AER Benchmark 2.0 Mode d’emploi

Printed in U.S.A. REVISED JUNE 14, 2010

Instruction

No.

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

GF-123

Installation, Operation

& Maintenance Instructions

Benchmark

2.0 Low NOx

Gas Fired

Boiler System

Natural Gas or Propane Fired

Condensing, Modulating,

Forced Draft, Hot Water Boiler

2,000,000 BTU/H Input

Applicable for Serial Numbers G-10-0927 and above

Telephone Support

Direct to AERCO Technical Support

(8 to 5 pm EST, Monday through Friday):

1-800-526-0288

AERCO International, Inc.

159 Paris Avenue

Northvale, NJ 07647-0128

www.aerco,com

The information contained in this

installation, operation and mainte-

nance 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.

FOREWORD

Foreword

The AERCO Benchmark 2.0 Low NOx (LN) Boiler is a modulating unit. It represents a true

industry advance that meets the needs of today's energy and environmental concerns.

Designed for application in any closed loop hydronic system, the Benchmark's modulating

capability relates energy input directly to fluctuating system loads. The Benchmark 2.0LN, with

its 20:1 turn down ratio and condensing capability, provides extremely high efficiencies and

makes it ideally suited for modern low temperature, as well as, conventional heating systems.

The boiler operates at inputs ranging from 100,000 BTU/hr. to 2,000,000 BTU/hr. The output of

the boiler is a function of the unit’s firing rate and return water temperature. Output ranges from

99,000 BTU/hr. to 1,933,000 BTU/hr., depending on operating conditions.

When installed and operated on natural gas in accordance with this Instruction Manual, the

Benchmark 2.0LN Boiler complies with the NOx emission standards outlined in:

•South Coast Air Quality Management District (SCAQMD), Rule 1146.2

Whether used in singular or modular arrangements, the Benchmark 2.0LN offers the maximum

flexibility in venting with minimum installation space requirements. The Benchmark's advanced

electronics are available in several selectable modes of operation offering the most efficient

operating methods and energy management system integration.

For service or parts, contact your local sales representative or AERCO INTERNATIONAL.

NAME:

ORGANIZATION:

ADDRESS:

TELEPHONE:

INSTALLATION DATE: _____________________________________________

CONTENTS

GF-123 - AERCO BENCHMARK 2.0LN GAS FIRED LOW NOx BOILER

Operating & Maintenance Instructions

FOREWORD A

Chapter 1 – SAFETY PRECAUTIONS 1-1

Para. Subject Page

1-1 Warnings & Cautions 1-1

1-2 Emergency Shutdown 1-2

Para. Subject Page

1-3 Prolonged Shutdown 1-2

Chapter 2 – INSTALLATION 2-1

Para. Subject Page

2.1 Introduction 2-1

2.2 Receiving the Unit 2-1

2.3 Unpacking 2-1

2.4 Site Preparation 2-1

2.5 Supply and Return Piping 2-3

2.6 Condensate Drain and Piping 2-3

2.7 Gas Supply Piping 2-4

2.8 AC Electrical Power Wiring 2-5

Para. Subject Page

2.9 Modes of Operation and Field

Control Wiring 2-6

2.10 I/O Box Connections 2-8

2.11 Auxiliary Relay Contacts 2-10

2.12 Flue Gas Vent Installation 2-10

2.13 Combustion Air 2-10

Chapter 3 – CONTROL PANEL OPERATING PROCEDURES 3-1

Para. Subject Page

3.1 Introduction 3-1

3.2 Control Panel Description 3-1

3.3 Control Panel Menus 3-4

3.4 Operating Menu 3-5

3.5 Setup Menu 3-5

Para. Subject Page

3.6 Configuration Menu 3-6

3.7 Tuning Menu 3-8

3.8 Combustion Cal. Menu 3-8

3.8 Start Sequence 3-8

3.9 Start/Stop Levels 3-10

Chapter 4 – INITIAL START-UP 4-1

Para. Subject Page

4.1 Initial Startup Requirements 4-1

4.2 Tools and Instruments for

Combustion Calibration 4-1

4.3 Natural Gas Combustion

Calibration 4-2

Para. Subject Page

4.4 Propane Combustion Calibration 4-6

4.5 Unit Reassembly 4-8

4.6 Over-Temperature Limit

Switches 4-9

CONTENTS

Chapter 5 – MODE OF OPERATION 5-1

Para. Subject Page

5.1 Introduction 5-1

5.2 Indoor/Outdoor Reset Mode 5-1

5.3 Constant Setpoint Mode 5-2

5.4 Remote Setpoint Mode 5-2

5.5 Direct Drive Modes 5-3

Para. Subject Page

5.6 Boiler Management System

(BMS) 5-4

5.7 Combination Control System

(CCS) 5-5

Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1

Para. Subject Page

6.1 Testing of Safety Devices 6-1

6.2 Low Gas Pressure Fault Test 6-1

6.3 High Gas Pressure Test 6-2

6.4 Low Water Level Fault Test 6-2

6.5 Water Temperature Fault Test 6-2

6.6 Interlock Tests 6-3

6.7 Flame Fault Test 6-3

Para. Subject Page

6.8 Air Flow Fault Test 6-4

6.9 SSOV Proof of Closure Switch 6-5

6.10 Purge Switch Open During

Purge 6-5

6.11 Ignition Switch Open During

Ignition 6-6

6.12 Safety Pressure Relief Valve

Test 6-6

Chapter 7 – MAINTENANCE REQUIREMENTS 7-1

Para. Subject Page

7.1 Maintenance Schedule 7-1

7.2 Ignitor-Injector 7-2

7.3 Flame Detector 7-3

7.4 Combustion Calibration 7-3

7.5 Safety Device Testing 7-3

7.6 Burner Assembly Inspection 7-3

Para. Subject Page

7.7 Condensate Trap 7-5

7.8 Shutting the Boiler Down For An

Extended Period of Time 7-5

7.9 Placing The Boiler Back In

Service After A Prolonged

Shutdown

7-5

Chapter 8 – TROUBLESHOOTING GUIDE 8-1

Para. Subject Page

8.1 Introduction 8-1

Para. Subject Page

CONTENTS

Chapter 9 – RS232 COMMUNICATION 9-1

Para. Subject Page

9.1 Introduction 9-1

9.2 RS232 Communication Setup 9-1

Para. Subject Page

9.3 Menu Processing Utilizing

RS232 Communication 9-1

9.4 Data Logging 9-2

APPENDICES

App Subject Page

A Boiler Menu Item Descriptions A-1

B Startup, Status and Fault

Messages B-1

C Temperature Sensor Resistance

Chart C-1

D Indoor/Outdoor Reset Ratio

Charts D-1

E Boiler Default Settings E-1

App Subject Page

F Dimensional and Part Drawings F-1

G Piping Drawings G-1

H Wiring Schematics H-1

I Recommended Periodic Testing

Checklist I-1

J Benchmark Control Panel Views J-1

K Recommended Spare Parts K-1

SAFETY PRECAUTIONS

CHAPTER 1 SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

Installers and operating personnel MUST, at all

times, observe all safety regulations. The

following warnings and cautions are general and

must be given the same attention as specific

precautions included in these instructions. In

addition to all the requirements included in this

AERCO Instruction Manual, the installation of

units MUST conform with local building codes,

or, in the absence of local codes, ANSI Z223.1

(National Fuel Gas Code Publication No. NFPA-

54). Where ASME CSD-1 is required by local

jurisdiction, the installation must conform to

CSD-1.

Where applicable, the equipment shall be

installed in accordance with the current

Installation Code for Gas Burning Appliances

and Equipment, CGA B149, and applicable

Provincial regulations for the class; which should

be carefully followed in all cases. Authorities

having jurisdiction should be consulted before

installations are made.

IMPORTANT

This Instruction Manual is an integral

part of the product and must be

maintained in legible condition. It must

be given to the user by the installer

and kept in a safe place for future

reference.

WARNINGS!

MUST BE OBSERVED TO PREVENT

SERIOUS INJURY.

WARNING!

BEFORE ATTEMPTING TO PER-

FORM ANY MAINTENANCE ON THE

UNIT, SHUT OFF ALL GAS AND

ELECTRICAL INPUTS TO THE UNIT.

WARNING!

THE EXHAUST VENT PIPE OF THE

UNIT OPERATES UNDER A

POSITIVE PRESSURE AND THERE-

FORE MUST BE COMPLETELY

SEALED TO PREVENT LEAKAGE

OF COMBUSTION PRODUCTS INTO

LIVING SPACES.

WARNING!

DO NOT USE MATCHES, CANDLES,

FLAMES, OR OTHER SOURCES OF

IGNITION TO CHECK FOR GAS

LEAKS.

WARNING!

FLUIDS UNDER PRESSURE MAY

CAUSE INJURY TO PERSONNEL

OR DAMAGE TO EQUIPMENT

WHEN RELEASED. BE SURE TO

SHUT OFF ALL INCOMING AND

OUTGOING WATER SHUTOFF

VALVES. CAREFULLY DECREASE

ALL TRAPPED PRESSURES TO

ZERO BEFORE PERFORMING

MAINTENANCE.

WARNING!

ELECTRICAL VOLTAGES UP TO

120 VAC ARE USED IN THIS

EQUIPMENT. THEREFORE THE

COVER ON THE UNIT’S POWER

BOX (LOCATED BEHIND THE

FRONT PANEL DOOR) MUST BE

INSTALLED AT ALL TIMES, EXCEPT

DURING MAINTENANCE AND SER-

VICING.

CAUTIONS!

Must be observed to prevent equip-

ment damage or loss of operating

effectiveness.

CAUTION!

Many soaps used for gas pipe leak

testing are corrosive to metals. The

piping must be rinsed thoroughly with

clean water after leak checks have

been completed.

CAUTION!

DO NOT use this boiler if any part has

been under water. Call a qualified

service technician to inspect and

replace any part that has been under

water.

1-1

SAFETY PRECAUTIONS

1.2 EMERGENCY SHUTDOWN

If overheating occurs or the gas supply fails to

shut off, close the manual gas shutoff valve

(Figure 1-1) located external to the unit.

IMPORTANT

The Installer must identify and indicate

the location of the emergency shutdown

manual gas valve to operating personnel.

1.3 PROLONGED SHUTDOWN

After prolonged shutdown, it is recommended

that the startup procedures in Chapter 4 and the

safety device test procedures in Chapter 6 of

this manual be performed, to verify all system-

operating parameters. If there is an emergency,

turn off the electrical power supply to the

AERCO boiler and close the manual gas valve

located upstream the unit. The installer must

identify the emergency shut-off device.

MANUAL GAS SHUTOFF VALVE

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.

•Prior to unit operation, the complete gas train and all connections must be leak tested using a

non-corrosive soap.

•If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed

upstream of the Fill/Makeup Valve.

•The vent termination must be located a minimum of 4 feet above grade level.

•If side-wall venting is used, the installation must conform to the following requirements extracted

from 248 CMR 5.08 (2):

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, 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, including but not limited to decks and porches, the following

requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the

side wall horizontal vented gas fueled equipment, 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. In addition, 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, building or structure served by the side

wall horizontal vented gas fueled equipment. 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.

1-2

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