AER Benchmark 3.0LN Series Mode d’emploi

Benchmark 3.0 Low NOx Boiler GF-116

USER MANUAL OMM-0038-0E

Applicable for Serial Numbers G-12-0454 and above

Installation,

Operation

& Maintenance

Instructions

Benchmark 3.0

Series

Gas Fired

Low NOx

Boiler System

Condensing, Modulating

Forced Draft, Hot Water Boiler

3,000,000 BTU/H Input

Latest Revision: October 10, 2017

Telephone Support

Direct to AERCO Technical Support

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

1-800-526-0288

100 Oritani Drive

Blauvelt, NY 10913

www.aerco,com

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.

Printed in U.S.A.

CONTENTS

Para.

Subject

Page

1-3 Prolonged Shutdown 1-2

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 Drains 2-3

2.7 Gas Supply Piping 2-5

2.8 AC Electrical Power Wiring 2-6

Para.

Subject

Page

3.6 Configuration Menu 3-6

3.7 Tuning Menu 3-8

3.8 Combustion Cal Menu 3-8

3.9 Start Sequence 3-8

3.10 Start/Stop Levels 3-10

Para.

Subject

Page

4.1 Initial Startup Requirements 4-1

4.2 Tools and Instruments for 4-1

4.3 Natural Gas Combustion 4-2

GF-116 - AERCO BENCHMARK 3.0LN 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 EmergencyShutdown 1-2

Chapter 2 – INSTALLATION 2-1

Para. Subject Page

2.9 Modes of Operation and Field

Control

Wiring

2-7

2.10 I/O Box Connections 2-9

2.11 Auxiliary Relay Contacts 2-11

2.12 Flue Gas Vent Installation 2-11

2.13 Combustion Air 2-11

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

Chapter 4 – INITIAL START-UP 4-1

Combustion Calibration

Para. Subject Page

4.4 Unit Reassembly 4-6

4.5 Over-TemperatureLimit Switch 4-6

Calibration

Para.

Subject

Page

6.8 Air Flow Fault Test 6-4

6.9 SSOV Proof of Closure Switch 6-4

6.10 Purge Switch Open During 6-5

6.11 Ignition Switch Open During 6-5

6.12 Safety Pressure Relief Valve 6-6

Para.

Subject

Page

7.7 Condensate Drain Trap 7-4

7.8 Shutting the Boiler Down For An 7-6

7.9 Placing The Boiler Back In 7-6

CONTENTS

Chapter 5 – MODE OF OPERATION 5-1

Para.

Subject

Page

Para.

Subject

Page

5.1

Introduction

5-1

5.6

Boiler Management System

5-4

5.2

Indoor/Outdoor Reset Mode

5-1

(BMS)

5.3

Constant Setpoint Mode

5-2

5.7

CombinationControl System

5-5

5.4

Remote Setpoint Mode

5-2

(CCS)

5.5

Direct Drive Modes

5-3

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

Purge

Ignition

Test

Chapter 7 – MAINTENANCE REQUIREMENTS 7-1

Para. Subject Page

7.1 Maintenance Schedule 7-1

7.2 Ignitor-Injector 7-1

7.3 Flame Detector 7-2

7.4 Combustion Calibration 7-3

7.5 Safety Device Testing 7-3

7.6 Burner Assembly Inspection 7-3

Extended Period of Time

Service After A Prolonged

Shutdown

Chapter 8 – TROUBLESHOOTING GUIDE 8-1

Para.

Subject

Page

Para.

Subject

Page

8.1

Introduction

8-1

CONTENTS

iii

Chapter 9 - RS232 COMMUNICATION 9-1

Para.

Subject

Page

Para.

Subject

Page

9.1

Introduction

9-1

9-3

Menu Processing Utilizing

9-1

9-2

RS232 Communication Setup

9-1

RS232 Communication

9-4

Data Logging

9-2

APPENDICES

App

Subject

Page

App

Subject

Page

Boiler Menu Item Descriptions

A-1

Piping Drawings

G-1

Startup, Status and Fault

B-1

Wiring Schematics

H-1

Messages

RecommendedPeriodic Testing

I-1

Temperature Sensor Resistance

C-1

Checklist

Chart

Benchmark Control Panel Views

J-1

Indoor/Outdoor Reset Ratio

D-1

RecommendedSpare Parts

K-1

Charts

Boiler Default Settings

E-1

Dimensional and Part Drawings

F-1

FOREWORD

Foreword

The AERCO Benchmark 3.0LN 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 3.0, with its 15:1 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 Benchmark 3.0 operates at inputs ranging from 200,000 BTU/hr. to 3,000,000 BTU/hr. The

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

ranges from 198,000 BTU/hr. to 2,900,000 BTU/hr., depending on operating conditions.

When installed and operated in accordance with this Instruction Manual, the Benchmark 3.0

Boiler complies with the NOx emission standards outlined in:

•

South Coast Air Quality Management District (SCAQMD), Rule 1146.1

Whether used in singular or modular arrangements, the Benchmark 3.0 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:

SAFETY PRECAUTIONS

1-1

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, CSA B149.1, 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

A DOUBLE-POLE SWITCH MUST BE

INSTALLED ON THE ELECTRICAL

SUPPLY LINE OF THE UNIT. THE

SWITCH MUST BE INSTALLED IN

AN EASILY ACCESSIBLE POSITION

TO QUICKLY AND SAFELY DIS-

CONNECT ELECTRICAL SERVICE.

DO NOT AFFIX SWITCH TO UNIT

SHEET METAL ENCLOSURES.

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 MAY BE 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

SERVICING.

CAUTIONS

Must be observed to prevent

equipment damage or loss of

operating effectiveness.

SAFETY PRECAUTIONS

1-2

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.

1.2 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 emergencyshut-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 horizontallyvented 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

Commonwealthand 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:

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