (BMS Model 168) and GF-124 (BMS II Model 5R5-384). connections are made from the BMS to the RS485 COMM terminals on the I/O Box terminal strip. An outside air temperature sensor (AERCO Part No. 30 VDC 5 AMPS RESISTIVE + + G - DANGER 120 VAC USED IN THIS BOX Figure 2-11.9. Also. (PWM) IN terminals on the I/O Box terminal strip.S.9.10. The BMS Mode can 2-8 .3 Boiler Management System Mode NOTE BMS Model 168 can utilize either pulse width modulation (PWM) or RS485 Modbus signaling to the Boiler. BMS -Operations Guides.8) 2. to control either the setpoint (Remote Setpoint Mode) or firing rate (Direct Drive Mode) of the Boiler.9.4 Remote Setpoint and Direct Drive Modes The Benchmark 3. or RS485 Modbus signaling. 2.1 and 2. 122790) is required. Building Automation System (BAS) or other source. fault monitoring or enable/disable interlock wiring can be utilized (see paragraphs 2. These formats are: • 4 to 20 mA/1 to 5 VDC • 0 to 20 mA/0 to 5 VDC • PWM – (Pulse Width Modulated signal. utilize either pulse width modulation (PWM) signaling.1 Constant Setpoint Mode The Constant Setpoint Mode is used when it is desired to have a fixed setpoint that does not deviate.M. 2. paragraph 5. connections are made from the AERCO Boiler Management System to the B.M.9. The boiler end of the shield must be left floating. For additional instructions. I/O Box Terminal Strip 2. BMS II Model 5R5-384 can utilize only RS485 signaling to the Boiler.9. Polarity must be maintained and the shield must be connected only at the AERCO BMS. the field wiring is connected between the BMS Panel and each Boiler’s I/O Box terminal strip (Figure 2-11).4) • Network (RS485 Modbus. refer to Chapter 5.10. RES + ANALOG IN+ B. other than AC electrical power connections. Twisted shielded pair wire from 18 to 22 AWG must be utilized for the connections.9.INSTALLATION OUTDOOR SENSOR IN SENSOR COMMON (AIR) AUX SENSOR IN REMOTE INTL'K IN EXHAUST SWITCH IN DELAYED INTL'K IN NOT USED NOT USED NC COM NO FAULT RELAY 120 VAC. 5A. See para.2 Indoor/Outdoor Reset Mode This mode of operation increases supply water temperature as outdoor temperatures decrease.10. 2.6 in this manual. However.S. 2. 5A. if desired. (PWM) IN SHIELD mA OUT RS-485 COMM. No wiring connections. RES AUX RELAY 120 VAC. are required for this mode.1 for additional information on outside air temperature sensor installation.

10.10 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 2-11 are described in the following paragraphs. The wiring must be accomplished using twistedshielded pair wire from 18 to 22 AWG. it must allow for free air circulation. For more information on wiring the 4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5 VDC. and the BMS Model 168 (Boiler Management System). The sensor end of the shield must be left free and ungrounded. Polarity must be maintained. Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA / 0 to 5 VDC signal may be used to vary the setpoint or firing rate. CAUTION DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. This feature allows the boiler to be enabled or disabled based on the outdoor air temperature.2 AIR SENSOR IN The AIR SENSOR IN is connected to the AUX SENSOR IN and SENSOR COMMON terminals on the I/O board.1 OUTDOOR SENSOR IN An outdoor air temperature sensor (AERCO Part No.10. it may not be the method best suited for the application. the CCP (Combination Control Panel). This temperature reading is one of the components used to calculate the rotational speed of the blower used in the combustion Calibration process (Chapter 4). a DIP switch must be set on the PMC Board located inside the Control Box. The factory default setting is for 4 to 20 mA / 1 to 5 VDC. refer to the GF-108 Boiler Management System Operations Guide and the CCP-1 data sheet. it is recommended that you consult with your local AERCO representative or the factory for the mode of operation that will work best with your application. It is connected to the OUTDOOR 2. The sensor must be wired to the AUX SENSOR IN and SENSOR COMMON terminals and must be similar to AERCO BALCO wire sensor Part No. The AIR SENSOR measures the temperature of the air input to the Air/Fuel Valve. 2.9.5 Combination Mode NOTE Only BMS Model 168 can be utilized for the Combination Mode. If a shield is used. see the Configuration menu in Chapter 3. 2. If voltage rather than current is selected as the drive signal. With a Combination Mode unit. For further instructions and wiring diagrams. Prior to selecting one of these modes of operation. not the BMS II (Model 5R5-384). 12449. The shield is to be connected only to the terminals labeled SHIELD in the I/O Box. The sensor must be shielded from direct sunlight as well as impingement by the elements. 2. however this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu described in Chapter 3. There is no polarity to observe when terminating these wires.10. 2. Attempting to do so may cause equipment damage.3. Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG. A resistance chart for this sensor is provided in Appendix C. To enable the sensor and/or select an enable/disable outdoor temperature. The factory default for the outdoor sensor is DISABLED. SENSOR IN and SENSOR COMMON terminals in the I/O Box (see Figures 2-10 and 2-11).9. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature.3 ANALOG IN The ANALOG IN + and – terminals are used when an external signal is used to drive the firing rate (Direct Drive Mode) or change the setpoint (Remote Setpoint Mode) of the Boiler. field wiring is between the unit’s I/O Box wiring terminals. When mounting the sensor. Connections between the signal source and the Boiler’s I/O Box must be made using twisted shielded pair wire from 18 to 2-9 . The outdoor sensor may be wired up to 200 feet from the boiler. Contact the AERCO factory for information on setting DIP switches. it must be located on the North side of the building where an average outside air temperature is expected. This input is always enabled and is a view-only input that can be seen in the Operating Menu. The AUX SENSOR IN terminals can be used to add an additional temperature sensor for monitoring purposes. see paragraph 2. All of the supplied signals must be floating (ungrounded) signals. 122790) will be required primarily for the Indoor/Outdoor reset mode of operation.INSTALLATION While it is possible to control a boiler or boilers using one of the previously described modes of operation.

4 B. 2. 2-10 . The circuit is labeled REMOTE INTL’K IN and is located inside the I/O Box on the front panel. This option is locate in the Configuration Menu (Chapter 3.10. Polarity must be maintained. a time delay (Aux Start On Dly) that holds the start sequence of the boiler long enough for a proving switch to make can be programmed. The BMS Model 168 utilizes a 12 millisecond. Table 3-4). are factory wired in the closed position.INSTALLATION 22 AWG.10. A 0% firing rate = a 5% ON pulse and a 100% firing rate = a 95% ON pulse.1 REMOTE INTERLOCK IN The remote interlock circuit is provided to remotely start (enable) and stop (disable) the Boiler. such as Belden 9841 (see Figure 2-11). they are linearly mapped to a 40°F to 240°F setpoint or a 0% to 100% firing rate. Outlet Temp or Fire Rate Out.10. This function is enabled in the Configuration Menu (Chapter 3. It can be connected to the proving device (end switch.10. (PWM) IN NOTE Only BMS Model 168 can utilize Pulse Width Modulation (PWM).10 INTERLOCKS The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers. IMPORTANT Both the Remote Interlock and Delayed Interlock MUST be in the closed position to allow the unit to fire.10. The Aux Start On Dly can be programmed from 0 to 120 seconds. flow switch etc. Regardless of whether voltage or current is used for the drive signal. The delayed interlock must be closed for the boiler to fire. ON/OFF duty cycle. Table 3-4). The wiring terminals for these interlocks are located inside the I/O Box on the unit front panel.) of an auxiliary piece of equipment started by the Boiler’s auxiliary relay. IMPORTANT DO NOT USE the mA OUT output to remotely monitor Setpoint. This duty cycle is Pulse Width Modulated (PWM) to control firing rate.6 mA OUT These terminals provide a 4 to 20 mA output to the VFD (if so equipped) to control the rotational speed of the blower. Energy Management System (EMS). Should the proving switch not prove within the programmed time frame.M. 2. If the delayed interlock is connected to a proving device that requires time to close (make). Building Automation System (BAS) or other suitable device. 2. 123463) that closes (trips) at 500°F. Only shields must be connected to these terminals. The shield must be connected only at the source end and must be left floating (not connected) at the Boiler’s I/O Box.S. This interlock circuit is located in the purge section of the start string. 2. 2.10.7 0 – 10V OUT These terminals provide a 0 to 10V output to control the rotational speed of the blower.5 SHIELD The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit. The exhaust switch should be a normally open type switch (such as AERCO Part No. the boiler will shut down.10. These terminals are used to connect the AERCO Boiler Management System (BMS) Model 168 to the unit. 2.10.10. 2.10. The circuit is 24 VAC and is factory pre-wired in the closed (jumpered) position. Both interlocks. These interlocks are called the Remote Interlock and Delayed Interlock (Figure 2-11). Table 3-4). 2. No scaling for these signals is provided 2.10. The I/O Box cover contains a wiring diagram which shows the terminal strip locations for these interlocks (REMOTE INTL’K IN and DELAYED INTL’K IN). described below. if desired. not the BMS II (Model 5R5-384). This function is enabled in the Configuration Menu (Chapter 3.10.8 RS-485 COMM These terminals are used for RS-485 MODBUS serial communication between the unit and an external “Master” such as a Boiler Management System (BMS).2 DELAYED INTERLOCK IN The delayed interlock is typically used in conjunction with the auxiliary relay described in paragraph 2.9 EXHAUST SWITCH IN These terminals permit an external exhaust switch to be connected to the exhaust manifold of the boiler.

12 FLUE GAS VENT INSTALLATION The minimum allowable vent diameter for a single Benchmark 3. Contact information for this supplier is as follows: Selkirk Corporation Heatfab Division 130 Industrial Blvd. Each opening must have a free area of not less than one square inch for each 4000 BTU/H boiler input. 2. The combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet of 8 inch ducting. GF-2050. MA 01376 Phone: 1-800-772-0739 www.11 AUXILIARY RELAY CONTACTS Each Boiler is equipped with a single pole double throw (SPDT) relay that is energized when there is a demand for heat and deenergized after the demand for heat is satisfied. degreasing compounds. The combustion air must be free of chlorine.10. an inlet screen will be attached at the air inlet on the top of the unit The more common methods of supplying combustion air are outlined below. GF-2050 MUST be consulted before any flue or combustion supply air venting is designed or implemented.13 COMBUSTION AIR The AERCO Benchmark Venting and Combustion Air Guide.C. halogenated hydrocarbons.1. 2. The AERCO Benchmark Venting and Combustion Air Guide.13. must be used for safety and code compliance. 2-11 . consult the AERCO Benchmark Venting and Combustion Air Guide.0 Boiler is UL listed for 100% sealed combustion. Common sources of these compounds are swimming pools. such as pumps and louvers. Turners Falls.3 for more information concerning sealed combustion air). For a natural draft installation the draft must not exceed ±0. watertight vent materials as specified in AERCO’s GF-2050. Refer to Figure 2-11 to locate the AUX RELAY terminals for wiring connections. horizontal sections of the flue vent system must be pitched back to the unit a minimum of 1/4 inch per foot to avoid condensate pooling and allow for proper drainage. The AERCO Benchmark 3. U/L listed. For more information concerning combustion air. NFPA-54. the Heatfab Division of the Selkirk Corporation provides vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts.com 2. The free area must take into account restrictions such as louvers and bird screens.13. For Massachusetts boiler installations. (See paragraph 2. These factors must be planned into the vent installation.1 Combustion Air From Outside the Building Air supplied from outside the building must be provided through two permanent openings. provided there is an adequate supply. the unit will not operate properly or reliably.INSTALLATION 2. The fault relay connections are shown in Figure 2-11. Since the unit is capable of discharging low temperature exhaust gases. If the maximum allowable equivalent lengths of piping are exceeded. plastic processing and refrigerants. If the sealed combustion air option is not being used. GF-2050. positive pressure. or other chemicals that can become hazardous when used in gasfired equipment. These codes should be consulted before a permanent design is determined.0 Boiler is 8 inches. It can also be installed using room air.25 inch W. The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed. combustion air must be supplied from a clean area outdoors for the protection and longevity of the equipment. Its contacts are rated for 120 VAC @ 5 amps. or can be used as a Boiler status indictor (firing or not firing). Whenever the environment contains these types of chemicals. 2. Fittings as well as pipe lengths must be calculated as part of the equivalent length. Combustion air supply is a direct requirement of ANSI 223.11 FAULT RELAY 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. must be consulted before any flue gas vent or inlet air venting is designed or installed. The relay is provided for the control of auxiliary equipment. and local codes.heat-fab.

In these situations.13. accumulated drywall dust.INSTALLATION 2. each unit must have a minimum 8-inch diameter connection at the unit. In a sealed combustion air application.13. above the boiler combustion air inlet.0 Boiler is used to provide heat temporarily during ongoing building construction. GF-2050.3 Sealed Combustion The AERCO Benchmark 3. The free area must take into account any restrictions such as louvers. sawdust and similar particles can accumulate in the unit’s combustion air intake filter and block combustion air flow.2 Combustion Air From Inside the Building When combustion air is provided from within the building. AERCO recommends that a disposable air intake filter be installed. 2122K315 Polyester Air Filter Roll Tackfield. 1/2” thick.13. Maximize the surface area of the filter covering the 8" diameter opening by creating a dome out of the filter material. During construction. 2-12 . 2. Each opening must have a free area of not less than one square inch per 1000 BTU/H of total boiler input. Cover the Benchmark 3. the screen on the air inlet duct of the unit must be removed.0 Boiler is UL listed for 100%-sealed combustion. See the AERCO Benchmark Venting and Combustion Air Guide. The inlet air ductwork must then be attached directly to the unit’s air inlet. the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run. AERCO recommends that the temporary air filter be cut from a McMaster-Carr part no. or equivalent. When using the boiler in a sealed combustion air configuration. it must be supplied through two permanent openings in an interior wall. check the filter for dust accumulation and replace it when the accumulation becomes noticeable.4 Temporary Combustion Air Filtering During Construction When the AERCO Benchmark 3. 2. For sealed combustion installations. temporarily.0 air inlet with the blue side of the filter material facing outward to hold the dust on the outside surface. 16” wide.

STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE. WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460. adjust and troubleshoot the Benchmark 3.0 Boiler using the Control Panel mounted on the front of the unit. indicators and displays are listed and described in Table 3-1. indicators and displays necessary to operate. Figure 3-1. THIS SITUATION WILL VOID ANY WARRANTY.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 3. Control Panel Front View 3-1 .CONTROL PANEL OPERATING PROCEDURES CHAPTER 3 3.0 Boiler.0 Control Panel shown in Figure 3-1 contains all of the controls. In addition. 1 3 4 12 5 6 11 10 7 8 9 3. 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. These operating controls. CONTROL PANEL OPERATING PROCEDURES 2 CAUTION All of the installation procedures in Chapter 2 must be completed before attempting to start the unit. IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS WARNING DO NOT ATTEMPT TO DRY FIRE THE BOILER. Additional information on these items are provided in the individual operating procedures provided in this Chapter.2 CONTROL PANEL DESCRIPTION The Benchmark 3. the following WARNINGS and CAUTIONS must be observed at all times. 208 AND 24 VOLTS AC.

Lockout type alarms will be latched and cannot be cleared by simply pressing this key. Pressing TEST opens the water level probe circuit and simulates a Low Water Level alarm. Pressing the CLEAR key (item 6) resets the display. Vacuum Fluorescent Display (VFD) consists of 2 lines each capable of displaying up to 16 alphanumeric characters. 3–Digit. 3 VFD Display 7 8 9 READY Indicator ON/OFF Switch LOW WATER LEVEL TEST/RESET Switches 3-2 . The °F or °C blinks when operating in the Deadband Mode. Red FAULT LED indicator lights when a boiler alarm condition occurs. Indicators and Displays ITEM NO. The °F or °C LED next to the display lights to indicate whether the displayed temperature is in degrees Fahrenheit or degrees Celsius. An alarm message will appear in the VFD. Allows operator to test operation of the water level monitor. Troubleshooting may be required to clear these types of alarms.CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls. Turns off the FAULT indicator and clears the alarm message if the alarm is no longer valid. Pressing RESET resets the water level monitor circuit. Enables and disables boiler operation. Lights when the unit is being controlled by an external signal from an Energy Management System Lights when there is a demand for heat. The information displayed includes: Startup Messages Fault Messages Operating Status Messages Menu Selection 4 5 6 RS-232 Port FAULT Indicator CLEAR Key Port permits a Laptop Computer or External Modem to be connected to the unit’s Control Panel. 1 CONTROL. INDICATOR OR DISPLAY LED Status Indicators COMM MANUAL REMOTE DEMAND 2 OUTLET TEMPERATURE Display FUNCTION Four Status LEDs indicate the current operating status as follows: Lights when RS-232 communication is occurring Lights when the unit is being controlled using the front panel keypad. Lights ON/OFF switch is set to ON and all Pre-Purge conditions have been satisfied. 7–Segment LED display continuously displays the outlet water temperature.

the MANUAL status LED will be off and the front panel controls disabled. Permits a setting to be changed (edited). this key allows you to go back to the top of a main menu category. If the CHANGE key was pressed and the menu item is flashing. pressing the ▲ arrow key will increment the selected setting. Also. pressing the ▲ arrow key will select the displayed menu category. pressing this key will select the displayed menu category. 12 VALVE POSITION Bargraph 20 segment red LED bargraph continuously shows the Air/Fuel Valve position in 5% increments from 0 to 100% ▲ (UP) Arrow ▼ (DOWN) Arrow CHANGE ENTER 11 AUTO/MAN Switch 3-3 . When in the Automatic (AUTO) mode. the displayed menu item will begin to flash.CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls. Saves the modified menu settings in memory. This switch toggles the boiler between the Automatic and Manual modes of operation. Continuously pressing this key will bring you back to the default status display in the VFD. Allows you to go back to the previous menu level without changing any information. INDICATOR OR DISPLAY MENU Keypad MENU BACK FUNCTION Consists of 6 keys which provide the following functions for the Control Panel Menus: Steps through the main menu categories shown in Figure 32. The display will stop flashing. Pressing the ▲ or ▼ arrow key when the item is flashing will increment or decrement the displayed setting. When in one of the main menu categories (Figure 3-2). The Menu categories wrap around in the order shown. When in the Manual (MAN) mode. When in one of the main menu categories (Figure 3-2). When the CHANGE key is pressed. pressing the ▼ arrow key will decrement the selected setting. If the CHANGE key was pressed and the menu item is flashing. the front panel controls are enabled and the MANUAL status LED lights. Indicators and Displays – Continued ITEM NO. 10 CONTROL.

To select and store a changed menu item. Prior to entering the correct password. with the exception of Internal Setpoint Temperature (Configuration Menu). The menu structure consists of five major menu categories which are applicable to this manual. 7.3. contain options which permit operating parameters to be viewed or changed. the options contained in the Operation. The displayed option will begin to flash. The display will show the Setup Menu. The menu option choices do not wrap around. Press the ▲ or ▼ arrow key to scroll through the available menu option choices for the option to be changed. press the ▲ or ▼ arrow key. 1. 3. 3.CONTROL PANEL OPERATING PROCEDURES 3. it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures. Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed. The Combustion Cal Menu is protected by the level 2 password which is used in Chapter 4 to perform combustion calibration prior to service use. none of the viewable menu options can be changed. The menu options will wraparound after the first or last available option is reached. if desired. and configure the unit.3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up. Press the MENU key. Once the valid level 1 password (159) is entered. Therefore. Continue pressing the MENU key until the desired menu is displayed. The menus are protected by a password levels to prevent unauthorized use. The first option in the selected menu will be displayed. Configuration and Tuning Menus can be viewed and changed.1 Menu Processing Procedure Accessing and initiating each menu and option is accomplished using the Menu Keys shown in Figure 3-1. However. which is the next menu category shown in Figure 3-2. the options listed in the Setup. 5. 2. 4. Each of the menus shown. 6. To change the value or setting of a displayed menu option. Pressing the ▲ or ▼ arrow key will display the other available data items in the Operating Menu. Pressing the ▲ arrow key will display the 3-4 Figure 3-2. This menu contains the Password option which must be entered if other menu options will be changed. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence. press the ENTER key. The Control Panel will normally be in the Operating Menu and the VFD will display the current unit status. Configuration and Tuning Menu categories can be viewed. available menu options in the Top-Down sequence. These categories are shown in Figure 3-2. Menu Structure . Setup. press the CHANGE key. With the desired menu displayed.

To prevent unauthorized use. Pressing the ▲ arrow key to display the menu items in the order listed (Top-Down). Operating Menu Menu Item Display Status Message Active Setpoint AIR Temp Outdoor Temp* Valve Position In Flame Strength Run Cycles Run Hours Fault Log 40°F -70°F -70°F 0% 0% 0 0 0 240°F 245°F 130°F Max Valve Position 100% 999. units of temperature measurements and entries required for external communication and control of the unit via the RS-232 port. NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 3-4). Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up).999 999. Table 3-2. Therefore. This menu is “Read-Only” and does not allow personnel to change or adjust any displayed items. it can be viewed at any time without entering a password.999.CONTROL PANEL OPERATING PROCEDURES NOTE The following paragraphs provide brief descriptions of the options contained in each menu. 3. status and error messages.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. the password will time-out after 1 hour. Refer to Appendix A for detailed descriptions of each menu option.999.4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3-2. In addition to permitting password entries. the correct password must be reentered when required. the Setup Menu is also used to enter date and time. Since this menu is “Read-Only”. 3. A view-only software version display is also provided to indicate the current Control Box software version. Refer to Appendix B for listings and descriptions of displayed startup.999 9 0 Available Choices or Limits Minimum Maximum Default 3-5 .

Water Heater 2010 0. under normal operating conditions.0 MBTU.00 Available Choices or Limits Minimum Maximum 0 English 11:59 pm 12/31/99 Fahrenheit 0 9600 127 Ver 9. 4800.0 MBTU 3. 19.0 MBTU Natural Gas. The remaining options in this menu require the valid password to be entered. Propane Constant Setpoint. Setpt is required for operation in the Constant Setpoint mode.5 MBTU 4. depending on the current operating mode setting. 5.2K 3. This menu contains a number of other configuration settings which may or may not be displayed.0 MBTU Fuel Type Boiler Mode Natural Gas Constant Setpoint 3-6 . Table 3-4. 9600.0 MBTU 6.0 MBTU. Setup Menu Menu Item Display Passsword Language Time Date Unit of Temp Comm Address Baud Rate Software 12:00 am 01/01/00 0 Ver 0. NOTE The Configuration Menu settings shown in Table 3-4 are Factory-Set in accordance with the requirements specified for each individual order. BMK Boiler Dual. KC Water Heater. BMK Boiler LN. BMK Boiler. 1. 2.CONTROL PANEL OPERATING PROCEDURES Table 3-3. prior to changing existing entries.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. Configuration Menu Menu Item Display Internal Setpt Unit Type Available Choices or Limits Minimum Maximum Lo Temp Limit Hi Temp Limit KC Boiler. Direct Drive Combination Outdoor Reset Default 130°F BMK Boiler LN Unit Size 1.5 MBTU. Remote Setpoint. KC Water Heater LN. Therefore. no changes will be required.0 MBTU 1. KC Boiler LN.99 9999 Default 0 English Fahrenheit or Celsius 2400. 3.5 MBTU.

Setpt Hi Limit 220°F 240°F 100% 30 min.CONTROL PANEL OPERATING PROCEDURES Table 3-4. 120 sec. Setpoint. Configuration Menu .2 Enabled or Disabled 30°F 100°F Disabled 60°F 40°F Setpt Lo Limit 40°F 40% 0 min.Continued Menu Item Display Remote Signal (If Mode = Remote Setpoint. DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve Position 0-10V). Valve Position 0-10V 2 sec. 0 sec. 0°F 5 Sec 0% 0 0 0 600 sec. Valve Position 4-20 mA.1 9. 10°F 999 Sec 100% 25 25 25 Enabled or Disabled *CAUTION: 1. Disabled 5°F 30 Sec 30% 10 2 2 Shutdown or Constant Setpt Off. Shutdown *Valve Position 0-10V 2 sec. Outlet Temp. 1-5V 70°F 0. 60°F 200°F 210°F 100% 0 min. 0 sec. 3-7 .9 1. Direct Drive or Combination) Bldg Ref Temp (If Mode = Outdoor Reset) Reset Ratio (If Mode = Outdoor Reset) Outdoor Sensor System Start Tmp (If Outdoor Sensor = Enabled) Setpt Lo Limit Setpt Hi Limit Temp Hi Limit Max Fire Rate Pump Delay Timer Aux Start On Dly Failsafe Mode *Analog Output (See CAUTION at end of Table 3-4 ) Low Fire Timer Setpt Limiting Setpt Limit Band Network Timeout HI DB Setpt EN Demand Offsert Deadband High Deadband Low Available Choices or Limits Minimum Maximum 4 – 20 mA/1 – 5V 0 -20 mA/0 – 5V PWM Input (BMS) Network 40°F 230°F Default 4 – 20 mA.

3.00 min No Yes. The firing rates (%) and default drive voltages are listed in Table 3-6. the READY light above the ON/OFF switch will light and the unit will be in the Standby mode. This is accomplished by providing a DC drive voltage to the motor which adjusts the rotational speed of the blower to maximize combustion efficiency and ensure the unit conforms to the Nitrogen Oxide (NOx) and Carbon Monoxide (CO) emissions specified in Chapter 4.20v 3.20 8.00 0. These switches include: • Safety Shut-Off Valve Proof of Closure (POC) switch • Low Water Level switch • High Water Temperature switch • High Gas Pressure switch • Low Gas Pressure switch • Blower Proof switch If all of the above switches are closed.25 .60 6. When there is a demand for heat.80v 3.00 min Default 70°F 1.CONTROL PANEL OPERATING PROCEDURES 3. No. the following events will occur: NOTE If any of the Pre-Purge safety device switches are open.8 COMBUSTION CAL MENU The Combustion Cal Table 3-6 are used unit’s blower motor and air density at (Calibration) Menu items in to vary the speed of the based on air temperature prescribed Air/Fuel Valve Table 3-5.00 0% .00 Monitor Blower Output Voltage 3.7 TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by Factory-Trained personnel. the appropriate fault messages will be displayed throughout the start sequence.9 START SEQUENCE When the Control Box ON/OFF switch is set to the ON position.00 0. Are You Sure? Table 3-6.00 2.0 min 120°F 2.20 8.20 100% Default 1.25 0% 8.25 . Also. if the required conditions are not observed. the appropriate fault message will be displayed. Tuning Menu Menu Item Display Prop Band Integral Gain Derivative Time Reset Defaults? Available Choices or Limits Minimum Maximum 1°F 0.20 8. it checks all pre-purge safety switches to ensure they are closed.20 8.25 .25 .20 8.80 4. Combustion Cal Menu Menu Item Display CAL Voltage 16% CAL Voltage 30% CAL Voltage 45% CAL Voltage 60% CAL Voltage 80% CAL Voltage 100% SET Valve Position Blower Output Available Choices or Limits Minimum Maximum . positions (% open).25 . 3-8 .70v 3.

Valve (Figure 3-6) will read between 25 and 35 to indicate that the valve is in the low-fire position. The display will show Purging and indicate the elapsed time of the purge cycle in seconds. (c) The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve. (b) The igniter relay is activated and provides ignition spark. The dial on the Air/Fuel Valve (Figure 3-4) will read 100 to indicate that it is full-open (100%). The DEMAND LED status indicator will light. 2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. SSOV Location 3. With all required safety device switches closed. See Figure 3-3 for SSOV location.CONTROL PANEL OPERATING PROCEDURES 1. (b) The Air/Fuel Valve rotates to the fullopen purge position and closes purge position switch. Figure 3-3. a purge cycle will be initiated and the following events will occur: (a) The Blower relay energizes and turns on blower. (c) The VALVE POSITION bargraph will show 100%. 5. Air/Fuel Valve In Purge Position Figure 3-5. the blower proof switch on the Air/Fuel Valve (Figure 3-5) closes. Next. the Control Box initiates an ignition cycle and the following events occur: (a) The Air/Fuel Valve rotates to the lowfire ignition position and closes the ignition switch. Upon completion of the purge cycle. The dial on the Air/Fuel Figure 3-4. The normal (default) time for the purge cycle is 7 seconds. 4. Blower Proof Switch 3-9 .

720. 3.000 1. 7. The boiler’s VALVE POSITION will be continuously displayed on the front panel bargraph. With the unit firing properly.000 3. Refer to Table 3-7 for the relationship between the boiler energy input and the Air/Fuel Valve position (% open) for a unit running on Natural Gas. Table 3-7 Relationship Between Air/Fuel Valve Position and Energy Input Air/Fuel Valve Position (% Open) 0% 10% 14% (Stop Level) 20% 30% 40% 50% 60% 70% 80% 90% 100% Energy Input (BTU/HR) 0 0 200. After 5 seconds. the Control Box will turn off the dual SSOV gas valves.000 2. These levels are Factory preset as follows: Start Level: 20% Figure 3-6. Once the demand for heat has been satisfied.000 Boiler Energy Input (% Of Full Capacity) 0 0 6. Flame Proven will be displayed and the flame strength will be indicated.67% 10% 16% 27% 39% 57% 77% 85% 91% 100% 3-10 . it will be controlled by the temperature controller circuitry. based on load.CONTROL PANEL OPERATING PROCEDURES 8.300. the current date and time will be displayed in place of the flame strength.000 2. Stop Level: 14% Normally.000.720. Standby will be displayed. Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position.000 486.000 2.000 1.000 802.000 287.550. these settings should not require adjustment. Air/Fuel Valve In Ignition Position 6. The blower relay will be deactivated and the Air/Fuel Valve will be closed.10 START/STOP LEVELS The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit. 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.180. After 2 seconds of continuous flame.

4. must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at: AERCO International. • 16 inch W. The following start-up instructions should be followed precisely in order to operate the unit safely and at a high thermal efficiency. THIS SITUATION WILL VOID ANY WARRANTY. Northvale.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION To properly perform combustion calibration. Close the main manual gas supply shut-off valve upstream of the unit. 4. An AERCO Gas Fired Startup Sheet. NJ 07647 4. 159 Paris Ave. The following paragraphs outline the necessary tools and instrumentation as well as their installation.2 Installing Gas Supply Manometer The gas supply manometer is installed in the gas train as follows: 1. venting.2. with low flue gas emissions. included with each Benchmark Boiler. 4-1 . the proper instruments and tools must be used and correctly attached to the unit. After following the steps in this chapter. 3. • 1/8 inch NPT-to-barbed fittings for use with gas supply manometer or gauge.4%. WARNING DO NOT ATTEMPT TO DRY FIRE THE BOILER. Remove the front door and left side panels from the boiler to access the gas train components.INITIAL START-UP CHAPTER 4 4. STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE. • Small and large flat blade screwdrivers.0 Boiler consists of the following: • • • • • Complete installation Perform combustion calibration Set proper controls and limits Set up mode of operation (see Chapter 5) Test safety devices (see Chapter 6) INITIAL START-UP CAUTION All applicable installation procedures in Chapter 2 must be completed before attempting to start the unit. Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1PPM. Starting a unit without the proper piping. manometer or equivalent gauge and plastic tubing. and the Safety Device Testing procedures in Chapter 6 to complete the initial unit start-up.C. Inc. • Tube of silicone adhesive Initial unit start-up is to be performed ONLY by AERCO factory trained start-up and service personnel.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. it will be necessary to perform the Mode of Operation settings in Chapter 5. or electrical systems can be dangerous and may void the product warranty. Remove the 1/8 inch NPT pipe plug from the leak detection ball valve on the downstream side of the Safety Shut Off Valve (SSOV) as shown in Figure 4-1.2. 2.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 3. Installation should be fully completed before performing initial start-up. and the start-up must be complete prior to putting the unit into service.

2. Open the natural gas supply valve(s) to the unit.INITIAL START-UP 4. the MANUAL LED will light. Factory Test Data sheets are shipped with each unit.0LN Boiler is combustion calibrated at the factory prior to shipping. Figure 4-2 Analyzer Probe Hole Location 4-2 . DO NOT install the probe at this time. Remove the plug from the probe port on the left or right side of the exhaust manifold. gas supply piping and supply regulators. 2.C. It is important to perform the following procedure as outlined. manometer. 6. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 inch W. adjust the stop on the combustion analyzer probe so that it will extend mid-way into the flue gas flow. Turn on external AC power to the unit. Ensure that the leak detection ball valve downstream of the SSOV is open. 8. The unit should begin its start sequence and fire. 5. 1/8" NPT PLUG (INSTALL MANOMETER HERE) LEAK DETECTION BALL VALVE HIGH GAS PRESSURE SWITCH 4. However.3 Accessing the Vent Probe Port The unit contains NPT plugs on both the left and right side of the exhaust manifold at the rear of the unit as shown in Figure 4-2. 7. recalibration as part of initial start-up is necessary due to changes in the local altitude. 5. 1. Also. Open the water supply and return valves to the unit and ensure that the system pumps are running. The display will show LOSS OF POWER and the time and date. Figure 4-1. Adjust the air/fuel valve position to 0% by pressing the ▼ arrow key.3 NATURAL GAS COMBUSTION CALIBRATION TO AIR/FUEL VALVE SSOV LOW GAS PRESSURE SWITCH GAS INLET The Benchmark 3. A flashing Manual Valve Position message will be displayed showing the present air/fuel valve % open position. Prepare the port for the combustion analyzer probe as follows: 1. These sheets must be filled out and returned to AERCO for proper Warranty Validation. Set the ON/OFF switch to the ON position. This will keep readjustments to a minimum and provide optimum performance. 2. 1/8 Inch Gas Plug Location 4. Install a NPT-to-barbed fitting into the tapped plug port. Set the control panel ON/OFF switch to the OFF position. 9. gas BTU content. If necessary. 4. Change the valve position to 29% using the ▲ arrow key. Set the unit to the Manual Mode by pressing the AUTO/MAN key. 3.

remove the brass hex nut covering the SSOV gas pressure adjustment screw (Figure 4-3). If gas pressure adjustment is required. 15. If necessary. Compare the measured oxygen level to the oxygen range for the inlet air temperature shown in Table 4-1.8” W.8” W. Figure 4-3 Regulator Adjustment Screw Location 11.2 % 5.C. Figure 4-4 Iris Air Damper Location/Adjustment 4-3 . verify that the gas pressure downstream of the SSOV is 1. Readjust pressure if necessary.8 % 5.0 % 5.3 % Carbon Monoxide <100 ppm <100 ppm <100 ppm <100 ppm NOx <30 ppm <30 ppm <30 ppm <30 ppm 14.8” W.2 4. Next. Increase the valve open position to 100% and verify that the gas pressure downstream of the SSOV remains at 1. With the valve position at 100%.INITIAL START-UP 10.C. insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer to settle. Table 4-1 Combustion Oxygen Levels for a 100% Open Air/Fuel Valve Position Inlet Air Temp >100°F 90°F 80°F <70°F Oxygen % ± 0. adjust the iris air damper shown in Figure 4-4 until the oxygen level is within the range specified in Table 4-1. for both FM and IRI gas trains. Make gas pressure adjustments using a flat-tip screwdriver to obtain 1. ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. Once the oxygen level is within the specified range at 100%. 13.C. Also. decrease the valve position to 70%. 12.

ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. Also. Press the ▲ arrow key until the SET Valve Position reads 70%. If the oxygen level is not within the specified range. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. . Press the CHANGE key. also ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown for each valve position. NOTE The remaining steps basically repeat the procedures in steps 18 through 25 for air/fuel valve positions of 50%. 27. The oxygen level at the 70% valve position should be as shown below. 34. press the down (▼) arrow key until CAL Voltage 70% is displayed. This will adjust the output voltage to the blower motor as indicated on the display. Press the MENU Key on the front panel of the C-MORE until Combustion Cal Menu appears on the C-More display. 20. Once the oxygen level is within the specified range at 50%. 25. SET Valve Position will begin to flash. these steps are repeated in their entirety. 26. Enter password 6817 and then press the ENTER key. Press the CHANGE key and observe that CAL Voltage 70% is flashing. 40%.2 6. 60%. CAL Voltage 50% will begin to flash.2 7. 18. The oxygen level at the 50% Valve Position should be as shown below. 45%. 23. Press the ▼ arrow key until the SET Valve Position reads 40%.0 % Carbon Monoxide <100 ppm NOx <30 ppm 24. since oxygen levels vary. 30% and 16% as described in the following steps. 22. This will adjust the output voltage to the blower motor as indicated on the display. 29. 4-4 32. 36. Combustion Oxygen Level at 50% Valve Position Oxygen % ± 0. If the oxygen level is not within the specified range.0 % Carbon Monoxide <50 ppm NOx <20 ppm Combustion Oxygen Level at 70% Valve Position Oxygen % ± 0. SET Valve Position will begin to flash. These steps assume that the inlet air temperature is within the range of 50°F to 100°F. adjust the level using the ▲ and ▼ arrow keys. 30% and 14% open. 19. Press the CHANGE key. Press the CHANGE key. 35. ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. Press the ENTER key. press the ENTER key to store the selected blower output voltage for the 70% valve position. Press the down ▼ arrow key until CAL Voltage 50% is displayed. adjust the level using the ▲ and ▼ arrow keys. However. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. 21. 17. SET Valve Position will begin to flash. 30. 31. Next. press the ENTER key to store the selected blower output voltage for the 50% Valve Position. Once the oxygen level is within the specified range at 70%. Also. Press the ▼ arrow key until the SET Valve Position reads 50% and then press the ENTER key. Pressing the ▲ arrow key increases the oxygen level and pressing the down ▼ arrow key decreases the oxygen level.INITIAL START-UP NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. 16. Press the MENU Key on the front panel of the C-MORE and access the Setup menu. 33. Press the CHANGE key. then press the ENTER key. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. 28. When performing these steps. The combustion calibration control functions will be used to adjust the oxygen level (%) at air/fuel valve positions of 80%.

Press the CHANGE key.INITIAL START-UP 37. then press the ENTER key. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level. arrow keys. 38. 54. ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. Press the ▼ arrow key until CAL Voltage 40% is displayed. 50. The oxygen level at the 40% valve position should be as shown below. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level. The oxygen level at the 30% Valve Position should be as shown below. then press the ENTER key. If the oxygen level is not within the specified range. Press the ▼ arrow key until the SET Valve Position reads 30%. If the oxygen level is not within the specified range.2 7. press the ENTER key to store the selected blower output voltage for the 40% valve position. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level.5 % Carbon Monoxide <50 ppm NOx <30 ppm 56. 43. press the ENTER key to store the selected blower output voltage for the 30% valve position. Also. 46. Press the ▼ arrow key until CAL Voltage 30% is displayed. 45.8 % Carbon Monoxide <50 ppm NOx <20 ppm 40. adjust the level using the ▲ and ▼ arrow keys.2 8.0 % Carbon Monoxide <50 ppm NOx <20 ppm IMPORTANT Repeat steps 18 through 57 until the blower output voltage does not require adjustment when sequencing from 70% to 14%. 53. Press the CHANGE key. 41. This will adjust the output voltage to the blower motor as indicated on the display. ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. The oxygen level at the 14% Valve Position should be as shown below. adjust the level using the ▲ and ▼ 4-5 . 39. adjust the level using the ▲ and ▼ arrow keys. 52. Once the oxygen level is within the specified range at 40%.2 8. 51. Also. 58. CAL Voltage 14% will begin to flash. Press the ▼ arrow key until CAL Voltage 14% is displayed. Once the oxygen level is within the specified range at 14%. SET Valve Position will begin to flash. Combustion Oxygen Level at 14% Valve Position Oxygen % ± 0. This will adjust the output voltage to the blower motor as indicated on the display. 49. 44. Once the oxygen level is within the specified range at 30%. This completes the natural gas combustion calibration procedure. CAL Voltage 30% will begin to flash. This will adjust the output voltage to the blower motor as indicated on the display. 55. Press the CHANGE key. Combustion Oxygen Level at 40% Valve Position Oxygen % ± 0. Press the CHANGE key. If the oxygen level is not within the specified range. 57. Also. Press the CHANGE key. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. 48. ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. SET Valve Position will begin to flash. Press the ▼ arrow key until the SET Valve Position reads 14%. press the ENTER key to store the selected blower output voltage for 14% Valve Position. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. CAL Voltage 40% will begin to flash. 42. 47. Combustion Oxygen Level at 30% Valve Position Oxygen % ± 0.

4 UNIT REASSEMBLY Once the combustion calibration adjustments are properly set. 3. RESET button before the boiler can be restarted. These switches are mounted on a plate attached to the boiler shell as shown in Figure 4-6. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound. Shut off the gas supply to the unit. Set the ON/OFF switch in the OFF position. Following an over-temperature condition. Set the automatic overtemperature switch to the desired setting.5 OVER-TEMPERATURE LIMIT SWITCHES The unit contains both automatic and manual reset over-temperature limit switches. Replace the NPT plug in the vent hole using a suitable pipe joint compound. 4. it must be manually reset by pressing the Figure 4-6 Over Temperature Limit Switch Locations 4-6 . The manual reset switch is not adjustable and is permanently fixed at 210°F. Remove the combustion analyzer probe from the vent hole. The switches can be accessed by removing the left side panels of the unit. 5. Replace the unit’s side panels and front door. once the temperature drops below its temperature setting. 2. the unit can be reassembled for service operation. 1. The automatic reset over-temperature switch is adjustable and allows the boiler to restart. Disconnect AC power from the unit. This switch will shut down and lock out the boiler if the water temperature exceeds 210°F.INITIAL START-UP 4. 6. 4.

6°F.2 INDOOR/OUTDOOR RESET MODE This mode of operation is based on outside air temperatures.6 is used. if a reset ratio of 1. 6. As the outside air temperature decreases. go up that column to the Reset Ratio row to find the corresponding reset ratio. 5. Factory defaults are listed in Appendix E. Use shielded 18 to 22 AWG wire for connections.9. NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data 4. The sensor may be mounted up to two hundred feet from the unit. 5. Each boiler is shipped from the factory tested and configured for the ordered mode of operation.2.2. 5. 5. 5.2.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. it must allow free air circulation. For instance.1 Reset Ratio Reset ratio is an adjustable number from 0. go across the chart to the desired supply header temperature for the design temperature chosen in step 3.1 to 9. Refer to Chapter 2. All temperature related parameters are at their factory default values which work well in most applications.6 is used. it is necessary to install an outside air sensor as well as select a building reference temperature and a reset ratio. Next. Choose the chart corresponding to the desired Building Reference Temperature. as well as direct impingement by the elements. After reading this chapter. 2.MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5.3 Outdoor Air Temperature Sensor Installation The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected. Refer to the Indoor/Outdoor reset ratio charts in Appendix D. if a reset ratio of 1. 3. Sensor connections are made at the Input/Output (I/O) Box on the front of the boiler. 5-1 .2 Building Reference Temperature This is a temperature from 40°F to 230°F. If a cover or shield is used. However.1 for additional wiring information. it may be necessary to change certain parameters to customize the unit to the system environment. it is the temperature that the system references to begin increasing its temperature. the supply header temperature will increase by 1. 5. Once the design outdoor air temperature is chosen. for each degree that outside air temperature decreases the supply header temperature will increase by 1. and we select a building reference temperature of 70°F. The following paragraphs in this Chapter provide descriptions of each of these operating modes. Go down the left column of the chart to the coldest design outdoor air temperature expected in your area. the supply header temperature will increase by that number for each degree that the outside air temperature decreases.9. Once adjusted. (Building Reference Temperature). The sensor must be shielded from the sun's direct rays. parameters can be customized to suit the needs of the specific application.2. Access the Configuration Menu and scroll through it until the display shows Bldg Ref Temp. Once selected. For this mode. Connections are made at the terminals labeled OUTDOOR SENSOR IN and SENSOR COMMON inside the I/O Box.4 Indoor/ Outdoor Startup Startup in the Indoor/Outdoor Reset Mode is accomplished as follows: 1.6° to 71. A complete listing and descriptions of the temperature related parameters are included in Appendix A. the supply header temperature will increase and vice versa. then at an outside temperature of 69°F. For instance. A wiring diagram is provided on the cover of the I/O Box. paragraph 2.6 degrees.

Press ENTER to save the change. Common uses of this mode of operation include water source heat pump loops. 9. or Network Refer to paragraph 3. In order to enable the Remote Setpoint Mode. the following menu setting must be made in the Configuration Menu: MENU OPTION Boiler Mode Remote Signal SETTING Remote Setpoint 4-20mA/1-5V. see Appendices A and E. is used to change the unit's setpoint. sent by an EMS or BAS. Press ENTER to save any changes. For descriptions of temperature-related functions and their factory defaults. and indirect heat exchangers for potable hot water systems or processes. Use the ▲ and ▼ arrow keys to select the Reset Ratio determined in step 5. it is suggested that an AERCO representative be contacted. No external sensors are required to operate in this mode. To set the unit for operation in the Constant Setpoint Mode. Next. The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters. Refer to paragraph 3. a 4 to 20 mA/1 to 5 Vdc signal. In addition to the current and voltage signals described above.3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is desired. The 4 mA/1V signal is equal to a 40°F setpoint while a 20 mA /5V signal is equal to a 240°F setpoint.4 REMOTE SETPOINT MODES The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). When a 0 to 20 mA/0 to 5 Vdc signal is used. With this setting. NOTE If a voltage. 5. the Remote Setpoint mode can also driven by a RS485 Modbus Network signal from an EMS or BAS. The display will begin to flash. The display will begin to flash. a DIP switch adjustment must be made on the CPU Board located in the Control Panel Assembly. 5. Contact your local AERCO representative for details.3 for detailed instructions on changing menu options.3. While it is necessary to set the desired setpoint temperature.20 mA/1 . The Remote Setpoint modes of operation can be used to drive single as well as multiple units.3 for detailed instructions on changing menu options. 0-20mA/0-5V. 5-2 . 12.MODE OF OPERATION 7. other than the setpoint. the following menu settings must be made in the Configuration Menu: MENU OPTION Boiler Mode Internal Setpt SETTING Constant Setpoint Select desired setpoint using ▲ and ▼ arrow keys (40°F to 240°F) Refer to paragraph 3. 5. Use the ▲ and ▼ arrow keys to select the desired Building Reference Temperature. 13. 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 .3 for detailed instructions on menu changing. 11. scroll through the Configuration Menu until the display shows Reset Ratio. Press the CHANGE key. 0 mA is equal to a 40°F setpoint.1 Setting the Setpoint The setpoint temperature of the unit is adjustable from 40°F to 240°F. 8. 10. rather than current signal is used to control the remote setpoint. Press the CHANGE key. it is not necessary to change any other temperature-related functions.5 Vdc.

Contact your local AERCO representative for details. NOTE If a voltage.1 Remote Setpoint Field Wiring The only wiring connections necessary for the Remote Setpoint mode are connection of the remote signal leads from the source to the unit’s I/O Box. When driving multiple units. To operate the unit in the Manual mode. the connections are made at the ANALOG IN terminals in the I/O Box. The I/O Box is located on the front panel of the boiler. The signal must be floating. For descriptions of temperature-related functions and their factory defaults.5 DIRECT DRIVE MODES The unit’s air/fuel valve position (% open) can be changed by a remote signal which is typically sent from an Energy Management System (EMS) or from a Building Automation System (BAS). It is suggested that an AERCO representative be contacted. each unit’s wiring must conform to the above. 5. the following menu setting must be made in the Configuration Menu: MENU OPTION Boiler Mode Remote Signal SETTING Direct Drive 4-20mA/1-5V. Direct Drive can be used to drive single. A 4 mA/1V signal is equal to a 0% valve position. 5-3 . the unit is a slave to the EMS or BAS and does not have a role in temperature control. the connections are made at the RS-485 COMM terminals in the I/O Box. or multiple units. (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. 5. zero is equal to a 0% valve position. the unit is factory preset with settings that work well in most applications. Refer to Modbus Communication Manual GF-114 for additional information. no startup instructions are necessary. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting. 0-20mA/0-5V. refer to Appendices A and E. a valid Comm Address must be entered in the Setup Menu.3 for instructions on changing menu options. The source end of the shield must be connected at the source. When in a Direct Drive mode. 5. prior to changing any temperature related function settings. In addition to the current and voltage signals described above.2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled. The REMOTE LED will go off and the MANUAL LED will light. With this setting. while a 20 mA /5V signal is equal to a 100% valve position. To enable the Direct Drive Mode. sent by an EMS or BAS is used to change the unit’s valve position from 0% to 100%. Polarity must be observed.4. For a Network setting. the REMOTE LED will light when the external signal is present. To change back to the Remote Setpoint mode. When a 0-20 mA/0-5 Vdc signal is used.4. simply press the AUTO/MAN switch. rather than current signal is used to control the remote setpoint. The Direct Drive mode 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 Direct Drive mode is 4-20 mA/1-5 Vdc. the Direct Drive mode can also driven by a RS485 Modbus Network signal from an EMS or BAS. While it is possible to change the settings of temperature related functions.MODE OF OPERATION If the Network setting is selected for RS485 Modbus operation. a DIP switch adjustment must be made on the CPU Board located in the Control Box Assembly. press the AUTO/MAN switch. a 4 to 20 mA signal. In this mode. or Network Refer to paragraph 3. The REMOTE LED will again light and the MANUAL LED will go off.

MODE OF OPERATION
If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information. header. The BMS can control up to 40 boilers; 8 via pulse width modulation (PWM) and up to 32 via Modbus (RS485) network communication. For BMS programming, operation, and Header Sensor installation details, see GF-108M (BMS Model 168) and GF-124 (BMS II Model 5R5384), BMS Operations Guides. For operation via an RS485 Modbus network, refer to Modbus Communication Manual GF-114. To enable the BMS Mode, the following menu settings must be made in the Configuration Menu: MENU OPTION Boiler Mode Remote Signal SETTING Direct Drive BMS (PWM Input) or Network (RS485)

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. 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. Polarity must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

Refer to paragraph 3.3 for instructions on changing menu options.

5.5.2 Direct Drive Startup
Since this mode of operation is factory preset and the valve position is being externally controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when the signal is present. 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 Direct Drive mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off.

5.6.1 BMS External Field Wiring
Wiring connections for BMS control using PWM signaling are made between connector JP2 on the BMS panel (boilers 1 through 8), and the B.M.S. (PWM) IN terminals in the I/O Box on the front of the boilers. Refer to the wiring diagram provided on the cover of the I/O Box. Wiring connections for RS485 Modbus control are made between connector JP11 on the BMS (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 BOILER MANAGEMENT SYSTEM (BMS) 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. The BMS mode of operation is used in conjunction with an AERCO Boiler Management System. The BMS mode is used when it is desired to operate multiple units in the most efficient manner possible. For this mode of operation, a BMS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant's supply water 5-4

5.6.2 BMS Setup and Startup
This mode of operation is factory preset and the AERCO BMS 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

MODE OF OPERATION
To change back to the BMS mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off. Combination Control Panel see the AERCO CCP-1 literature.

5.7 COMBINATION CONTROL SYSTEM (CCS) NOTE
Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5R5-384). A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. An AERCO Boiler Management System (BMS) Model 168 and a Combination Control Panel (CCP) are necessary to configure this system. Typically, an adequate number of boilers are installed to cover the space-heating load on the design day, however one or more units are used for the domestic hot water load. The theory behind this type of system is that the maximum space-heating load and the maximum domestic hot water load do not occur simultaneously.+ Therefore, boilers used for the domestic hot water are capable of switching between constant setpoint and BMS modes of operation. These boilers are the combination units and are referred to as the combo boilers. The combo boilers heat water to a constant setpoint temperature. That water is then circulated through a heat exchanger in a domestic hot water storage tank. When the space-heating load is such that all the space-heating boilers are at the 100% valve position, the BMS will then ask the Combination Control Panel for the domestic boilers to become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot water) boilers will then become spaceheating boilers. If the domestic hot water load is not satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch over to space heating, but there is a call for domestic hot water, the CCP switches the combo units back to the domestic load. When the combo units are satisfying the domestic load they are in constant setpoint mode of operation. When the combo units switch over to space heating, their mode of operation changes to the BMS mode. For more information concerning the operation of the

5.7.1 Combination Control System Field Wiring
Wiring for this system is between the BMS Model 168 panel, the CCP and the B.M.S. (PWM) IN terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above. For a complete CCP system-wiring diagram see the AERCO CCP-1 literature.

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. Enter the following settings in the Configuration Menu: MENU OPTION Boiler Mode Remote Signal Internal Setpt SETTING Combination BMS (PWM Input) 40°F to 240°F

Refer to paragraph 3.3 for instructions on changing menu options. While it is possible to change other temperaturerelated functions for combination mode, thes functions are preset to their factory default values. These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Appendix E. To set the unit to the manual mode, press the AUTO/MAN switch. The MANUAL LED will light. To set the unit back to the auto mode, press the AUTO/MAN switch. The MANUAL LED will go off and the REMOTE LED will light. When the boiler is switched to BMS mode, the AERCO BMS controls the valve position. There are no setup requirements to the boiler(s) in this mode.

5-5

The following tests check to ensure that the system is operating as designed. The unit should shut down and display a LOW GAS PRESSURE fault message at approximately 2. see Chapter 3. 3. 220.6” W. 1/8" NPT PLUG (INSTALL MANOMETER HERE FOR LOW GAS PRESSURE FAULT TEST) BALL VALVE Figure 6-1 Low & High Gas Pressure Testing 7. 5. 6. For a complete explanation of these modes. Replace the 1/8 “ plug removed in step 1. during and after the start sequence.SAFETY DEVICE TESTING CHAPTER 6 SAFETY DEVICE TESTING 6.2 LOW GAS PRESSURE FAULT TEST Refer to Figure 6-1 and ensure that the leak detection ball valve located at the high gas pressure switch is closed. slowly close the external manual gas shut-off valve.C. 6-1 . close the ball valve and remove the manometer. 6. Remove the 1/8 “ plug from the ball valve at the low gas pressure switch shown in the lower portion of Figure 6-1. 2. 9. 120 AND 24 VOLTS AC. While the unit is firing. Operating controls and safety devices should be tested on a regular basis or following service or replacement.0LN control system comprehensively monitors all combustion-related safety devices before. 1/8" NPT PLUG (INSTALL MANOMETER HERE FOR HIGH GAS PRESSURE FAULT TEST) HIGH GAS PRESSURE SWITCH LEAK DETECTION BALL VALVE NOTE MANUAL and AUTO modes of operation are required to perform the following tests. TO AIR/FUEL VALVE SSOV LOW GAS PRESSURE SWITCH NOTE It will be necessary to remove the front door and side panels from the unit to perform the following tests. POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK.C. Upon test completion. The fault message should clear and the FAULT indicator should go off. Fully open the external manual gas shut-off valve and press the CLEAR button on the Control Box. Install a 0 – 16 “ W. The unit should restart. GAS INLET WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460. gauge where the 1/8" plug was removed. 1. The Benchmark 3. manometer or a W. Place the unit in Manual Mode and adjust the air/fuel valve position (% open) between 25 and 30%.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly.C. 4. Slowly open the ball valve near the low gas pressure switch. All testing must conform to local codes such as ASME CSD-1. 8. The FAULT indicator should also start flashing.

If the unit does start. Start the unit in the normal operating mode. 1. Close the water shut-off valves in the supply and return piping to the unit. Once the adjustable over-temperature switch setting is approximately at. 12. close the ball valve and remove the manometer.6” W.C. or just below. 11. This switch is accessible from the left side of the unit as shown in Figure 6-2. Place the unit in the Manual Mode and raise the valve position above 30%. the unit should shut down. Set the ON/OFF switch to the OFF position 2. Reduce the gas pressure back to 1.3 HIGH GAS PRESSURE TEST To simulate a high gas pressure fault. If necessary the unit’s relief valve may be opened to aid in draining.SAFETY DEVICE TESTING 6. Open the water shut-off valve in the return piping to the unit. The READY light should remain off and the unit should not start. The unit should shut down and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 2. Set the ON/OFF switch to the ON position. 7. the actual outlet water temperature.C. The unit should restart. Set the ON/OFF switch to the ON position. Slowly open the drain valve on the rear of the unit. gauge) where the 1/8” plug was removed. The unit is now ready for operation. 3. 9.C. The FAULT indicator should also start flashing. 9. Start the unit in Manual mode at a valve position (firing rate) between 25 and 30%.C. 2. Open the water supply shut-off valve to the unit to refill.5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the automatic over-temperature switch. Replace the 1/8“ plug removed in step 1. 10. Install a 0 – 16” W. manometer (or W. 10. Press the CLEAR button on the Control Box to clear the fault. Slowly open the leak detection ball valve 4. Upon test completion. Close the drain and pressure relief valve used in draining the unit. 6. 3.8” W. Reset the adjustable over-temperature switch to its original setting. Continue draining the unit until a LOW WATER LEVEL fault message is displayed and the FAULT indicator flashes. After the shell is full.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault: 1. refer to Figure 6-1 and proceed as follows: 1. shut the unit off immediately and refer fault to qualified service personnel. 5. press the LOW WATER LEVEL RESET button to reset the low water cutoff. 4. Slowly increase the gas pressure using the adjustment screw on the SSOV Actuator (see Figure 4-3). It should not be possible to restart the unit. Lower the adjustable over-temperature switch setting to match the displayed OUTLET TEMPERATURE. 6. Press the CLEAR button to reset the FAULT LED and clear the displayed error message. 5. The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature. 6. 6. Remove the 1/8 “ plug from the leak detection ball valve shown in the upper portion of Figure 6-1. 6-2 . Allow the unit to stabilize at its setpoint. 7. 8. The FAULT indicator should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be displayed. 8. The fault message should clear and the FAULT indicator should go off.

Place the unit in the Manual Mode and set the valve position between 25% and 30%. HIGH LIMIT 2. the unit should shut down. 5.6.7 FLAME FAULT TESTS Flame faults can occur during ignition or while the unit is already running.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. 4. Reconnect the wire or jumper removed in step 3 to restore the interlock. remove one side of the jumper. Set the ON/OFF switch to the OFF position. If the interlock is connected to a proving switch of an external device. However. The unit should shut down and display a DELAYED INTERLOCK OPEN fault message. 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. or to prove 6. To simulate each of these fault conditions. each of these interlocks may be utilized in the field as a remote stop and start. disconnect one of the wires leading to the proving switch.1 REMOTE INTERLOCK 1.SAFETY DEVICE TESTING RESET BUTTON FOR MANUAL RESET TEMPERATURE LIMIT SWITCH that a device such as a pump.6. If there is a jumper across the REMOTE INTL’K IN terminals. or louver is operational. It should not be possible to restart the unit. ADJUSTABLE TEMPERATURE LIMIT SWITCH MOUNTING PLATE ON SHELL 6. Start the unit in the Manual Mode and set the valve position between 25% and 30%. The FAULT LED should be flashing. Press the CLEAR button to reset the fault The unit should start. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals. If there is a jumper across the DELAYED INTL’K IN terminals.2 DELAYED INTERLOCK Figure 6-2 Temperature Limit Switch Setting Once the adjustable over-temperature switch setting is approximately at. These circuits can shut down the unit in the event that an interlock is opened. the actual outlet water temperature. an emergency cut-off. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals. These interlocks are shipped from the factory jumpered (closed). gas booster. 3. proceed as follows: 1. 6. either open the interlock via the external device or disconnect one of the wires leading to the external device. Once the interlock connection is reconnected. remove one side of the jumper. Start the unit in the Manual Mode at a valve position between 25% and 30%. 2. 6. 6-3 . or just below. The FAULT indicator should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be displayed. the INTERLOCK OPEN message should automatically clear and the unit should restart. The unit should shut down and display INTERLOCK OPEN. Reset the adjustable over-temperature switch to its original setting. The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature. If the interlock is being controlled by an external device.

4. 1. (c) The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. 10. The unit should restart and fire. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV) and the Air/Fuel Valve (see Figure 6-3). 2. Restart the unit and allow it to prove flame. close the manual gas valve located between the SSOV and the Air/Fuel Valve. then press the CHANGE key. BLOCKED INLET SWITCH P/O FRAME 6. (b) The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. The unit will display AIRFLOW FAULT DURING PURGE. The unit should perform two IGNITION RETRY cycles and then shut down on the third successive ignition attempt. PARTIAL LEFT SIDE VIEW Figure 6-3 Manual Gas Shut-Off Valve Location 4. 8. (b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed. Set the ON/OFF switch to the ON position to start the unit. 5.SAFETY DEVICE TESTING 3. 6. The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps: (a) The unit will execute a 30 second reignition delay and display WAIT RETRY PAUSE. Once flame is proven. 7. (b) The unit will execute a 30 second reignition delay and display WAIT RETRY PAUSE. Open the valve previously closed in step 8. 3.8 AIR FLOW FAULT TESTS SSOV AIR/FUEL VALVE MANUAL GAS SHUTOFF VALVE HANDLE GAS INLET These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-3. The unit should shut down after reaching the Ignition cycle and display FLAME LOSS DURING IGN. Press the CLEAR button. AIR INLET BLOWER PROOF SWITCH BLOWER (a) The unit will execute a shutdown purge cycle for a period of 15 seconds and display WAIT FAULT PURGE. Disable the blower output drive voltage as follows: (a) Press the MENU key until CONFIGURATION MENU is displayed. Start the unit in the Manual Mode at a valve position between 25% and 30%. then press the ENTER key. Open the valve previously closed in step 3 and press the CLEAR button. 9. The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps: 6-4 . (c) Press the ▼ arrow key until OFF is displayed.

8. 6. Lift off the cover to access the terminal wiring connections. Set the ON/OFF switch to ON to start the unit. 7. 10. Re-enable the blower output drive voltage by performing the following steps: (a) Press the MENU key until CONFIGURATION MENU is displayed. 11. 8. 2. Press the CLEAR button. Remove the Air/Fuel Valve cover by rotating the cover counterclockwise to unlock it and then lift up (see Figure 6-5). Analog Output menu item and select OFF. proceed as follows: 1. The unit should restart. 6-5 . then press the CHANGE key. (b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed. 13. Set the unit’s ON/OFF switch to the OFF position. The proof of closure switch circuit is checked as follows: 1. The Blower Proof Switch will open and the blower should stop. 6. Disconnect wire #148 from the SSOV to “open” the proof of closure switch circuit. Return the Iris Air Damper to its previous setting. turn off the blower by going to the Configuration Menu. Next. 2. ACTUATOR COVER SCREW Figure 6-4 SSOV Actuator Cover Location 6. To check the switch. Press the CLEAR button. SSOV ACTUATOR COVER 5. 12. check the Blocked Inlet Switch by first noting the current position of the Iris Air Damper and then closing the Damper to position 8. Place the unit in Manual Mode and set the valve position between 25% and 30% 3. 3. The unit should restart. Replace wire #148 and press the CLEAR button. Refer to Figure 6-1 and locate the SSOV. (c) Press the ▲ arrow key until VALVE POSITION 0-10V is displayed. Analog Output item and select Valve Position 0-10v.SAFETY DEVICE TESTING 5. 9. Once the unit has proved flame. 7. Set the unit’s ON/OFF switch to the OFF position.9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6-1 contains a proof of closure switch. Replace the wire on the SSOV and press the CLEAR button. 11. 4. The unit should shut down and again display AIRFLOW FAULT DURING RUN. Remove the wire again when the unit reaches the purge cycle and PURGING is displayed. Go to the Configuration Menu.10 PURGE SWITCH OPEN DURING PURGE The Purge Switch (and Ignition Switch) is located on the Air/Fuel Valve. The unit should shut down and display SSOV FAULT DURING PURGE. The unit should restart. Remove one of the two wires (#171 or #172) from the Purge Switch (Figure 6-6). The unit should shut down and display AIRFLOW FAULT DURING RUN. Remove the cover from the SSOV by loosening the screw shown in Figure 6-4. then press the ENTER key. 10. 6. The unit should fault and display SSOV SWITCH OPEN. Place the unit in manual mode and set the valve position between 25% and 30%. 9.

Replace the wire on the Purge Switch and depress the CLEAR button. Replace the wire on the Ignition Switch and press the CLEAR button. The unit should begin it’s start sequence. 3. 7. 6. Initiate a unit start sequence. Place the unit in Manual Mode and set the valve position between 25% and 30%. Remove the Air/Fuel Valve cover (Figure 6-5) by rotating the cover counterclockwise to unlock and lift up to remove. 5. 5. 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code. 9 17 16 2 170 171 IGNITION POSITION SWITCH PURGE POSITION SWITCH Figure 6-6 Air/Fuel Valve Purge and Ignition Switch Locations 6. To check the switch. AIR/FUEL VALVE COVER (ROTATE CCW TO REMOVE) Figure 6-5 Air/Fuel Valve Cover Location 6-6 . The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION.SAFETY DEVICE TESTING 4. The unit should restart. Remove one of the two wires (#169 or #170) from the Ignition Switch (Figure 6-6). 2. Initiate a unit start sequence. 4. Set the unit’s ON/OFF switch to the OFF position. Section VI. STEPPER MOTOR DIAL TO BLOWER AIR IN 6.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. then shut down and display PRG SWITCH OPEN DURING PURGE. proceed as follows: 1. The unit should restart.

For best operation and life of the unit. 3. NOTE The 24-Month Waterside/Fireside Inspection Kit also includes the items contained in the Annual Maintenance Kit. STAGED IGNITION ASSY IGNITORINJECTOR FLAME DETECTOR & GASKET (SECURED WITH 2 SCREWS) Appendix K contains recommended spare parts lists for maintenance of the boiler. • SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT-OFF VALVE PROVIDED WITH THE UNIT • ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO PREVENT BURNING OR SCALDING 7-1 . the following maintenance kits are available through your local AERCO Sales Representative: • Annual Maintenance Kit. Disconnect the staged ignition assembly from the ignitorinjector. Remove the top and side panels from the unit. In order to perform the maintenance tasks specified in Table 7-1. Using a 7/16” open-end wrench. only Kit Part No. care should be exercised to avoid burns. Disconnect AC power from the unit 2. proceed as follows: 1. Part No.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability. The ignitor-injector may be hot. 58025-04 (See NOTE below) BURNER HOUSING MAINTENANCE 7. Therefore. 58025-04 is required when performing the waterside/fireside inspections. 4. Disconnect the cable from the ignitor-injector.MAINTENANCE CHAPTER 7 7. WARNING TO AVOID PERSONAL INJURY. this component also contains a gas injector tube which connects to the staged ignition assembly. 58023) is located in the body of the burner (see Figure 7-1). the following routine maintenance procedures should be carried out in the time periods specified in Table 7-1. PRIOR TO SERVICING: • DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER. 58025-01 • 24-Month Waterside/Fireside Inspection Kit. Set the ON/OFF switch on the control panel. See Appendix I for a complete CSD-1 inspection check list. Figure 7-1. to the OFF position. therefore.2 IGNITOR-INJECTOR The ignitor-injector (part no. Part No. It is easier to remove the ignitor-injector from the unit after the unit has cooled to room temperature. disconnect the compression nut securing the gas injector tube of the ignitor-injector to the elbow of the staged ignition assembly. Burner Assembly – Top View To inspect/replace the Ignitor-injector. In addition to providing the ignition spark required to light the burner.

If needed. 7-2 . BURNER HOUSING IGNITORINJECTOR HOUSING CENTERLINE 120 120 DEG.7 ITEM Ignitor-Injector (58023) Flame Detector (66006) Combustion Calibration Testing of Safety Devices Burner Condensate Drain Traps 6 Mos. If carbon build-up is present.MAINTENANCE 5. Reconnect the ignitor-injector cable. Prior to reinstalling the ignitor-injector. Replace Replace Labor Time 15 mins. 58023) is being installed. the ignitor-injector should be replaced. Check the ignitor-injector for evidence of erosion or carbon build-up. 6. 1 hr. 10. Table 7-1 . clean the component using fine emery cloth. torque to 180 in-lbs. 9. If there is evidence of substantial erosion or carbon build-up. Next. then loosen and retighten to 80 to 90 in-lbs. a high temperature.5 7. Reinstall the ignitor-injector in the burner housing and torque to 80 to 90 in-lbs. 1 hr. anti-seize compound must be applied to the threads. * Only performed after initial 6 month period after initial startup. These washers may be needed to properly position the gas injector tube of the ignitor-injector within the 120° angle shown in Figure 7-2. Refer to Chapter 4 for combustion calibration procedures. NOTE If a replacement ignitor-injector (part no. However. 7.6 7. Repeated carbon build-up is an indication that the combustion settings of the unit should be checked. Connect the staged ignition assembly to the gas injector tube of the ignitor-injector by securing the compression nut to the elbow of the staged ignition assembly. conductive.3 7. GAS INJECTOR TUBE MUST BE WITHIN THIS RANGE Fgurei 7-2 Burner Assembly – Top View 8. 3 indexing washers are also included.4 7. *Inspect *Inspect *Check 12 Mos. 11. 15 mins. 20 mins.2 7.Maintenance Schedule PARAGRAPH 7. if the burner housing was replaced just prior to replacing the ignitor-injector. 2 hrs. loosen and remove the ignitor-injector from the burner housing using a 1" open-end wrench. Reinstall the side and top panels on the unit. Inspect Inspect Check See CSD-1 Chart in Appendix I Inspect *Inspect Inspect & Clean 24 Mos. a compression nut containing a built-in ferrule will be included with the replacement part.

3 FLAME DETECTOR The flame detector. part no. Remove the eight (8) 3/8-16 nuts from the burner flange (Figure 7-3) using a 9/16” wrench. 9. Set the ON/OFF switch on the control panel. Reinstall the top and side panels on the unit. Remove the two (2) screws securing the flame detector to the burner housing. require that these tests be performed on a scheduled basis. Inspect the detector thoroughly. 7.MAINTENANCE 7. The flame detector may be HOT. Remove the flame detector and gasket from the burner housing. See Chapter 6-Safety Device Testing Procedures. 81030 81048 Description Burner Gaskets (Qty=2) Flame Detector Gasket To inspect or replace the burner assembly: 1. Using a 7/16” open-end wrench. the detector should be replaced. to the OFF position. Disconnect AC power from the unit and turn off the gas supply. 8. 3. 8. is located in the body of the burner (see Figure 7-1). such as ASME CSD-1. disconnect the compression nut securing the gas injector tube of the ignitor-injector to the elbow of the staged ignition assembly. Reconnect the flame detector lead wire. Remove the top panels from the unit. 5. To inspect or replace the flame detector: 1. Otherwise clean the detector with a fine emery cloth. Remove the flame detector and gasket from the burner housing. 7. Disconnect the lead wire from the flame detector. 6. 66006. Disconnect the burner housing from the blower by removing the six (6) 1/4-20 screws using a 3/8” wrench. Allow the unit to cool sufficiently before removing the flame detector. 6. Set the ON/OFF switch on the control panel. 7. Refer to Chapter 4 for combustion calibration instructions. 4. The burner assembly may be hot.4 COMBUSTION CALIBRATION Combustion settings must be checked at the intervals shown in Table 7-1 as part of the maintenance requirements. Allow the unit to cool sufficiently before removing the burner assembly.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. 4. 9. 3. Disconnect the cable from the ignitor-injector. Remove the side and top panels from the unit. The flame detector is secured to the burner housing with one (1) #10-32 screw and one (1) #8-32 screw. The flame detector is secured to the burner housing with one (1) #10-32 screw and one (1) #8-32 screw. Loosen and remove the ignitor-injector from the burner plate using a 1" wrench. 2. 5. Disconnect the staged ignition assembly from the ignitorinjector. The results of the tests should be recorded in a log book. 7-3 . 7. 2. Remove the two (2) screws securing the flame detector to the burner housing (Figure 7-1). 10. Reinstall the flame detector and flame detector gasket. to the OFF position. The following replacement parts will be necessary for reassembly following inspection: Part No. Disconnect AC power from the unit. 7. Test schedules must conform to local jurisdictions.6 BURNER ASSEMBLY INSPECTION The burner assembly is located at the top front of the unit. Certain code requirements. If eroded. Disconnect the lead wire from the flame detector (see Figure 7-1).

if the burner housing was replaced during inspection. 17. Remove the grounding screw.7 CONDENSATE DRAIN TRAPS The Benchmark 3. Figure 2-5. 11. 2. proceed as follows: 1.7. Remove the burner by pulling straight up. anti-seize compound is applied to the threads of the ground screw and the ignitor-injector. These traps should be inspected and. 16.1 Connecting Manifold Condensate Trap To inspect and clean the condensate trap (part no.2. 7-4 . if necessary. Loosen the thumbscrew securing the trap adaptor (Figure 2-6) to the condensate drain pipe on the connecting manifold. Beginning with the burner removed in step 13. Remove and replace the burner gaskets. then loosen and re-tighten to 80 to 90 in-lbs.MAINTENANCE BURNER HOUSING 3/8-16 NUTS (8) STAGED IGNITION ASSEMBLY STAGED IGNITION ASSEMBLY FLAME DETECTOR GROUNDING SCREW IGNITORINJECTOR BURNER GASKET BURNER HOUSING BURNER BURNER GASKET 1/4-20 SCREWS (6) Figure 7-3 Burner Disassembly Diagram . ensure that conductive. However. One trap is located external to the unit and attached to the drain pipe from the connecting manifold. Remove the nipples and connections on the inlet and outlet sides of the condensate trap shown in Figure 7-5. reinstall all the components in the reverse order that they were removed. Also. Check to ensure that the grounding screw is reinstalled. Follow the procedures in paragraphs 7. high-temperature. 7. cleaned to ensure proper operation.Top View NOTE The burner housing is heavy.0 Boiler contains two condensate traps as shown in Chapter 2. weighing approximately 25 pounds. 13.1 and 7.7. Make sure to align the burner housing with the blower and the heat exchanger top head. Figure 7-4 Burner Assembly . 24060) attached to the connecting manifold. The other trap is an integral part of the exhaust manifold. 14. Refer to the exploded view in Figure 7-4. Torque the ignitorinjector to 80 to 90 in-lbs. 12. torque to 180 in-lbs.Exploded View 7.7. Remove the burner housing from burner flange by pulling straight up. 15.

7. 7. 5. 6. HOSE Figure 7-5 External Condensate Trap 7. Thoroughly clean the trap. 6. Loosen the four (4) thumbscrews securing the cover on the condensate trap. remove the float and orifice gasket from the condensate trap. Remove the four bolts securing the flue to the top of the exhaust manifold. Also. The only difference is that the orifice gasket in the exhaust manifold trap has a 0.2 Exhaust Manifold Condensate Trap The exhaust manifold condensate trap also contains a float and orifice gasket similar to those shown in Figure 7-5. 3. Remove the cover. replace the gasket and float in the condensate trap. 1. Ensure that the trap is level and then tighten the adaptor thumbscrew.MAINTENANCE 3. float and gasket.75" I. 4. Disconnect the hose. 9. 2. Separate the flue from the exhaust manifold. inspect the drain hose for blockage. Place a suitable support under the trap to maintain it in the level position. float and gasket. replace the trap.D. Loosen the clamp securing the hose to the condensate drain (Figure 7-6). Reassemble all piping and hose connections to the condensate trap inlet and outlet. After the above items have been inspected and cleaned. FLUE BOLTS (4) UNIT FRAME COVER O-RING THUMB SCREWS (4) EXHAUST MANIFOLD FLOAT ORIFICE GASKET 3/4 NPT PORT OUTLET INLET CONDENSATE TRAP DRAIN 3/4 NPT PORT HOSE CLAMP 1" I. From the top of the exhaust manifold. Remove the orifice gasket from the trap. Remove the float from the condensate trap.D. Also inspect the drain piping for blockage. Thoroughly clean the trap.D. Replace the four bolts securing the flue to the exhaust manifold and connect the hose to the manifold condensate drain. Reconnect the condensate trap adaptor to connecting manifold drain pipe. replace the orifice gasket and float in the condensate trap and replace the trap cover. 4. After the above items have been inspected and thoroughly cleaned.25" I. refer to Figure 7-6 and proceed as follows: TO FLOOR DRAIN Figure 7-6 Exhaust Manifold Condensate Trap & Drain 7-5 . 5. opening and the gasket shown in Figure 7-5 has a 0. To inspect and clean the trap. If the trap cannot be thoroughly cleaned. 8.

Close external gas supply valve. 2. Perform initial startup per Chapter 4. air duct (if applicable). 2. the following instructions must be followed.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown (one year or more). 5. 3. 5. 1. 7-6 . Review installation requirements included in Chapter 2.MAINTENANCE 7. 4. Inspect all piping and connections to the unit. Inspect exhaust vent. Set ON/OFF switch on the front panel to the OFF position to shut down the boiler’s operating controls. Perform safety device testing and the scheduled maintenance procedures per Chapters 6 and 7 of this manual. 4. Close the water supply and return valves to isolate boiler. 7. the following procedures must be followed: 1. Open relief valve to vent water pressure. 3.8 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). Disconnect AC power from the unit.

TROUBLESHOOTING Chapter 8. Continue checking each additional Probable Cause for the existing fault until the fault is corrected. Probable Cause and Corrective Action. 8-1 . When a fault occurs in the Benchmark Boiler. 2. 6.0 Boiler. Refer to Chapter 9 of this manual for detailed RS232 communication set-up and procedures. The numbered items in the Probable Cause and Corrective Action columns correspond to each other. The troubleshooting procedures contained herein are presented in tabular form on the following pages. 1. Observe the fault messages displayed in the Control Box display. This RS232 communication feature permits service personnel to view menu items and data logs which can be useful in isolating faults. Paragraph 8. 1 corresponds to Corrective Action No. 7. For example. contact your local AERCO Representative. 3.TROUBLESHOOTING GUIDE 8. etc. 4. Probable Cause No. These tables are comprised of three columns labeled: Fault Indication. NOTE: The front panel of the C-More Control Box contains an RS232 port which can be interfaced to a laptop computer or other suitable device.2 and Table 8-2 contain additional troubleshooting information which may apply when no fault message is displayed. 5. proceed as follows to isolate and correct the fault: 1. Perform the checks and procedures listed in the Corrective Action column for the first Probable Cause candidate.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 3. If the fault cannot be corrected using the information provided in the Troubleshooting Tables. Refer to the Fault Indication column in Troubleshooting Table 8-1 which follows and locate the Fault that best describes the existing conditions. Proceed to the Probable Cause column and start with the first item (1) listed for the Fault Indication.

2. 11. 8. Refer to CORRECTIVE ACTION 7 and verify that the voltage conforms to the values shown in Appendix C. Remove the Blower proof switch and inspect for signs of blockage. 10. Defective blocked-air inlet switch 7. clean or replace as necessary. Check the Analog Out option on the C-More Configuration Menu. Blocked Blower inlet or inlet ductwork 3. 6. 3. 9. Wrong 0-10V output selection on the control box 12. replace the switch. The position on the VALVE POSITION bar graph should match the reading on the Air/Fuel Valve dial. BOILER TROUBLESHOOTING FAULT INDICATION AIRFLOW FAULT DURING IGNITION PROBABLE CAUSES 1. 9. If there is an erratic resistance reading or the resistance reading is greater than zero ohms. Defective temperature sensor Loose wire connection between the 0-10V signal from I/O box to the Blower Motor input 10. A voltage of 8. 5. Blower stopped running due to thermal or current overload 2. replace the switch. Check the actual inlet air temperature and measure voltage at AUX input in the I/O Box. 4. Blocked Blower proof switch 4. Defective Blower proof switch CORRECTIVE ACTION 1. Defective I/O box 11. 12. Check wire connection from I/O Box 0-10V signal to the Blower Motor. 50% and 100% open positions. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices. Remove the blocked-air inlet switch and inspect for signs of blockage.2V equates to a 100% open air/fuel valve position. If there is an erratic resistance reading or the resistance reading is greater than zero ohms. Loose temperature to AUX connection in I/O Box 8. Measure the Blower proof switch for continuity with the combustion blower running. Measure the blocked-air inlet switch for continuity with the combustion blower running. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage. Valve Position 0-10V should be selected. Verify that the voltage conforms to the values shown in the tabular listing provided in Appendix C. 6. Blocked blocked-air inlet switch 5. Defective Air-Fuel Valve potentiometer 8-2 . Measure voltage at the I/O box 0-10V output. 7. clean or replace as necessary.APPENDIX B TABLE 8-1. Check Air/Fuel Valve position at 0%.

No voltage to switch from control box. PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT DURING IGNITION also apply for this fault AIRFLOW FAULT DURING RUN 1. Blocked Blower inlet or inlet ductwork 3. perform combustion calibration. Blower stopped running due to thermal or current overload 2. 3.TROUBLESHOOTING TABLE 8-1. 4. 4. Blocked Blower inlet or inlet ductwork. If the unit rumbles or runs rough. Remove the airflow switch and inspect for signs of blockage. Blower not running or running too slow CORRECTIVE ACTION 1. If the relay is okay. Defective airflow switch 5. 5. Combustion oscillations 6. check the blower. Replace the switch if there is no continuity. If 24VAC is not present refer to qualified service personnel. PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT DURING IGNITION applies for this fault 2. 2. Start the unit. 5. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage. If the blower does not run check the blower solid state relay for input and output voltage. Defective Air Flow Switch 3. check the airflow switch for continuity. See CORRECTIVE ACTION from 3 to 12 for AIRFLOW FAULT DURING IGNITION 1. If the blower runs. 5. Blocked airflow switch 4. BOILER TROUBLESHOOTING – Continued FAULT INDICATION AIRFLOW FAULT DURING PURGE PROBABLE CAUSES 1. Start the unit. Run unit to full fire. Check combustion blower for signs of excessive heat or high current draw that may trip thermal or current overload devices. If there is an erratic resistance reading or the resistance reading is greater than zero ohms. clean or replace as necessary. 2. Measure the airflow switch for continuity with the combustion blower running. replace the switch. Blocked Air flow Switch 4. clean or replace as necessary. PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT DURING IGNITION applies for this fault 8-3 . Measure for 24 VAC during start sequence from each side of the switch to ground. 3. 6. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage. 6. 6. Remove the air flow switch and inspect for signs of blockage.

BOILER TROUBLESHOOTING – Continued FAULT INDICATION DELAYED INTERLOCK OPEN PROBABLE CAUSES 1. Check control signal type set in Configuration Menu. DIRECT DRIVE SIGNAL FAULT FLAME LOSS DURING IGN 1. 3. Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. Replace if necessary. 3. 2. Refer fault to qualified service personnel. Defective SSOV 8-4 . louver. Worn flame detector 3. Control Box signal type selection switches not set for correct signal type (voltage or current). Signal defective at source. (jumper may be temporarily installed to test interlock) 1. If there are 2 external wires on these terminals. check to see if an end switch for a device such as a pump. Install and arc a spark igniter outside the unit. check polarity. No spark from Spark Plug 4. 6. If there is no spark. Signal is not isolated (floating). While externally arcing the spark igniter. Inspect and install/retighten Burner Ground Screw. Broken or loose wiring. Burner Ground Screw not installed or loose. 4. the IGST board in the Control Box may be defective. Direct drive signal is not present: Not yet installed. Ensure that the device and or its end switch are functional. If 120VAC is not present. 2. Check for a jumper properly installed across the delayed interlock terminals in the I/O box. Delayed Interlock Jumper not installed or removed. observe the open/close indicator in the Safety Shut-Off Valve to ensure it is opening. Close the internal gas valve in the boiler. If the valve does not open. 3. 1. the IGST Board in the Control Box may be defective. 2. If installed. Check continuity of wiring between source and boiler. Refer fault to qualified service personnel. 1. Wrong polarity. Device proving switch hooked to interlocks is not closed CORRECTIVE ACTION 1. 2. Hook up if not installed. Defective Ignition Transformer 5. check for 120VAC at the primary side of the ignition transformer during the ignition cycle. check for 120VAC at the valve’s input terminals. If 120VAC is not present. is tied these interlocks. Remove and inspect the flame detector for signs of wear. 2. Measure signal level. 5.TROUBLESHOOTING TABLE 8-1. Defective Ignition/Stepper (IGST) Board 6. Check signal at source to ensure it is isolated. etc. 2. Check I/O Box to ensure signal is hooked up.

Staged ignition ball valve closed. Defective relay. Remove the burner and inspect for any carbon or debris. 5. 3. Debris on burner. Calibrate or repair as necessary. 10. If the fault persists. HIGH EXHAUST TEMPERATURE 2. Poor combustion calibration. Worn Flame Detector or cracked ceramic. 9. Adjust as necessary. If the exhaust temperature is less than 475 F and the exhaust sensor shows continuity replace the sensor. 1. CORRECTIVE ACTION 7. FLAME LOSS DURING RUN 3. Carbon or other debris on Burner 8. Relay is activated when not in Demand 1. 2. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure that the gas pressures into and out of the valve are correct. 1. 1. Remove the burner and inspect for any carbon or debris. Clean and reinstall. Blocked condensate drain. 10. The Heat Demand Relays on the Ignition/Stepper board failed to activate when commanded 2. If exhaust temperature is greater than 500 F. 8. 2. Measure the actual exhaust temperature and continuity of the o exhaust sensor. listen to the solenoid valve for a clicking sound to ensure it is opening. Defective SSOV Regulator. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Press CLEAR button and restart the unit. Carboned heat exchanger due to incorrect combustion calibration 8-5 . Remove blockage in condensate drain. 9. replace Ignition/Stepper (IGST) Board. check combustion calibration. Replace if necessary. Open 1/4” ball valve downstream of the SSOV (see Figure 8-1). Staged ignition solenoid valve doesn’t open. Remove and inspect staged ignition piece for blockage. BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) PROBABLE CAUSES 7. 1. 4. 4. Replace IGST Board. Defective exhaust sensor. Clogged staged ignition piece. o 2. HEAT DEMAND FAILURE 2.TROUBLESHOOTING TABLE 8-1. 5. When boiler goes to ignition. 1. Clean and reinstall. Check combustion calibration.

If the system is a variable flow system. No interlock to boiler or BMS to disable boiler(s) in event that system pumps have failed. 4. (see para. 7. to 1. HIGH WATER TEMP SWITCH OPEN 1. 2. 7. System flow rate changes are occurring faster than boilers can respond. 3. 3. Check setpoint of unit and setpoint of Temperature Switch. 3. 2. 1. record the current readings then reset them to the default values. the SSOV Actuator gas pressure adjustment regulator may be defective. BOILER TROUBLESHOOTING – Continued FAULT INDICATION HIGH GAS PRESSURE PROBABLE CAUSES 1. Gas pressure snubber not installed.8” W. Defective High Gas Pressure Switch 4. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. 2. Check the BMS for changes to PID default values. check to see if there are flow switches interlocked to the BMS or boiler. CORRECTIVE ACTION 1.3. 3. 5. Ensure that the temperature switch is set higher than the unit’s setpoint. 4. If unit is in Manual Mode switch to Auto Mode.C. 6. Faulty shell temperature sensor. 8-6 .TROUBLESHOOTING TABLE 8-1. 4. Boiler Management System PID or other settings not correctly setup. If system pump is controlled by Energy Management System other than BMS or pumps are individually controlled by boiler. Replace the switch if it does not show continuity. See Figure 8-1. Check to ensure gas pressure at inlet of SSOV is 2 psig maximum. Unit setpoint is greater than Over Temperature Switch setpoint. Defective SSOV Actuator gas pressure adjustment regulator. Using the resistance charts in the Appendix C. Measure the resistance of Shell sensor and BTU sensor at a known water temperature. 8. correct as necessary. monitor system flow changes to ensure that the rate of flow change is not faster than what the boilers can respond to. Unit in Manual mode 5. Incorrect supply gas pressure. 4. Test the temperature switch to insure it trips at its actual water temperature setting. Ensure that the gas pressure snubber is installed at the high gas pressure switch. Incorrect PID settings. 2. Faulty Water temperature switch. 6. 8. If the settings have been changed. If gas supply pressure downstream of the SSOV cannot be lowered. step 10). Check PID settings against Menu Default settings in the Appendix.

Start the unit. the problem may be in the Air-Fuel Valve or the Control Box. Defective IGST Board 8-7 . Defective Power Supply Board or fuse 5. replace IGST Board. the problem may be in the Air/Fuel Valve or the Control Box. check the ignition position switch for continuity between the N. Check DS1 & DS2 LEDs on Power Supply Board. If fault persists. Check DS1 & DS2 LEDs on Power Supply Board. replace Power Supply Board. Defective IGST Board IGN SWTCH OPEN DURING IGNITION 1. 2.O. If the switch shows continuity when not in contact with the cam replace the switch. Defective ignition switch 3. replace IGST Board 1. If the Air/Fuel Valve does rotate to the ignition position. See HIGH WATER TEMPERATURE SWITCH OPEN. If they are not steady ON. 1. If not. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). Refer fault to qualified service personnel. 2. replace Power Supply Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second.O. Temp HI Limit setting is too low.TROUBLESHOOTING TABLE 8-1. 3. 2. If they are not steady ON. then back to ignition position (towards closed) during the ignition cycle. Press CLEAR button and restart unit. Refer to qualified service personnel 2. 1. 2. If the valve does not rotate at all or does not rotate fully open. The Air/Fuel Valve should rotate to the purge (open) position. contact qualified Service Personnel. Defective Power Supply Board or fuse 4. replace the switch 4. and COM terminals. The Air/Fuel Valve should rotate to the purge (open) position. 1. Air/Fuel Valve not rotating to ignition position. If calibration is okay. If calibration is okay. 5. If the Air/Fuel Valve does rotate to purge. Check Temp HI Limit setting. check the ignition switch for continuity between the N. Defective or shorted switch 3. If not. BOILER TROUBLESHOOTING – Continued FAULT INDICATION HIGH WATER TEMPERATURE IGN BOARD COMM FAULT IGN SWTCH CLOSED DURING PURGE PROBABLE CAUSES 1. Air/Fuel Valve not rotating CORRECTIVE ACTION 1. 3. Switch wired incorrectly 4. 4. . check the Air/Fuel Valve calibration. Start the unit. If the switch is wired correctly. If the valve does not rotate back to the ignition position. check the Air/Fuel Valve calibration. and COM terminals when in contact with the cam. Communication fault has occurred between the PMC board and Ignition/Stepper (IGST) board 1. See HIGH WATER TEMPERATURE SWITCH OPEN. 2. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second.

TROUBLESHOOTING TABLE 8-1. Ensure it is at least 3. MODBUS COMM FAULT PRG SWTCH CLOSED DURING IGNITION 1. Incorrect supply gas pressure.0” W. Insufficient water level in system 2.1). If the valve does not rotate back to the ignition position. Line and Neutral switched in AC Power Box. then back to ignition position (towards closed) during the ignition cycle. Measure gas pressure at the low gas pressure switch. Device proving switch hooked to interlocks is not closed. Check continuity of probe end to the shell. Measure gas pressure upstream of the supply gas regulator with the unit firing.6” W. check the Air/Fuel Valve calibration. Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons. The Air/Fuel Valve should rotate to the purge (open) position. for FM gas train. against the power box transformer wiring diagram to ensure it is wired correctly 1. 3. 2. Start the unit.C. Check that proving switch for any device hooked to the interlock circuit is closing and that the device is operational. Defective Low Pressure Gas Switch LOW WATER LEVEL 1. 2. 1. Incorrect power supply transformer wiring. the problem may be in the Air/Fuel Valve or the Control Box. change probe if there is no continuity.. in AC Power Box. Refer fault to qualified service personnel. Max. If there are two external wires on these terminals check any Energy Management system to see if they have the units disabled (a jumper may be temporarily installed to see if the interlock circuit is functioning). Defective water level probe. measure continuity across the switch and replace if necessary. Check Line (hot) and Neutral in AC Power Box to ensure they are not reversed 2. Replace water level circuitry if it does not respond. 1. 3. BOILER TROUBLESHOOTING – Continued FAULT INDICATION INTERLOCK OPEN PROBABLE CAUSES 1.7.C. Check transformer wiring. Check system for sufficient water level. Energy Management System does not have boiler enabled. 2. or 4. for IRI gas train.C. 1. 1. CORRECTIVE ACTION 1. 2. 2.5” W. 1. 1. 3. Check network connections. Defective water level circuitry. If calibration is okay. contact qualified Service Personnel. Check for a jumper properly installed across the interlock terminals in the I/O box 2. allowable pressure is 2 psig (see para. If it is greater than 2. Boiler not seeing information from Modbus network 1. If fault persists. Interlock jumper not installed or removed 2. LINE VOLTAGE OUT OF PHASE LOW GAS PRESSURE 3. A/F Valve rotated open to purge and did not rotate to ignition position 8-8 .

Defective or shorted switch. Switch wired incorrectly. Check continuity of wiring between source and boiler. check the purge switch for continuity between the N. 3. Check resistance of sensor to determine if it is within specification. Remote setpoint signal not present: Not yet installed. CORRECTIVE ACTION 2. 1. Defective purge switch. Defective IGST Board OUTDOOR TEMP SENSOR FAULT 1. 2. Inspect Outdoor Temperature sensor for loose or broken wiring. check the purge switch for continuity when closing. 3. Hook up if not installed. If not. replace IGST Board. Check signal at source to ensure it is isolated. 3. check polarity. 4. 1. If the Air/Fuel Valve does rotate to the ignition position. If the air-fuel valve does rotate. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. Ensure that the correct sensor is installed. If 24VAC is not present. BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) PROBABLE CAUSES 2. replace Power Supply Board. Measure signal level. If they are not steady ON. replace Power Supply Board. Defective IGST Board PRG SWTCH OPEN DURING PURGE 1. 3. Loose or broken wiring. Signal is not isolated (floating) if 4 to 20 mA. If the switch is wired correctly. If not. 4. Check control signal type set in Configuration Menu. Switch wired incorrectly. 2. 2. 2. replace IGST Board. 5. Broken or loose wiring. 3. No voltage present at switch. check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). 2. Replace switch if continuity does not exist. 1. Measure for 24 VAC from each side of the switch to ground. REMOTE SETPT SIGNAL FAULT 8-9 . 5.TROUBLESHOOTING TABLE 8-1. 4. 4. Defective Sensor. If they are not steady ON. refer fault to qualified service personnel. Defective Power Supply Board or fuse 5. 3. Signal defective at source.O. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. replace the switch. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). Check I/O Box to ensure signal is hooked up. Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. 1. If installed. and COM terminals. 3. Check DS1 & DS2 LEDs on Power Supply Board. Control Box signal type selection switches not set for correct signal type (voltage or current). If the switch shows continuity when not in contact with the cam. 2. Incorrect Sensor. Check DS1 & DS2 LEDs on Power Supply Board. 3. Wrong polarity. Defective Power Supply Board or fuse 5.

1. para. it may be powered continuously. 6. either adjust or replace the switch or actuator. Close gas shut-off valve downstream of SSOV. Remove the electrical cover from the SSOV and check switch continuity. SSOV SWITCH OPEN 3. If fault persists. Refer fault to qualified service personnel. 1. SSOV switch closed for 15 seconds during run. 1.1). If the switch does not show continuity with the gas valve closed. SSOV powered when it should not be 3. Defective Flame Detector SSOV FAULT DURING PURGE SSOV FAULT DURING RUN SSOV RELAY FAILURE See SSOV SWITCH OPEN 1. If fault persists. SSOV relay failed on board. The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two. If operation is not correct. Normally this measurement should be near zero or no more than a few millivolts.2. Check SSOV power wiring. replace actuator. Close the gas supply and remove power from the unit. Verify that the VALVE POSITION bargraph and the dial on the Air/Fuel Valve track each other to indicate proper operation. 2. SSOV not fully closed. STEPPER MOTOR FAILURE 1. Hot and Neutral reversed at SSOV. CORRECTIVE ACTION 1. Floating Neutral. replace the valve and or actuator. 6. 2. replace Ignition/Stepper (IGST) Board. 4.TROUBLESHOOTING TABLE 8-1. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. 3. 1. Press CLEAR button and restart unit. 2. 2. Refer to GF-112 and perform Stepper Test (para. 2. Install a manometer or gauge in a gas test port between the SSOV and the gas shut off valve. Observe operation of the Safety Shut-Off Valve (SSOV) through indicator on the Valve actuator and ensure that the valve is fully and not partially closing. If not fully closed. Ensure that the SSOV Proof of Closure switch is correctly wired. Incorrectly wired switch. If a gas pressure reading is observed replace the SSOV valve and or actuator. 1. Actuator not allowing for full closure of gas valve 2. Replace or adjust microswitch in SSOV actuator. 8-10 . BOILER TROUBLESHOOTING – Continued FAULT INDICATION RESIDUAL FLAME PROBABLE CAUSES 1. If the SSOV never closes. 3. Replace Flame Detector.3. Defective Switch or Actuator 4.5) to ensure stepper motor rotates properly between the 0% (fully closed) and 100% (fully open) positions. Air/Fuel Valve out of calibration. 1. perform the Stepper Feedback Calibration (GF-112.

TABLE 8-2. If they are not steady ON. Replace stepper motor. 4. 2. 1. 4. Gas pressure going into unit is fluctuating. Damping Orifice not installed. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT Hard Light-Off PROBABLE CAUSES 1. Fluctuating Gas Pressure 1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) PROBABLE CAUSES 2. troubleshoot Building Supply Regulator. 5. 8-11 .TROUBLESHOOTING TABLE 8-1. Clogged/damaged Ignitor. 5. 3. replace Power Supply Board. Air/Fuel Valve “hunting” at 80% valve position 1. Open the 1/4” Ball Valve downstream of the SSOV (Fig. Check DS1 & DS2 LEDs on Power Supply Board. 3. the Damping Orifice is installed in the downstream SSOV Actuator. Defective Power Supply Board or fuse 6. Defective Air/Fuel Valve stepper motor. 1. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. Staged Ignition Ball Valve closed. 3.Injector (Figure 8-2). 2. 8. 6. 2. Check to ensure that the Damping Orifice is installed in the SSOV Actuator (Figure 8-3). For IRI Gas Trains. Inspect for loose connections between the Air/Fuel Valve motor and the wiring harness. 2. Close the 2” and the 1/4” Ball Valve downstream of the SSOV (Fig. 8-1). 8-1). Defective IGST Board CORRECTIVE ACTION 2. If not. E or higher. Check that the Air/Fuel Valve is connected to the Control Box. IGST and Power Supply Boards in Control Box are outdated. Remove and inspect gas injector to ensure it is not clogged or damaged. Loose wiring connection to the stepper motor. replace the Staged Ignition Solenoid. Start the unit and listen for a “clicking” sound that the Staged Ignition Solenoid makes during Ignition Trial. Defective Staged Ignition Solenoid (Figure 8-2) CORRECTIVE ACTION 1. Check to ensure that the IGST and Power Supply Boards are Rev. If “clicking” sound is not heard after 2 or 3 attempts.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. Air/Fuel Valve unplugged. replace IGST Board. 3. If necessary. Stabilize gas pressure going into unit.

TROUBLESHOOTING Figure 8-2 Staged Ignition Solenoid Location Figure 8-1 High Pressure Gas Switch & Snubber Locations Figure 8-3 Damping Orifice Location 8-12 .

RS232 COMMUNICATION CHAPTER 9 9. Fault and Sensor log displays. enter the valid RS232 password (jaguar) in lower case letters and press Enter.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. followed by the number to the right of the displayed option to be changed. 1 stop bit. 9. Configuration and Tuning Menus. Tables 3-2 through 3-5 for allowable entry ranges and settings for the Operating. Shortcut keys are also available to go directly to a specific menu. Refer to Chapter 3. The RS232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line.2 RS232 COMMUNICATION SETUP Regardless of the terminal emulation utilized. An asterisk (*) prompt should appear. These shortcut keys are: m0 m1 m2 m3 m4 m5 Default (Operating) Menu Setup Menu Configuration Menu Tuning Menu Calibration Menu Diagnostic Menu 9. (The Calibration and Diagnostic Menus should only be used by Factory-Trained service personnel).2K 2. When viewing menus containing more than 10 options. RS232 COMMUNICATION M = Display next Menu D = Display menu items N = Display next menu items Cxx = Change item xx F = Fault log display S = Sensor log display T = Time line display L = Log off NOTE: The Level 1 password (159) must be entered to change options in the Setup. 2. At the prompt. Start the emulator software program and ensure that the specified baud rate and data formats have been entered. The Menu title and first 10 options will be displayed. The Level 2 password (6817) must be entered to view or change options in the Calibration and Diagnostics Menus. and then press <Rtn>. With the exception of the password entry. Baud Rate – The baud rates which can be used with the C-More Control Panel are: 2400 4800 9600 (Default) 19. all other keyboard entries can be made using either upper or lower case. 6. proceed as follows: (a) Enter C. 4. RS232 communication can be accomplished using any “Dumb Terminal” emulation. 7. the following guidelines must be adhered to when setting up the RS232 communication link: 1. no parity and either Xon/Xoff or No flow control. such as “Hyper Terminal” which is included with Microsoft Windows. 3. Data Format – The program must be set for: 8 data bits. 5. 9-1 . Press the Enter key on the laptop. enter N <Rtn> to display the remaining options. (b) Enter the desired value or setting for the option and press <Rtn>. enter M <Rtn>. Configuration and Tuning Menus. Setup. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices: 8. To view the available menus in the top-down sequence shown in Figure 3-2. To change a value or setting for a displayed menu option.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS232 communication is accomplished as follows: 1.

press L followed by <Rtn>. 9. NOTE: The Operation Time (T) Log can store thousands of records. To view earlier records in reverse chronological order. The basic procedure for accessing each data log is described in paragraph 9. To display the Fault (F) Log.3 Sensor Log The sensor values can be logged at a different rate if needed by setting the Sensor Log Interval in the Diagnostics Menu. Refer to paragraph 9. To go back 200 or 700 records. To go back 200 or 1000 records. or the run mode must change. This means that no more than 30 minutes of data can be lost if the unit loses power.1 Fault Log The C-More Control Panel logs the last 10 faults (0 – 9) starting with the most recent (#0). 9.4. 11.2 Operation Time Log 9. Table 9-3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode. enter T200 or T1000. If the Fault Log already contains 10 faults.3. Therefore. the fire rate or flame strength must change by more than 5%. To view earlier records in reverse chronological order. the run-length is allowed to reach a maximum of 30 minutes before the record is logged. enter S200 or S700. For a new run record to be logged. Data is logged or the run-length incremented every 30 seconds. Sensor (S) Log or Time (T) Line Log.4 for descriptions and samples of these data logs.4 DATA LOGGING During operation. enter S and press Enter. faults and sensor readings associated with the boiler or water heater system. Descriptions of these data logs are provided in the following paragraphs. 9-2 . T0 <Enter>). NOTE: The Sensor (S) Log can store up to 1200 records. Events such as power-up. to view the most recently logged record. enter T and press Enter. 10. the C-More Control Panel continuously monitors and logs data associated with operational events. The operation time log can be cleared ONLY by factory authorized personnel using the Clear Log option in the Factory menu. Therefore. step 7. to view the most recently logged record.4.RS232 COMMUNICATION (c) Menu changes will be stored in nonvolatile memory. and press Enter. S0 <Enter>). Ten operation time records are displayed for each T command entry. S or T followed by <Rtn>.e. ignition and turn-off are time stamped.4. press F. 9. The log interval can vary from once every minute to once every day. enter “S” followed by 0 (zero) and then press Enter (i. The Fault Log cannot be cleared. enter “T” followed by 0 (zero) and press Enter (i. etc. To redisplay the menu and view the option which was just changed in step 5.e. The Operation Time Log consists of a string of ASCII records stored in non-volatile memory within the C-More Control Panel. etc. A sample Fault Log display is shown in Table 9-1. They can be viewed in the front panel display or via the RS232 port. enter D and press <Rtn>. Data logged while the unit is running are run-length encoded. Table 9-2 shows a sample Operation Time Log for a boiler: The Operation Time Log can only be accessed through the RS232 interface using a laptop or other terminal device. and press Enter. To log off and terminate the RS232 communication link. the earliest fault is overwritten when a new fault occurs. At steady-state. 9.

0 . Sample Sensor Log Display Setpt 130 130 130 130 130 130 130 130 130 130 Outlet 181 180 180 179 180 180 180 180 179 180 Outdr OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN FFWD OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN Aux OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN Inlet OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN Exhst OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN CO 0 0 0 0 0 0 0 0 0 0 O2 .RS232 COMMUNICATION Table 9-1. Sample Operation Time Log Display Status Off. Direct Drive Run.0 . Direct Drive Run. Direct Drive Ignition Off.0 Flow 0 0 0 0 0 0 0 0 0 0 Date 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 Time 5:51pm 5:46pm 5:41pm 5:36pm 5:31pm 5:26pm 5:21pm 5:16pm 5:11pm 5:06pm 9-3 . Sample Fault Log Display No.0 .0 . 0 1 2 Fault Message Direct Drive Signal Fault Low Gas Pressure Loss of Power Cycle 609 366 0 Date 1/10/02 7/04/01 1/01/01 Time 8:42am 5:29pm 11:50am Table 9-2.0 .0 .0 .0 . Direct Drive Run. Manual Ignition Power-up Fire Rate 0 38 31 35 29 0 0 40 0 0 Flame 0 100 100 100 100 0 0 100 0 0 Run Length 8 34 30 2 0 0 35 0 0 0 Date 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 1/15/02 Time 2:35pm 2:27pm 1:53am 1:23pm 1:21pm 1:20pm 12:30pm 11:55am 11:55am 11:50am Table 9-3. Direct Drive Run.0 . Switch Run.

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999. DESCRIPTION Air Temp Outdoor Temp Valve Position In Flame Strength Run Cycles Run Hours Fault Log A-1 . When in the Outdoor Reset Mode. Air Temp is the air temperature at the input to the Air/Fuel Valve. Displays flame strength from 0% to 100%.APPENDIX A APPENDIX A . When in the Remote Setpoint Mode. This reading is one of the parameters used to control the Blower Motor speed. Displayed only if outdoor sensor is installed and enabled. Displays information on the last 20 faults. Desired input valve position. When in the Constant Setpoint Mode. Displays the total number of run cycles from 0 to 999. This would normally be the same as the fire rate shown on the bargraph (valve position out) when the boiler is operating. this value is the setpoint equivalent to the remote analog signal supplied to the unit.BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint. Displays total run time of unit in hours from 0 to 9. Remote Setpoint or Outdoor Reset Mode.999. this is the derived value from the charts in Appendix D.999. this value is equal to the Internal Setpoint setting in the Configuration Menu.

Allows selection of KC Boiler. RS-232 should have its own (programmable) password. Default is Constant Setpoint Mode. Unit Size Fuel Type Boiler Mode Remote Signal Bldg Ref Temp A-2 . options in the Setup. Combination. or Outdoor Reset Mode.9).BOILER MENU ITEM DESCRIPTIONS . BMK Boiler. Default is 9600. Default is °F. Allows selection of Natural Gas or Propane It allows selection of: Constant Setpoint. Default is 130°F. Default is English. Language Time Date Unit of Temp Permits selection of English. KC Water Heater. BMK Boiler LN. Default address is 0. Direct Drive or Combination Mode.CONTINUED MENU LEVEL & OPTION SETUP MENU Password Allows password to be entered.5 to 6.0 to Ver 9. Default is 70°F. Displays dates from 01/01/00 to 12/31/99 Permits selection of temperature displays in degrees Fahrenheit (°F) or degrees Celsius (°C).APPENDIX A APPENDIX A . KC Water Heater LN. BMK Boiler Dual. Allows communications Baud Rate to be set (2400 to 19. Used to set the type of external signal which will be used when operating in the Remote Setpoint. KC Boiler LN. DESCRIPTION Comm Address Baud Rate Software Version CONFIGURATION MENU Internal Setpoint Unit Type Allows internal setpoint to be set . Displays time from 12:00 am to 11:59 pm. Spanish or French for displayed messages. Remote Setpoint.0 MBTU. Once the valid password (159) is entered. For RS-485 communications (0 to 127). Water Heater 2010 Sets unit size from 0. Configuration and Tuning Menus can be modified. Direct Drive. The factory default is 4-20 mA/1-5V. Allows the building reference temperature to be set when operating a boiler in the Outdoor Reset Mode. Default is 1.0 MBTUs. Identifies the current software version of the control box (Ver 0.2K).

0LN. This is the maximum allowable outlet temperature (40 to 240°F). If outdoor sensor is enabled. Default is Shutdown. Default is zero.Continued MENU LEVEL & OPTION CONFIGURATION MENU (Cont. Used to set the minimum allowable setpoint (40°F to Setpoint Hi Limit). Specifies the timeout value (seconds) before a Modbus fault is declared.APPENDIX A APPENDIX A . Reset Ratio is adjustable from 0. before going to the desired output. Default is 2 sec. Default is 60°F Used to set the maximum allowable setpoint (Setpoint Lo Limit to 240°F). Available settings range from 5 to 999 seconds. Must be set to Valve Position 0-10V for Benchmark 3. Default is 60°F. Specifies how long (2 to 600 sec. Allows outdoor sensor function to be enabled or disabled.BOILER MENU ITEM DESCRIPTIONS .2.) between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the boiler. Allows the Failsafe mode to be set to either Constant Setpoint or Shutdown. Any temperature above this setting will turn off the unit. Default is 200°F.) to keep the pump running after the unit turns off. The temperature must then drop 5° below this setting to allow the unit to run. Default is 1. Default is 100%. Specifies the amount of time to wait (0 to 120 sec. this menu item allows the system start temperature to be set from 30 to 100°F. Default is 0 sec.9.1 to 9. Sets the maximum allowable valve position for the unit (40% to 100%). Default is disabled. Default Hi Limit is 210°F.) to remain in the low fire position after ignition.) Reset Ratio Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode. DESCRIPTION Outdoor Sensor System Start Tmp Setpoint Lo Limit Setpoint Hi Limit Temp Hi Limit Max Valve Position Pump Delay Timer Aux Start On Dly Failsafe Mode Analog Output Lo Fire Timer Network Timeout A-3 . Specifies the amount of time (0 to 30 min.

the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH. the °F or °C LED will flash on and off. (Default is 2 for both Deadband High and Deadband Low) DESCRIPTION A-4 . Setting range is from 0 to 100. Setting range is 0 to 25. When the Outlet Temperature reaches Active Setpoint and remains there for a period of 15 seconds. In addition. The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint + Deadband High and Active Setpoint – Deadband Low. When the Outlet Temperature drifts out of the Deadband ZONE.) HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature.BOILER MENU ITEM DESCRIPTIONS . (Default is 30) Demand Offset This entry will reduce excessive ON/OFF cycling in AUTO mode. When this entry is set to zero. When operating at a Valve Position below this value. When this entry is a non-zero value. the unit will go into a DEADBAND MODE at which point no Fire Rate corrections will be attempted while the Outlet Temperature remains anywhere within the Deadband ZONE. the DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections. In which no Valve Position corrections will be attempted. Setting range is 0 to 25. the unit will not turn on again until Valve Position In reaches the Start Level value AND the Outlet Temperature goes below the Active Setpoint – Demand Offset. When the unit is in the DEADBAND MODE. (Default is 10) Deadband High Deadband Low Deadband High and Deadband Low settings create an “Outlet Temperature” Zone.APPENDIX A APPENDIX A .Continued MENU LEVEL & OPTION CONFIGURATION MENU (Cont. the unit will turn on again as soon as the Valve Position In reaches the Start Level value. There will not be a one minute delay when firing at the 29% Fire Rate level. the boiler will fire at the 29% Valve Position or below for a period of one minute.

Gain is adjustable from 0. If the error is equal to or greater than the proportional band setting. the fire rate will be 100%. If the actual error is less than the proportional band setting (1 to 120°F).0 to 20. This is the time that this action advances the output.0 min.00 to 1. Integral Gain Derivative Time Reset Defaults? A-5 . Allows Tuning Menu options to be reset to their Factory Default values. due to setpoint error.00 (Default is 0.APPENDIX A MENU LEVEL & OPTION TUNING MENU Prop Band DESCRIPTION Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature.) responds to the rate of change of the setpoint error. to add or subtract from the output each minute to move towards the setpoint. This value (0. This sets the fraction of the output.10). the fire rate will be less than 100%.

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The duration of the purge cycle counts up in seconds. Displayed during the purge cycle during startup. pm MM/DD/YY FLAME PROVEN DESCRIPTION Displayed if Demand Delay is active. Displayed if ON/OFF switch is set to OFF. Initially. the time and date are shown in place of flame strength. After 5 seconds has elapsed. Displayed when ON/OFF switch is in the ON position. Displayed during ignition trial of startup sequence. IGNITION TRIAL XX sec PURGING XX sec STANDBY WAIT WARMUP XX sec B-1 . STARTUP AND STATUS MESSAGES MESSAGE DEMAND DELAY XX sec DISABLED HH:MM pm. The display also shows the time (am or pm) and date that the unit was disabled. STATUS AND FAULT MESSAGES TABLE B-1. The duration of cycle counts up in seconds. Displayed after flame has been detected for a period of 2 seconds. Displayed for 2 minutes during the initial warm-up only. the flame strength is shown in %. The time and date are also displayed.APPENDIX B APPENDIX B . Prompts the operator to wait. but there is no demand for heat.STARTUP.

The Delayed Interlock is open. or air inlet is blocked. The temperature measured by the Feed Forward (FFWD) Sensor is out of range. The Ignition Position Limit switch on the Air/Fuel Valve closed during purge. The Flame signal was lost during run.APPENDIX B TABLE B-2. B-2 . A communication fault has occurred between the PMC board and Ignition board. The RS-485 network information is not present or is corrupted. The Heat Demand Relays on the Ignition board failed to activate when commanded. The Blower Proof Switch opened during run. The Low Water Cutoff board is indicating low water level. The Ignition Position Limit switch on the Air/Fuel Valve opened during ignition. The Flame signal was not seen during ignition or lost within 5 seconds after ignition. The High Gas Pressure Limit Switch is open. The High Water Temperature Limit Switch is open. The direct drive signal is not present or is out of range. The Low Gas Pressure Limit Switch is open. The Remote Interlock is open. FAULT MESSAGES FAULT MESSAGE AIRFLOW FAULT DURING PURGE AIRFLOW FAULT DURING IGN AIRFLOW FAULT DURING RUN DELAYED INTERLOCK OPEN DIRECT DRIVE SIGNAL FAULT FFWD TEMP SENSOR FAULT FLAME LOSS DURING IGN FLAME LOSS DURING RUN HEAT DEMAND FAILURE HIGH EXHAUST TEMPERATURE HIGH GAS PRESSURE HIGH WATER TEMPERATURE HIGH WATER TEMP SWITCH OPEN IGN BOARD COMM FAULT IGN SWTCH CLOSED DURING PURGE IGN SWTCH OPEN DURING IGNITION INTERLOCK OPEN LINE VOLTAGE OUT OF PHASE LOW GAS PRESSURE LOW WATER LEVEL NETWORK COMM FAULT FAULT DESCRIPTION The Blower Proof Switch opened during purge. The Line (Hot) and Neutral wires are reversed. The High Exhaust Temperature Limit Switch is closed. The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting. The Blower Proof Switch opened during ignition.

FAULT MESSAGES . A failure has been detected in one of the relays that control the SSOV. The SSOV switch opened during standby.Continued FAULT MESSAGE OUTDOOR TEMP SENSOR FAULT OUTLET TEMP SENSOR FAULT FAULT DESCRIPTION The temperature measured by the Outdoor Air Sensor is out of range. The Flame signal was seen for more than 60 seconds during standby. The SSOV switch opened during purge. The SSOV switch closed for more than 15 seconds during run. The Purge Position Limit Switch on the Air/Fuel Valve opened during purge.APPENDIX B TABLE B-2. The Stepper Motor failed to move the Air/Fuel Valve to the desired position. The SSOV switch closed or failed to open during ignition. PRG SWTCH CLOSED DURING IGNITION PRG SWTCH OPEN DURING PURGE REMOTE SETPT SIGNAL FAULT RESIDUAL FLAME SSOV SWITCH OPEN SSOV FAULT DURING PURGE SSOV FAULT DURING IGN SSOV FAULT DURING RUN SSOV RELAY FAILURE STEPPER MOTOR FAILURE B-3 . The temperature measured by the Outlet Sensor is out of range: • OUTLET TEMPERATURE display = SHt Indicates sensor is shorted • OUTLET TEMPERATURE display = OPn indicates sensor is open-circuited The Purge Position Limit Switch on the Air/Fuel Valve closed during ignition. The Remote Setpoint signal is not present or is out of range.

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0 1418.58 *Voltage at AUX & Common terminals in the I/O Box C-1 .9 978.93 1.0 797.3 1137.96 1.2 1445.9 956.5 816.6 894.7 915.50 2.20 2.0 1044.25 2.34 2.41 2.15 2.4 1337.43 2.17 2.4 854.07 2.39 2.47 2.0 1022.5 1234.2 1209.9 1185.54 2.7 1260.32 2.12 2.0 1113.45 2.10 2.1 935.99 2.7 VOLTS* 1.56 2.APPENDIX C TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART (BALCO) TEMP (°F) -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 RES (OHMS) 779.3 1000.30 2.4 1067.6 1311.02 2.0 1090.7 1364.0 1160.8 874.05 2.27 2.52 2.0 1285.3 835.36 2.23 2.2 1391.

.

4 50 57 64 71 78 85 92 99 106 113 120 127 134 141 148 1.2 50 56 62 68 74 80 86 92 98 104 110 116 122 128 134 1.4 60 72 84 96 108 120 132 144 156 168 180 192 204 216 D-1 .6 50 58 66 74 82 90 98 106 114 122 130 138 146 154 162 1.8 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 124 1. .8 60 69 78 87 96 105 114 123 132 141 150 159 168 177 186 195 204 2.0 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 2.6 50 53 56 59 62 65 68 71 74 77 80 83 86 89 92 0.APPENDIX D APPENDIX D.INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1.2 60 71 82 93 104 115 126 137 148 159 170 181 192 203 214 2.8 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 2.2 60 66 72 78 84 90 96 102 108 114 120 126 132 138 144 150 156 1.2 50 60 72 83 94 105 116 127 138 149 160 171 182 193 204 2.0 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 2.4 50 62 74 86 98 110 122 134 146 158 170 182 194 206 218 Table D-2.0 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 1.8 50 54 58 62 66 70 74 78 82 86 90 94 98 102 106 1.6 60 63 66 69 72 75 78 81 84 87 90 93 96 99 102 105 108 0.0 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 1. Header Temperature for a Building Reference Temperatrure of 60F RESET RATIO Air Temp 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F -20F 0. 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 0.4 60 67 74 81 88 95 102 109 116 123 130 137 144 151 158 165 172 1.6 60 68 76 84 92 100 108 116 124 132 140 148 156 164 172 180 188 1.

4 65 72 79 86 93 100 107 114 121 128 135 142 149 156 163 170 177 201 1.6 65 68 71 74 77 80 83 86 89 92 95 98 101 104 107 110 113 116 0.6 70 73 76 79 82 85 88 91 94 97 100 103 106 109 112 115 118 121 124 0.0 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 2.2 65 76 87 98 109 120 131 142 153 164 175 186 197 208 219 2. 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 0.0 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 1.8 70 74 78 82 86 90 94 98 102 106 110 114 118 122 126 130 134 138 142 1.0 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 1.6 70 78 86 94 102 110 118 126 134 142 150 158 166 174 182 190 198 206 214 1.APPENDIX D Table D-3.6 65 73 81 89 97 105 113 121 129 137 145 153 161 169 177 185 193 218 1.4 70 77 84 91 98 105 112 119 126 133 140 147 154 161 168 175 182 189 196 1.8 65 69 73 77 81 85 89 93 97 101 105 109 113 117 121 125 129 133 1. Header Temperature for a Building Reference Temperature of 70F RESET RATIO Air Temp 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F -20F 0.2 70 81 92 103 114 125 136 147 158 169 180 191 202 213 2.2 65 71 77 83 89 95 101 107 113 119 125 131 137 143 149 155 161 167 1.8 65 74 83 92 101 110 119 128 137 146 155 164 173 182 191 200 209 2.0 65 75 85 95 105 115 125 135 145 155 165 175 185 195 205 215 2.2 70 76 82 88 94 100 106 112 118 124 130 136 142 148 154 160 166 172 178 1.4 70 82 94 106 118 130 142 154 166 178 190 202 214 D-2 .4 65 77 89 101 113 125 137 149 161 173 185 197 209 Table D-4.8 70 79 88 97 106 115 124 133 142 151 160 169 178 187 196 205 214 2.

APPENDIX D Table D-5.4 75 82 89 96 103 110 117 124 131 138 145 152 159 166 173 180 187 194 201 1.4 80 92 104 116 128 140 152 164 176 188 200 212 D-3 . 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. Header Temperature for a Building Reference Temperature of 80F RESET RATIO Air Temp 80F 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F 0.6 75 78 81 84 87 90 93 96 99 102 105 108 111 114 117 120 123 126 129 0.8 80 84 88 92 96 100 104 108 112 116 120 124 128 132 136 140 144 148 152 1.0 75 85 95 105 115 125 135 145 155 165 175 185 195 205 215 2.2 75 81 87 93 99 105 111 117 123 129 135 141 147 153 159 165 171 177 183 1.4 80 87 94 101 108 115 122 129 136 143 150 157 164 171 178 185 192 199 206 1.6 80 88 96 104 112 120 128 136 144 152 160 168 176 184 192 200 208 216 1.6 75 83 91 99 107 115 123 131 139 147 155 163 171 179 187 195 203 211 219 1.6 80 83 86 89 92 95 98 101 104 107 110 113 116 119 122 125 128 131 134 0.8 75 79 83 87 91 95 99 103 107 111 115 119 123 127 131 135 139 143 147 1.4 75 87 99 111 123 135 17 159 171 183 195 207 219 Table D-6.0 80 90 100 110 120 130 140 150 160 170 180 190 200 210 2.0 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 1.2 80 86 92 98 104 110 116 122 128 134 140 146 152 158 164 170 176 182 188 1.0 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 1.2 80 91 102 113 124 135 146 157 168 179 190 201 212 2.8 80 89 98 107 116 125 134 143 152 161 170 174 188 197 206 215 2.8 75 84 93 102 111 120 129 138 147 156 165 174 183 192 201 210 219 2.2 75 86 97 108 119 130 141 152 163 174 185 196 207 218 2.

6 90 98 106 114 122 130 138 146 154 162 170 178 186 194 202 210 218 1.4 90 102 114 126 138 150 162 174 186 198 210 D-4 .8 90 99 108 117 126 135 144 153 162 171 180 189 198 207 216 2.2 90 101 112 123 134 145 156 167 178 189 200 2.2 90 96 102 108 114 120 126 132 138 144 150 156 162 168 174 180 186 192 198 1.0 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 1.APPENDIX D Table D-7.0 90 100 110 120 130 140 150 160 170 180 190 200 210 2. 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 0.8 90 94 98 102 106 110 114 118 122 126 130 134 138 142 146 150 154 158 162 1.4 90 97 104 111 118 125 132 139 146 153 160 167 174 181 188 195 202 209 216 1.6 90 93 96 99 102 105 108 111 114 117 120 123 126 129 132 135 138 141 144 0.

Direct Drive or Combination) Bldg Ref Temp (If Boiler Mode = Outdoor Reset) Reset Ratio (If Boiler Mode = Outdoor Reset) Outdoor Sensor System Start Tmp (If Outdoor Sensor = Enabled) Setpt Lo Limit Setpt Hi Limit Temp Hi Limit Max Fire Rate Pump Delay Timer Aux Start On Dly Failsafe Mode Analog Output 130°F Boiler 1.5 MBTU Constant Setpoint 4 – 20 mA / 1-5V 70°F 1.2 Disabled 60°F 60°F 200°F 215°F 100% 0 min 0 sec Shutdown Fire Rate Out 0-10V CAUTION: DO NOT Change Lo Fire Timer Setpt Limit Band (If Setpt Limiting = Enabled) 2 sec 5°F E-1 .APPENDIX E BOILER DEFAULT SETTINGS MENU & OPTION Setup Menu Password Language Unit of Temp Comm Address Baud Rate 0 English Fahrenheit 0 9600 FACTORY DEFAULT Configuration Menu Internal Setpt Unit Type Unit Size Boiler Mode Remote Signal (If Mode = Remote Setpoint.

APPENDIX E BOILER DEFAULT SETTINGS .Continued MENU & OPTION Configuration Menu --Continued Network Timeout Hi DB Setpt En Demand Offset Deadband High Deadband Low 30 seconds 30 10 2 2 FACTORY DEFAULT Tuning Menu Prop Band Integral Gain Derivative Time 70°F 1.0 min E-2 .00 0.

2) N/A 36 11/16 (93. (PSIG) 240 MAXIMUM TEMP. "A" DIM. GAUGE CONTROL PANEL DISPLAY 69 5/8 (176.1) 12 1/16 (30./TEMP.4) DOOR SWING 4"-150# FLG'D HOT WATER OUTLET CONN.6) 15 7/16 (39.X.1) 15 (38.7) THIS AREA TO BE ACCESSIBLE FOR MAINTENANCE. CAPACITY MBH MAX. DWN.4) 64 (162.X.6) "A" "C" "B" 2" NPT PROPANE GAS INLET CONN.0) 4"-150# FLG'D COLD WATER INLET CONN. GAS 28 15/16 ONLY (73.2) DUAL-FUEL WITH IRI GAS TRAIN 25 7/16 (64. LOW NOx BTU GAS FIRED BOILER DIMENSIONAL DRAWINGS REV.5) 42 1/8 (107.) SECTION VIII STAMP U (SECONDARY H. 1-1/2" NPT FOR DUAL-FUEL DRAIN CONN.BY CZ SCALE CHKD.6) 13. RELIEF VALVE 18 (45.0) 1" NPT GAS VENT CONN.7) PRESS. NJ 07647 BENCHMARK 3 MIL. OPTION ONLY CONDENSATE PORT 4" CONCRETE PAD . RELIEF VA. "B" DIM.SET UNIT FLUSH AT REAR AERCO NORTHVALE.3) 23 3/16 (58.0) 3000 MIN. APPENDIX F NOTES: 1) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS).0 LN MODEL DIM.8) 23 5/8 (60. (SEE NOTE 3) 2 5/8 (6.DATE DATE072606 A SIZE APPD. CONDENSATE PORT BMK3. 3) FIELD PIPING TO THE BOILER MUST ENSURE THAT THE HOT WATER OUTLET CONNECTION FLEXIBLE PIPING (LOCATED INSIDE THE BOILER) IS LEVEL OR SLOPING UP AS IT EXITS THE BOILER. (PSIG) 160 210 ASME B & PV CODE: SECTION IV STAMP H (PRIMARY H.7) 28 (71.4) 16 3/16 (41.9) 54 5/16 (137. AP-A-811 E F-1 . TRIDICATOR & CONDENSATE TRAP ARE INCLUDED SEPARATELY IN SHIPMENT.1) 38 (96. 33 (84.9) 8" AIR INLET 6 7/8 (17. "C" 25 5/16 (64.) 23 (58. (°F) TEST PRESS. NAT. REV.HEAT EXCHANGERS & COMBUSTION CHAMBER DESIGN STANDARDS LIFTING LUGS 7 15/16 (20.6) PRESS. FOR "IRI" GAS TRAIN OPTION" ONLY N/A FOR IRI GAS TRAIN OPTION 5 7/8 (14. 2) RELIEF VALVE.5 (34.3) 2" NPT NATURAL GAS INLET CONN. 178 14 5/16 (36.3) 5 1/4 (13.4) DUAL-FUEL WITH FM GAS TRAIN 25 7/16 (64.FT.4) 8" EXHAUST OUTLET 7 7/16 (18.0) 12 3/4 (32.9) 79 (201. WORKING PRESS.1) 3/4" ELECTRICAL CONDUIT CONNECTION HT'G SURFACE SQ.6) 78 (198.

NORTHVALE.BY SCALE APPD. INC.5) 64 (162.8) INTERNATIONAL.6) 36 7/8 (93.7) 1 1/2 (3. LOW NOx BTU GAS FIRED BOILER ANCHOR BOLT LOCATIONS DATE 061506 DATE 061506 NOTES: 1) DOTTED LINES REPRESENT BENCHMARK SHEET METAL 2) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 3) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS) REV.9) 62 (157.91) THRU HOLES 4 PL APPENDIX F 26 FRONT (66.0) 23 (58. MC BENCHMARK 3 MIL. NJ 07647 AERCO GS DWN. SD-A-680 A .F-2 ANCHOR HOLE 4 X Ø.4) 28 REAR (71.1) 9 (22.75 (Ø1.

INC. A 57" FRONT CLEARANCE WILL BE NEEDED TO ALLOW THE REMOVAL OF EXHAUST CONNECTING MANIFOLD.SIDE VIEW TOP VIEW 78" 18" 24" 56" 101" 79" 43" (SEE NOTE) 24" 24" REAR FRONT 4" HIGH PAD INSTALLATION CLEARANCES 1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING 2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS: LEFT AND RIGHT SIDES: 24'' FRONT: 24" REAR: 43" (SEE NOTE) CEILING HEIGHT: 101" 3) THE INNER SIDE PANELS MUST BE REMOVED FROM BOTH UNITS FOR ZERO SIDE CLEARANCE INSTALLATIONS 4) THE ZERO SIDE CLEARANCE OPTION CAN ONLY BE EMPLOYED IN TWO UNIT SETS INTERNATIONAL. MC BENCHMARK 3 MIL. WHEN USING A REAR CLEARANCE OF LESS THAN 43".BY SCALE APPD. NORTHVALE. AND LOCAL CODE REQUIREMENTS. ARRANGEMENT. APPENDIX F REV. SD-A-683 C F-3 . NJ 07647 AERCO GS DWN. BTU LOW NOx GAS FIRED BOILER ZERO SIDE CLEARANCE INSTALLATION DATE 061506 DATE NOTE: REAR CLEARANCE MAY BE REDUCED TO 24" DEPENDENT UPON PIPING AND VENTING COMPONENT SELECTION. HOWEVER.

BY SCALE APPD. HOWEVER. NOTE: REAR CLEARANCE MAY BE REDUCED TO 24" DEPENDENT UPON PIPING AND VENTING COMPONENT SELECTION. BENCHMARK 3 MIL. NJ 07647 INTERNATIONAL. INC. MC NORTHVALE. A 57" FRONT CLEARANCE WILL BE NEEDED TO ALLOW THE REMOVAL OF EXHAUST CONNECTING MANIFOLD. AND LOCAL CODE REQUIREMENTS. WHEN USING A REAR CLEARANCE OF LESS THAN 43".F-4 TOP VIEW 18" 24" 101" 79" (SEE NOTE) 28" 43" 24" 24" REAR FRONT 4" HIGH PAD INSTALLATION CLEARANCES 1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING 2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS: LEFT AND RIGHT SIDES: 24'' FRONT: 24" REAR: 43" (SEE NOTE) CEILING HEIGHT: 101" APPENDIX F SIDE VIEW 78" AERCO GS DWN. B . BTU LOW NOx GAS FIRED BOILER INSTALLATION CLEARANCES DATE 061506 DATE SD-A-686 REV. ARRANGEMENT.

HIGH GAS PRESS SWITCH P/N: 61002-3 TEST COCK PRESSURE SNUBBER P/N: 99017 1/8" NPT PLUG (INSTALL MANOMETER HERE) TO AIR/FUEL VALVE ASSEMBLY FULL PORT BALL VALVE 2" NPT P/N: 123540 LOW GAS PRESS SWITCH P/N: 61002-1 2" SAFETY SHUT-OFF VALVE BODY P/N: 124136 SAFETY SHUT-OFF VALVE ACTUATOR P/N: 64048 (INCLUDES RESISTOR) AERCO FM GAS TRAIN ASSY. NJ 07647 2" SCH.A .0 LOW NOx FM GAS TRAIN DRWN BY:SJD DATE:3/09/09 *NOT TO SCALE* APPENDIX F AP . NORTHVALE. P/N: 22026-1 INTERNATIONAL. 40 PIPE BENCHMARK 3. INC.844 B REV F-5 .

BENCHMARK3. APPD.40 PIPE VENT TO ATMOSPHERE PER ANSI Z223.BY CZ DATE 072806 SCALE NTS SIZE CHKD. NJ 07647 INTERNATIONAL.1 (NFPA54) AERCO NORTHVALE. INC.40 PIPE 1"-SCH.F-6 HIGH GAS PRESS. AP-A-803 REV. SWITCH P/N: 61002-1 1" NORMALLY OPEN VENT VALVE P/N 123769 ENTIRE ASSEMBLY PART NUMBER 22026-2 BOILER BOUNDARY APPENDIX F TO AIR-FUEL VALVE ASS'Y FULL PORT BALL VALVE 2" NPT P/N: 123540 2" DOUBLE BODY CONNECTING FLANGE P/N: 124156 2" SAFETY SHUT-OFF DOUBLE-BODY GAS VALVE P/N 124142 2"-SCH.0 LOW NOx IRI GAS TRAIN DWN. SWITCH P/N: 61002-3 1/8" NPT PLUG (INSTALL MANOMETER HERE) TEST COCK SAFETY SHUT-OFF VALVE ACTUATOR w/ GAS PRESSURE ADJUSTMENT P/N 64048 SAFETY SHUT-OFF VALVE ACTUATOR P/N 69038 LOW GAS PRESS. E .

15 5 11 13
19 18 1 1 4 1 1 1 2 1 6 1 1 2 1 5 4 3 2 1 ITEM NO. 1 1 1 2 1 QTY 54016 54015 55027 81019 122377 9-75 59104 24227 66006 46013 81030 43016 PART NUMBER 81048 9-25 123534 123886 58023 81129 17 16 15 14 13 12 11 10 9 8 7 6 1 44084 PLUG, GAS INJECTOR GASKET, PLUG IGNITOR-INJECTOR WASHER, FLAT #10 PLUG, HEX 1/8 NPT PLUG, 1/2" NPT GASKET, FLAME ROD LOW NOX SCREW, MACH #10-32 X .50 LG SCREW, MACH #8-32 X 3/8 LG
BOLT, HEX HD SERRATED 1/4-20 X 1.75 LG

4

7 1 17 16 7 18 19 12

14

GASKET, BURNER HOUSING SCREW, MACH #10-32 X 3/8 LG PLUG, 1" NPT OBSERVATION PORT STAGED IGNITION ASSY, BMK LOW NOX FLAME ROD BURNER, BMK 3.0 LOW NOX GASKET, BURNER 9.65 DIA LOW NOX HOUSING, BURNER LOW NOX DESCRIPTION

10

9

6

2

3

AERCO

NORTHVALE, NJ 07647 BENCHMARK 3.0 LOW NOx BURNER ACCESSORIES
REV. DWN.BY CZ DATE 072606 SCALE SIZE CHKD. APPD. REV. DATE

INTERNATIONAL, INC.

2

PL-A-151

D

APPENDIX F

F-7

APPENDIX F

EXHAUST MANIFOLD ITEM PART NO. 1 2 3 4 39033 49102 39036 81098 QTY 1 3 1 1 DESCRIPTION EXHAUST MANIFOLD EXHAUST MANIFOLD SEAL CONNECTING MANIFOLD EXHAUST MANIFOLD ORIFICE GASKET 27 28 29 30 31 32 33 34 35 36

HOSES,GASKETS, & INSULATION ITEM PART NO. 88003 59041 80024-8 80024-12 80021-12 80022 80023 4-58 62005 59030 QTY 1 1 1 1 1 1 2 3 1 1 DESCRIPTION O-RING #2-339 HOSE ASSEMBLY, 4" INSULATION 4" FLEX PIPE 8 LONG INSULATION 4" FLEX PIPE 12" LONG INSULATION 4" PIPE 12" LONG CONNECTING INSULATION TOP MANIFOLD INSULATION 4" FLANGE GASKET CORD GRIP HOSE ASSY, 4" (FLEXIBLE)

ITEM

GAS TRAIN ASSEMBLY PART NO. QTY DESCRIPTION 22026-1 STD FM GAS TRAIN ASSEMBLY IRI GAS TRAIN ASSEMBLY DUAL FUEL FM GAS TRAIN DUAL FUEL IRI GAS TRAIN

(3)

5

22026-2 22040-1 22040-2

1

BURNER & AIR/FUEL VALVE ITEM PART NO. 6 7 46013 24010 24010-1 24227 81030 81019 QTY 1 1 DESCRIPTION BURNER A/F VALVE ASSEMBLY DUEL FUEL A/F VALVE ASSY. BMK3.0LN STAGED IGNITION ASSY. BURNER GASKET BURNER HOUSING GASKET

8 9 10

1 2 1

HEAT EXCHANGER ITEM PART NO. 11 12 13 14 15 80018 80019 80020 28030 28029 QTY 1 1 1 1 1 DESCRIPTION PRIMARY HEAT EXCH. UPPER INSULATION PRIMARY HEAT EXCH. LOWER INSULATION SECONDARY HEAT EXCH. INSULATION PRIMARY HEAT EXCH. SECONDARY HEAT EXCH.

BLOWER ITEM PART NO. 16 17 18 19 20 21 22 23 24 25 26 24045 123815 123681 33028 124245 81057 96006 96009 96008 123990 123583 QTY 1 1 1 1 4 1 1 1 1 1 1 DESCRIPTION BLOWER ASSEMBLY IRIS AIR DAMPER 8"x6" REDUCING COUPLING BLOWER BRACKET 5/16 DAMPENER BLOWER GASKET 6" 90 DEG ELBOW 6" DIAM. x 4" LG DUCT W/PORT 6" DIAM. x 4" LG DUCT REDUCER OFFSET COVER CLAMP HOSE SAE #96

AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647
BENCHMARK 3.0 LOW NOx BOILER PARTS LIST
DRAWN BY DATE 2/18/09 SJD

PL - A - 150
(SHEET 1 OF 7)

H

F-8

APPENDIX F

CONTROLS ITEM PART NO. 37 38 39 40 41 42 43 44 45 46 47 (4) (4) (4) (1) (4) 48 49 50 51 52 53 55 56 57 65091 123966 123552 60011-1 61002-5 161560 181197 GP-122464 33030 64068 93230 124310 124380 58009 63060 79002 61024 GP- 122569 63016 124320 QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION DRIVE REACTOR OVER TEMP SWITCH AUTO OVER TEMP SWITCH MANUAL BLOWER PROOF SWITCH BLOCKED INLET SWITCH I /O WIRING BOX C-MORE CONTROL BOX IGNITION TRANSFORMER VFD MOUNTING BRACKET VFD ORIFICE SNUBBER 460V TRANSFORMER 500 VAC, 4 AMP FUSE 460V Terminal Cover Kit DRIVE REACTOR TO VFD WIRING HARNESS 460V TRANSFORMER LABEL AIR TEMP SENSOR IGNITION CABLE ASSY. BMK3.0LN SHELL HARNESS BLOWER HARNESS ITEM 80 81 82 83 84 85 86 87 88 58 89 (1)(5) 73 (1)(5) 74 (5)(6) 75 (5) 76 (5) (5) 77 78

OTHER DUAL FUEL COMPONENTS ITEM PART NO. 72031 72032 63032 65024 33036 72030 63034 QTY 1 1 1 1 1 1 1 DESCRIPTION "PROPANE" LABEL "NAT. GAS" LABEL DOUBLE GAS TRAIN WIRING HARNESS FUEL SELECTOR SWITCH FUEL SELECTOR SWITCH MOUNTINGBRACKET FUEL SELECTOR SWITCH LABEL DUAL FUEL WIRING HARNESS

(5) 79

SHEET METAL / PANEL ASSEMBLY PART NO 37004 37003 49028 201233 201113 201120 GP-122620 30022 37002 74004 QTY 1 1 2 1 1 1 4 2 4 1 OTHER PARTS DESCRIPTION LEFT REAR PANEL RIGHT REAR PANEL TOP RAIL MOUNTING PANEL FRONT PANEL ENCLOSURE FRONT DOOR ASSY. HANDLE TOP PANEL SIDE PANEL BMK3.0LN LOGO

59 (1) (6) 60 61 62 63 (7) 64

64016 64017 63015 122843 123449 161521 61002-1 61002-3

1 1 1 1 1 1

208V POWER WIRING BOX 460V POWER WIRING BOX BMK3.0LN GAS TRAIN WIRING HARNESS LOW WATER CUT-OFF SHELL TEMP. SENSOR
THERMOWELL, DUAL AQUASTAT BULB

ITEM 90 (1) 91 92

PART NO 99017 93283 80066

QTY 1 1 1

DESCRIPTION GAS PRESSURE SNUBBER PART OF GAS TRAIN CONDENSATE TRAP ADAPTER ASSY TOP MANIFOLD INSULATION(WITH FLAP)

LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE SWITCH (NON DUAL FUEL) NOTES: (1) (2) (3) (4) (5) (6) (7) (8) NOT SHOWN IN DRAWING -5 (30 AND 50 PSI RELIEF VALVE SETTING) -6 (60,75,100 & 125 PSI RELIEF VALVE SETTING) -7 (150 PSI RELIEF VALVE SETTING) FOR PICTORAL PURPOSES ONLY, FM GAS TRAIN (NON DUAL FUEL) IS SHOWN FOR 460 V OPTION ONLY ONLY NEEDED ON DUAL FUEL PART OF GAS TRAIN ASSY. TWO (2) REQUIRED FOR DUAL FUEL BMK3.0 LN SEE DRAWING AP-A-826 FOR DUAL FUEL DETAILS

(6) (8)

65

61002-15 61002-16

1

DUAL FUEL HGPS - NAT. GAS DUAL FUEL HGPS - PROPANE

OTHER ACCESORIES / PARTS ITEM PART NO. (1)(2) 66 67 (1)(7) 68 (1) 69 70 71 (1) 72 69087 123540 91030 12820-11 59043 24060 QTY 1 1 1 1 1 1 DESCRIPTION PRESS./TEMP. GAUGE PRESSURE RELIEF VALVE EXT. MANUAL SHUT-OFF VALVE 1" DRAIN HOSE, 60" LG 1-1/2" NPT BALL VALVE CONDENSATE FLOAT COND. TRAP ASSEMBLY

SEE SD-A-700 1

AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647
BENCHMARK 3.0 LOW NOx BOILER PARTS LIST
DRAWN BY DATE 2/18/09 SJD

PL - A - 150
(SHEET 2 OF 7)

H
F-9

APPENDIX F A 1 2 11 13 15 14 12 2 3 18 24 17 23 10 39 9 55 40 BLOWER PROOF SWITCH 25 53 61 92 2 6 8 41 22 26 38 44 47 16 DETAIL A SCALE 1 : 10 5 AERCO INTERNATIONAL. NORTHVALE.150 (SHEET 3 OF 7) H F-10 .A . NJ 07647 BENCHMARK 3. INC.0 LOW NOx BOILER PARTS LIST DRAWN BY DATE 2/18/09 SJD PL .

NORTHVALE.A . NJ 07647 BENCHMARK 3. INC.0 LOW NOx BOILER PARTS LIST DRAWN BY DATE 2/18/09 SJD PL .150 (SHEET 4 OF 7) H F-11 .APPENDIX F 31 67 34 30 28 20 19 B B 71 SECTION B-B SCALE 1 : 18 4 36 70 34 32 29 33 34 21 27 7 35 63 62 AERCO INTERNATIONAL.

INC.150 (SHEET 5 OF 7) H F-12 .A . NORTHVALE.0 LOW NOx BOILER PARTS LIST DRAWN BY DATE 2/18/09 SJD PL .APPENDIX F 37 59 46 DETAIL B: TERMINAL COVER ARE HIDEN 43 B 45 C 42 52 SEE DETAIL C 49 48 50 DETAIL C: FUEL SELECTOR SWITCH (DUAL FUEL ONLY) 78 76 77 79 65 90 IRI GAS TRAIN (NON DUAL FUEL) 56 64 57 AERCO INTERNATIONAL. NJ 07647 BENCHMARK 3.

APPENDIX F 82 83 80 81 AERCO INTERNATIONAL. NORTHVALE. NJ 07647 BENCHMARK 3. INC.0 LOW NOx BOILER PARTS LIST 84 DRAWN BY DATE 2/18/09 SJD PL .A .150 (SHEET 6 OF 7) H F-13 .

APPENDIX F F-14 .

LEGEND
CHECK VALVE (TYP.) SYSTEM PUMP RELIEF VALVE (TYP.)
P&T

HEATING SYSTEM SUPPLY AIR SEPARATOR AT MAXIMUM BTU/HR INPUT, MAINTAIN MINIMUM NATURAL GAS PRESSURE AT 3.5" W.C. (FM GAS TRAIN)/4.0" W.C. (IRI GAS TRAIN) MAX GAS PRESSURE = 2.0 PSIG. (SEE NOTE 6)

AUTOMATIC AIR VENT Y STRAINER ISOLATION VALVE UNION BALANCING VALVE PRESSURE & TEMPERATURE GAUGE

WATER

SUPPLY

PRESSURE REDUCING FILL VALVE
P&T

Diagram 1
(SEE NOTE 8) MAINTAIN A REGULATED 3.5" W.C. (NAT. GAS, FM/ 4.0" W.C. (NAT. GAS, IRI/GAS PRESSURE AT MAX BTU/HR INPUT

LINE SIZE BYPASS
(TO BOILER)

BACKFLOW PREVENTER

GAS SUPPLY

DIAPHRAGM TYPE EXPANSION TANK 1-1/2" NPT DRAIN CONN. HEATING SYSTEM RETURN GAS SUPPLY * CONDENSATE DRAIN TRAP * 2" MANUAL SHUTOFF VALVE

* 2" MANUAL SHUTOFF VALVE DRIP TRAP

DRIP TRAP

NOTES: 1) FOR ACTUAL SIZES AND LOCATIONS OF PIPING AND OTHER CONNECTIONS TO THE BOILER, SEE DIMENSIONAL DRAWING (AP-A-802). 2) SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN FREELY, BY GRAVITY, TO A CONVENIENT FLOOR DRAIN. RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A

(SEE NOTE 7)

HEIGHT 18'' ABOVE FLOOR. 3) ALL (*) ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT FROM FACTORY.

4) LOCATE WATER INLET AND OUTLET FITTINGS (i.e. UNIONS, ELBOWS, ETC.) A MINIMUM OF 6'' FROM BOILER

FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PANELS AND COVERS. ALL PIPING AND
INTERNATIONAL, INC.
NORTHVALE, NJ 07647

ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE

BE 6'' AWAY FROM SIDE PANELS.

5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED. 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.0 PSIG, A LOCK-UP STYLE REGULATOR MUST BE INSTALLED DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG.

AERCO

7) EACH CONDENSATE PORT CAN BE PIPED INDIVIDUALLY TO MAIN DRAIN.

BENCHMARK 3 MIL. BTU LOW NOx GAS FIRED BOILER SINGLE UNIT INSTALLATION
DATE 061506 DATE

8) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE, SEE DIAGRAM 1

REV.
DWN.BY SD SCALE MC APPD.

SD-A-681

C

APPENDIX G

G-1

G-2
CHECK VALVE (TYP.) SYSTEM PUMP AUTOMATIC AIR VENT RELIEF VALVE (TYP.)

HEATING SYSTEM SUPPLY

LEGEND

WATER

AIR SEPARATOR

SUPPLY
P&T

APPENDIX G

AT MAXIMUM BTU/HR INPUT, MAINTAIN MINIMUM NATURAL GAS PRESSURE AT 3.5" W.C. (FM GAS TRAIN)/4.0" W.C. (IRI GAS TRAIN) MAX GAS PRESSURE = 2.0 PSIG. (SEE NOTE 6)
Y STRAINER ISOLATION VALVE UNION BALANCING VALVE PRESSURE & TEMPERATURE GAUGE

PRESSURE REDUCING FILL VALVE
P&T

LINE SIZE BYPASS

BACKFLOW PREVENTER
P&T

Diagram 1
DIAPHRAGM TYPE EXPANSION TANK

(SEE NOTE 8)

MAINTAIN A REGULATED 4" W.C. GAS PRESSURE AT MAX BTU/HR INPUT

(TO BOILER) GAS SUPPLY

1-1/2" NPT DRAIN CONN. * 2" MANUAL SHUTOFF VALVE

(SEE NOTE 7)
DRIP TRAP * CONDENSATE DRAIN TRAP

* 2" MANUAL SHUTOFF VALVE DRIP TRAP

HEATING SYSTEM RETURN

GAS SUPPLY

NOTES:

1) FOR ACTUAL SIZES AND LOCATIONS OF PIPING AND OTHER CONNECTIONS TO THE BOILER, SEE DIMENSIONAL DRAWING (AP-A-802). 2) SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN FREELY, BY GRAVITY, TO A CONVENIENT FLOOR DRAIN. RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A

HEIGHT 18'' ABOVE FLOOR. 3) ALL (*) ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT FROM FACTORY.

4) LOCATE WATER INLET AND OUTLET FITTINGS (i.e. UNIONS, ELBOWS, ETC.) A MINIMUM OF 6'' FROM BOILER

FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PANELS AND COVERS. ALL PIPING AND ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE
INTERNATIONAL, INC.
NORTHVALE, NJ 07647

BE 6'' AWAY FROM SIDE PANELS.

AERCO
SD DWN.BY SCALE APPD. MC

5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED. 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.0 PSIG, A LOCK-UP STYLE REGULATOR MUST BE INSTALLED DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG. 7) EACH CONDENSATE PORT CAN BE PIPED INDIVIDUALLY TO MAIN DRAIN.

BENCHMARK 3 MIL. BTU LOW NOx GAS FIRED BOILER MULTIPLE UNIT INSTALLATION
DATE 061506 DATE

REV.

8) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1

SD-A-682

C

APPENDIX G

G-3

0" W. INSTALLATION WITH ZERO SIDE CLEARANCE DATE 072606 DATE REV. ALL PIPING AND ELECTRIC CONNECTIONS (SERVICE SWITCHES. A LOCK-UP STYLE REGULATOR MUST BE INSTALLED DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.e. RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A HEIGHT 18'' ABOVE FLOOR. TO A CONVENIENT FLOOR DRAIN.C. CONDUIT BOXES) SHOULD LIKEWISE BE 6'' AWAY FROM SIDE PANELS. GAS PRESSURE AT MAX BTU/HR INPUT 1-1/2" NPT DRAIN CONN. BTU LOW NOx GAS FIRED BOILER MULT.G-4 CHECK VALVE (TYP. AERCO SD DWN. 4) LOCATE WATER INLET AND OUTLET FITTINGS (i. NJ 07647 FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PANELS AND COVERS. (FM GAS TRAIN)/4.C. 7) EACH CONDENSATE PORT CAN BE PIPED INDIVIDUALLY TO MAIN DRAIN. REGARDLESS OF SUPPLY PRESSURE.0 PSIG. SEE DIMENSIONAL DRAWING (AP-A-802).) A MINIMUM OF 6'' FROM BOILER INTERNATIONAL. 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2. 3) ALL (*) ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT FROM FACTORY.0 PSIG.) LEGEND WATER APPENDIX G SUPPLY Y STRAINER ISOLATION VALVE UNION BALANCING VALVE PRESSURE & TEMPERATURE GAUGE PRESSURE REDUCING FILL VALVE P&T AT MAXIMUM BTU/HR INPUT. * CONDENSATE DRAIN TRAP (TO BOILER) GAS SUPPLY (SEE NOTE 7) DRIP TRAP * 2" MANUAL SHUTOFF VALVE * 2" MANUAL SHUTOFF VALVE DRIP TRAP HEATING SYSTEM RETURN GAS SUPPLY NOTES: 1) FOR ACTUAL SIZES AND LOCATIONS OF PIPING AND OTHER CONNECTIONS TO THE BOILER. NORTHVALE. UNIONS. 5) THIS IS A TYPICAL INSTALLATION DRAWING.0 PSIG. MAINTAIN MINIMUM NATURAL GAS PRESSURE AT 3. ELBOWS.C. (IRI GAS TRAIN) MAX GAS PRESSURE = 2.BY SCALE APPD. 2) SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN FREELY. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED.) SYSTEM PUMP AIR SEPARATOR P&T HEATING SYSTEM SUPPLY AUTOMATIC AIR VENT RELIEF VALVE (TYP. SEE DIAGRAM 1 SD-A-691 C .5" W. BENCHMARK 3 MIL. (SEE NOTE 6) P&T LINE SIZE BYPASS BACKFLOW PREVENTER DIAPHRAGM TYPE EXPANSION TANK P&T Diagram 1 P&T (SEE NOTE 8) MAINTAIN A REGULATED 4" W. 8) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS. INC. ETC. BY GRAVITY.

APPENDIX G G-5 .

.

SENSOR FLAME ROD 352 PROOF OF CLOSURE SWITCH 1 WHT GRN LOW GAS PRESS. 1 OF 2) H-1 . 3 PHASE REF: 68007 REV. BLU 321 BLOCKED AIR INLET SW. SW.0 LN 208 VAC. I (SHT. IGNITOR 153 151 SAFETY SHUTOFF VALVE 351 149 148 NC C 1K H N SHELL TEMP. BMK 3. YEL BLK RED 2 3 A 5K 53 B C 10K HIGH GAS PRESS. 141 WATER LEVEL PROBE GND AIR TEMP. SW. SENSOR IGNITION POSITION SWITCH PURGE POSITION SWITCH 142 STEPPING MOTOR G 154 147 146 150 145 AIR/FUEL VALVE 209 AUTO RESET FUSE 152 137 MANUAL RESET 136 201 207 208 FUSE OVER TEMPERATURE SWITCHES 200 TO I/O BOX AIR TEMP SENSOR 364 363 209 24 VAC XFMR 202 204 TO I/O BOX 0-10V 6 PIN CONNECTOR 201 202 GND NEU 208 VAC 3O 60 HZ L3 L2 L1 321 320 260 203 263 262 200 261 260 206 142 AGND FUSE BLOCK 190 191 192 193 194 195 204 206 209 208 203 GND BLOCK 263 L3 262 L2 261 L1 366 20 AMP 20 AMP 20 AMP 333 332 331 333 332 331 330 A1 A2 B1 B2 C1 C2 GND 333 332 331 375 T1 T2 T3 T4 T5 T6 L1 L2 L3 PE PE U V W 303 302 301 300 BLOWER MOTOR TO CONTROL BOX ENCLOSURE { 330 POWER BOX 375 DRIVE REACTOR VFD SOLENOID 350 WIRING SCHEMATIC.APPENDIX H CONTROL BOX CONNECTORS 19-PIN CONNECTOR 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 16-PIN CONNECTOR 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 9-PIN CONNECTOR 5 4 3 2 1 7-PIN CONNECTOR 7 6 5 4 3 2 1 141 191 193 194 137 155 136 154 135 138 192 140 190 195 172 170 168 166 164 162 173 171 169 167 165 163 161 152 153 151 150 148 146 149 147 145 133 134 IGNITION TRANSFORMER BLOWER PROOF SW.

C. C N. 7 6 5 4 3 2 1 NOT USED DELAYED INTLK EXHAUST TEMP REMOTE INTLK IN OUT IN OUT IN OUT 7 6 5 4 3 2 1 APPENDIX H H-2 .O.C.O. C N.OUTDOOR AIR SENSOR IN FROM AIR TEMP SENSOR SENSOR COMMON IN 3 4 5 6 7 8 9 10 11 12 13 14 15 SHIELD 16 1 2 + ANALOG OUT + RS-485 IN GND A IN TO VFD B 0-10V AGND 1 2 3 1 2 3 4 AUX SENSOR IN + CO SENSOR IN + FLOW SENSOR IN + OXYGEN SENSOR IN SENSOR EXCIT. (12 VDC) + ANALOG IN + BMS (PWM) IN - 1 2 NOT USED AUX RELAY FAULT RELAY N. N.

I (SHT. SW. PROOF OF CLOSURE SWITCH NC C 1K H N G IGNITION POSITION SWITCH PURGE POSITION SWITCH 142 STEPPING MOTOR B C SHIELD 154 AIR/FUEL VALVE 152 150 SAFETY SHUTOFF VALVE 153 151 149 148 SHELL TEMP. HIGH GAS PRESS.APPENDIX H CONTROL BOX CONNECTORS 16-PIN CONNECTOR 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 9-PIN CONNECTOR 5 4 3 2 1 7-PIN CONNECTOR 7 6 5 4 3 2 1 141 191 193 194 137 155 136 154 135 138 192 140 190 195 173 172 170 168 166 164 162 171 169 167 165 163 161 152 153 151 150 148 146 149 147 145 133 134 BLOWER PROOF SW. SW.0 LN 460 VAC. IGNITION TRANSFORMER 141 AIR TEMP. 1 OF 2) H-3 . IGNITOR BLU BLK 2 3 A 5K 53 10K LOW GAS PRESS. SENSOR WATER LEVEL PROBE GND FLAME ROD 351 352 1 YEL WHT GRN RED 321 BLOCKED AIR INLET SW. 3 PHASE REF: 68006 REV. SENSOR 147 146 145 363 364 137 209 136 FUSE 201 FUSE 207 209 208 24 VAC XFMR 202 204 200 200 203 315 314 120 VAC CONTROL TRANSFORMER 315 FUSE 4 AMPS 319 X2 XF X1 TO I/O BOX AIR TEMP SENSOR AUTO RESET MANUAL RESET OVER TEMPERATURE SWITCHES 314 460VAC H1 H2 H3 H4 316 317 FUSE BLOCK 263 L3 262 L2 142 GND BLOCK TO I/O BOX AGND 0-10V 6 PIN CONNECTOR 201 190 191 192 193 194 195 TO CONTROL BOX ENCLOSURE GND L3 60 HZ 3O 460VAC L2 L1 206 321 320 260 316 263 317 262 261 260 204 206 209 208 202 VFD 333 332 331 330 A1 A2 B1B2 C1 C2 GND 333 332 331 375 T1 T2 T3 T4 T5 T6 203 15 AMP 15 AMP 15 AMP L1 L2 L3 PE PE U V W 303 302 301 300 BLOWER MOTOR 261 L1 319 366 { 330 POWER BOX 375 DRIVE REACTOR VFD SOLENOID 350 375 WIRING SCHEMATIC. BMK 3.

C.O. C N. (12 VDC) + ANALOG IN + BMS (PWM) IN - 1 2 NOT USED AUX RELAY FAULT RELAY N.C. 7 6 5 4 3 2 1 NOT USED DELAYED INTLK EXHAUST TEMP REMOTE INTLK IN OUT IN OUT IN OUT 7 6 5 4 3 2 1 APPENDIX H H-4 .OUTDOOR AIR SENSOR IN FROM AIR TEMP SENSOR SENSOR COMMON IN 3 4 5 6 7 8 9 10 11 12 13 14 15 SHIELD 16 1 2 + ANALOG OUT + RS-485 IN GND A IN TO VFD B 0-10V AGND 1 2 3 1 2 3 4 AUX SENSOR IN + CO SENSOR IN + FLOW SENSOR IN + OXYGEN SENSOR IN SENSOR EXCIT. C N.O. N.

APPENDIX H H-5 .

0 LN 208 VAC 3 PHASE IRI REF: 68025 REV.O.C. D (SHT. C N. N.C.APPENDIX H CONTROL BOX CONNECTORS 24-PIN CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 16-PIN CONNECTOR 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 250 251 252 253 254 226 221 220 219 216 215 214 213 212 211 J3 J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 J2 1 LS4 2 3 4 5 6 7 8 9 10 11 12 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4 LS3 LS2 LS1 OUTDOOR AIR SENSOR IN SENSOR COMMON IN AUX SENSOR IN 0-10V AGND A B 7 6 5 4 3 2 1 7 RS-485 IN GND SHIELD SENSOR EXCIT. BMK 3. 2 OF 2) EXHAUST TEMP REMOTE INTLK NOT USED AUX RELAY TO VFD FAULT RELAY 4 3 OUT 2 IN 1 IN IN 5 OUT + + + + + + + - - - - - - - IN 6 OUT H-6 .O. (12 VDC) BMS (PWM) IN ANALOG OUT ANALOG IN FLOW SENSOR IN CO SENSOR IN OXYGEN SENSOR IN N. C N. NOT USED DELAYED INTLK FROM AIR TEMP SENSOR AUX SENSOR IN INPUT/OUTPUT BOX WIRING SCHEMATIC.

APPENDIX H H-7 .

C N.O. 7 6 5 4 3 2 1 NOT USED DELAYED INTLK EXHAUST TEMP REMOTE INTLK IN OUT IN OUT IN OUT 7 6 5 4 3 2 1 APPENDIX H H-8 .O. C N.C.OUTDOOR AIR SENSOR IN FROM AIR TEMP SENSOR SENSOR COMMON IN 3 4 5 6 7 8 9 10 11 12 13 14 15 SHIELD 16 1 2 + ANALOG OUT + RS-485 IN GND IN TO VFD A B 0-10V AGND 1 2 3 1 2 3 4 AUX SENSOR IN + CO SENSOR IN + FLOW SENSOR IN + OXYGEN SENSOR IN SENSOR EXCIT. N.C. (12 VDC) + ANALOG IN + BMS (PWM) IN - 1 2 NOT USED AUX RELAY FAULT RELAY N.

Flue. stack or Visually inspection condition and check for Monthly Operator intake air duct obstructions Igniter Weekly Operator See paragraph 7. See paragraph 7.4 safety control test Technician Operating controls Annually Operator See paragraph 3. Boiler and Pressure Vessel Safety valves As required Operator Code. Section IV Inspect burner SemiService See paragraph 7.4.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.E.S.11 position switch Technician Check per A.4 and alarm Perform a slow drain test in accordance with SemiSlow drain test Operator ASME Boiler and Pressure Vessel Code. Annually Section IV. monitors and Visual inspection and record readings in operator Daily Operator indicators log Instrument and Visual check against factory recommended Daily Operator equipment settings specifications Weekly Operator Verify factory settings SemiService Firing Rate Control Verify factory settings Annually Technician Service Check with combustion calibration test Annually Technician equipment. Accomplished Frequency By Remarks Refer to indicated paragraphs of this manual for detailed procedures Gauges. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage. vent.4 and Chapter 4. See paragraph 6.6 High and low gas Monthly Operator See paragraphs 6.2 Low air flow Monthly Operator See paragraph 6.2 and 6. Close manual gas shutoff valve and check safety Flame failure Weekly Operator shutdown. Low water level cut off Weekly Operator See paragraph 6.M.3 pressure interlocks Air/Fuel Valve purge Service Annually See paragraph 6.8) Service Check for leakage in accordance with the SSOV SSOV Leakage test Annually Technician manufacturer’s (Siemens) recommendations.6 components Annually Technician Item I-1 .7 Check flame strength using the Control Panel Flame signal strength Weekly Operator Operating Menu.2 Air/Fuel Valve position Weekly Operator Check position indicator dial (paragraph 3. Tests should be conducted on a regular basis and the results recorded in a log-book.10 position switch Technician Air/Fuel Valve ignition Service Annually See paragraph 6. The owner or user of an automatic boiler system should set up a formal system of periodic preventive maintenance and testing. See paragraph 3. High water temperature Service Annually See paragraph 6.

.

APPENDIX J BENCHMARK CONTROL PANEL EXPLODED VIEW J-1 .

APPENDIX J BENCHMARK CONTROL PANEL REAR VIEW J-2 P1 P2 P3 P4 P5 P6 .

Used on: • ALL FM gas train models • Downstream SSOV of IRI gas train models SSOV Actuator Without Proof of Closure Switch . Spare Parts Recommended for Maintenance DESCRIPTION Annual Maintenance Kit 24-month Waterside/Fireside Inspection Kit PART NUMBER 58025-01 58025-04 Table K-3. contact your local AERCO Sales Representative for Temperature Switch rated for 200°F max.APPENDIX K 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. Optional Spare Parts DESCRIPTION C-More Control Box Burner Temperature Switch .Used on: • Upstream SSOV of IRI gas train models Temperature Switch . If boiler is installed in the State of Kentucky.Auto Reset (SEE NOTE 1) PART NUMBER 181197 46013 123966 NOTE: 1. K-1 . Table K-1.Manual Reset (SEE NOTE 1) 123552 69038 PART NUMBER 24045 64048 Table K-2. Recommended Emergency Spare Parts DESCRIPTION 3-Phase Blower SSOV Actuator/Regulator Combo .

.

mechanical defects or workmanship. The pressure vessel/heat exchanger shall not be warranted from failure due to scaling. with the exception of the ignitor and flame detector. Any claim relating to the product must be filed with AERCO not later than 14 days after the event-giving rise to such claim. or maintained or if the buyer has permitted any unauthorized modification. AERCO MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES. rebuild or exchange. OTHER COMPONENTS: 18 MONTHS FROM SHIPMENT All other components. 02/04/08 W-1 C103.Standard Warranty: Benchmark Gas-Fired Hydronic Boiler International. The warranty as set forth on the back page of the Operations & Maintenance Manual is in lieu of and not in addition to any other express or implied warranties in any documents. AERCO shall accept no responsibility if such item has been improperly installed. are conditionally guaranteed against any failure for 18 months from shipment. thermal stress. liming. operated. An Officer of AERCO must do any modifications to this warranty in writing. AERCO disclaims all responsibility for any special. AERCO will repair. or erosion due to water or installation conditions. corrosion. at its option the heat exchanger/combustion chamber according to the following schedule: Year 1 through 7 8 9 10 Discount From Then Prevailing List Price 100% 70% 40% 25% “C-MORE” CONTROL PANEL: 2 YEARS FROM SHIPMENT AERCO labeled control panels are conditionally warranted against failure for (2) two years from shipment. The sale of the product is specifically conditioned upon acceptance of these terms. Inc.0 . PRESSURE VESSEL/HEAT EXCHANGER: 10 YEARS FROM SHIPMENT The pressure vessel/heat exchanger shall carry a 10-year prorated. adjustment. incidental or consequential damages. or under any law. and/or repairs to the item. limited warranty from shipment against any failure due to condensate corrosion. Operation of the boiler using contaminated air will void the warranty. No salesman or other representative of AERCO has any authority to expand warranties beyond the face of the said warranty and purchaser shall not rely on any oral statement except as stated in the said warranty. Rev. Any claims relating to this product shall be limited to the sale price of the product at the time of sale.

In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges. at its option. Start-Up and Troubleshooting) Technician and an AERCO start-up sheet is completed. which identifies the item’s return address. register number and factory authorized RGA number. repair or exchange the defective item. whichever comes first.Standard Warranty: Benchmark Gas-Fired Hydronic Boiler International. Rev. attached to the shipping carton. AERCO shall have the option of having the item returned. Inc. 02/04/08 W-2 C103. modify. adjustment.1 . 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). or maintained or if the buyer has permitted any unauthorized modification. AERCO shall. The use of replacement parts not manufactured or sold by AERCO will void any warranty. Warranty coverage for all components and equipment mentioned in said warranty are not valid unless the Hydronic boiler is started up by a factory certified SST (Service. and/or repairs to the item. All other geographical areas carry a standard warranty of 18 months from date of shipment or 12 months from startup. AERCO shall accept no responsibility if such item has been improperly installed. the returned item must include a Returned Goods Authorization (RGA) label. In addition. This warranty coverage is only applicable within the United States and Canada. In order to process a warranty claim a formal purchase order number is required prior to shipment of any warranty item. FOB its factory. express or limited. or to make field replacements at the point of installation. operated.

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