Watts AERCO Benchmark 2.0 Manuel utilisateur

GF-110

OMM-0020_0A

Benchmark 2.0 Gas-Fired Boiler

USER MANUAL

Applicable for Serial Numbers G-02-533 thru G-10-1060

Benchmark 2.0

Gas Fired

Boiler System

Condensing, Modulating

Forced Draft, Hot Water Boiler

2,000,000 BTU/H Input

Patent # : 2.155.12

GF-110

OMM-0020_0A

Benchmark 2.0 Gas-Fired Boiler

USER MANUAL

Telephone Support

Direct to AERCO Technical Support

(8 to 5 pm EST, Monday through Friday)

(800) 526-0288

AERCO International, Inc.

100 Oritani Drive

Blauvelt, NY 10913

www.aerco.com

The information contained in this 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 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.

CONTENTS

GF-110 - THE AERCO BENCHMARK 2.0 GAS FIRED BOILER

Operating & Maintenance Instructions

FOREWORD A

Chapter 1 – SAFETY PRECAUTIONS 1-1

Para.

Subject

Page

1-1

Safety Warnings

1-1

1-2

Emergency Shutdown

1-2

Para.

Subject

Page

1-3

Prolonged Shutdown

1-2

Chapter 2 – INSTALLATION PROCEDURES 2-1

Para.

Subject

Page

2.1

Receiving the Unit

2-1

2.2

Unpacking

2-1

2.3

Installation

2-2

2.4

Gas Supply Piping

2-3

2.5

Electrical Supply

2-5

2.6

Mode of Operation and Field

Control Wiring

2-6

Para.

Subject

Page

2.7

I/O Box Connections

2-8

2.8

Auxiliary Relay Contacts

2-9

2.9

Flue Gas Vent Installation

2-9

2.10

Combustion Air

2-10

Chapter 3 – CONTROL PANEL COMPONENTS AND

OPERATING PROCEDURES 3-1

Para.

Subject

Page

3.1

Introduction

3-1

3.2

Control Panel Description

3-1

3.3

Control Panel Menus

3-3

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

3-7

3.8

Start Sequence

3-7

3.9

Start/Stop Levels

3-9

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

4-3

Para.

Subject

Page

4.4

Combustion Calibration for

Propane on Dual Fuel Unit

4-5

4.5

Unit Reassembly

4-6

4.6

Over-Temperature Limit Switch

4-7

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

6-1

6.4

Low Water Level Fault Test

6-2

6.5

Water Temperature Fault Test

6-2

6.6

Interlock Tests

6-2

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

6-4

6.10

Purge Switch Open During

Purge

6-5

6.11

Ignition Switch Open During

Ignition

6-5

6.12

Safety Pressure Relief Valve

Test

6-5

Chapter 7 – MAINTENANCE REQUIREMENTS 7-1

Para.

Subject

Page

7.1

Maintenance Schedule

7-1

7.2

Spark Igniter

7-1

7.3

Flame Detector

7-2

7.4

Combustion Calibration

7-2

7.5

Safety Device Testing

7-3

7.6

Burner

7-3

Para.

Subject

Page

7.7

Condensate Drain Trap

7-4

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

iii

APPENDICES

App

Subject

Page

Boiler Menu Item Descriptions

A-1

Startup, Status and Fault

Messages

B-1

Temperature Sensor Resistance

Chart

C-1

Indoor/Outdoor Reset Ratio

Charts

D-1

Boiler Default Settings

E-1

App

Subject

Page

Dimensional and Part Drawings

F-1

Piping Drawings

G-1

Wiring Schematics

H-1

Recommended Periodic Testing

Checklist

I-1

Benchmark Control Panel Views

J-1

Benchmark Dual-Fuel Propane

Switch-Over Instructions

K-1

WARRANTIES W-1

FOREWORD

Foreword

The AERCO Benchmark boiler is 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's 20:1 turn down ratio and condensing capability offers extremely

high efficiencies and makes the Benchmark ideally suited for modern low temperature, as well

as, conventional heating systems.

Whether used in singular or modular arrangements the Benchmark 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 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 general warnings and cautions must be

given the same attention as specific precautions

included in these instructions. In addition to all

the requirements included in this 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.

See pages 1-2 and 1-3 for important

information regarding installation of units

within the Commonwealth of Massachusetts.

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 ANY BOILER

MAINTENANCE.

WARNING!

ELECTRICAL VOLTAGES UP TO 460

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 the 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.

SAFETY PRECAUTIONS

1-2

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

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

SAFETY PRECAUTIONS

1-3

monoxide detectors.

Extracted Information From 248 CMR 5.08 (2) – Continued

a. In the event that the side wall horizontally vented gas fueled equipment is installed in

a crawl space or an attic, the hard wired carbon monoxide detector with alarm and

battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of

completion of installation, the owner shall have a period of thirty (30) days to comply with

the above requirements; provided, however, that during said thirty (30) day period, a

battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. 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.

3. 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. The sign

shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW.

KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled

equipment shall not approve the installation unless, upon inspection, the inspector observes

carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. 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; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or

structure separate from the dwelling, building or structure used in whole or in part for residential

purposes.

the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting

system design or venting system components with the equipment, the instructions provided by the

manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system

components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does

not provide the parts for venting the flue gases, but identifies "special venting systems", the following

requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or

equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions

for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled

equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design

instructions shall remain with the appliance or equipment at the completion of the installation.

_______________________________ [End of Extracted Information From 248 CMR 5.08 (2)]

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