Aerco BMK 3.0 LN Dual Fuel 2007 Bedienungsanleitung

Printed in U.S.A. REVISED JANUARY, 2009 GF-117 Instruction No.AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 076

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

12/02/08EAERCO(SHEET 4 OF 7)PL - A - 150NORTHVALE, NJ 07647SDDRAWN BY INTERNATIONAL, INC.DATE BENCHMARK 3.0 LOW NOxBOILER PARTS LIST63277213562S

AERCOINTERNATIONAL, INC.)PL - A - 150BENCHMARK 3.0 LOW NOxSD(SHEET 5 OF 7BOILER PARTS LISTNORTHVALE, NJ 07647DRWN BY DATE 12/02/08E49505258DETAI

8284838081DRWN BY SD)(SHEET 6 OF 7BOILER PARTS LISTNORTHVALE, NJ 07647INTERNATIONAL, INC.AERCOBENCHMARK 3.0 LOW NOxPL - A - 150DATE 12/02/08EAP

DRWN BY SD)(SHEET 7 OF 7BOILER PARTS LISTNORTHVALE, NJ 07647INTERNATIONAL, INC.AERCOBENCHMARK 3.0 LOW NOxPL - A - 150DATE 12/02/08E8785898688AP

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APPENDIX G G-2 NORTHVALE, NJ 07647INTERNATIONAL, INC.APPD.DWN.BYSCALEDATECZDATEJK070507AERCOSD-A-724 BREV.BENCHMARK 3 MIL. BTU LOW NOxDUAL FUEL GAS

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APPENDIX G G-4 NORTHVALE, NJ 07647INTERNATIONAL, INC.APPD.DWN.BYSCALEDATEDATEJK070207AERCOSD-A-726 BREV.BENCHMARK 3 MIL. BTU LOW NOxDUAL FUEL GAS FI

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INSTALLATION 2-1 CHAPTER 2 INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and ins

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APPENDIX I I-1 RECOMMENDED PERIODIC TESTING CHECK LIST WARNING NOTE: Periodic testing of all boiler controls and safety devices is required to deter

APPENDIX J J-1 VERTICAL OVERLAY, BENCHMARKP/N 124718FRONT FACE PLATE, BENCHMARKP/N 124949FISH PAPER INSULATORP/N 124960ENCLOSUREP/N 124951V.F.D.

APPENDIX J J-2 P1P2P3P4P5P6 BENCHMARK CONTROL PANEL REAR VIEW

APPENDIX K K-1 BENCHMARK 3.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS Prior to operating a Benchmark 3.0 Dual-Fuel Unit on either Natural Gas or Propane,

APPENDIX K K-2 POWER BOXCONTROLPANELI/O BOXTRANSFORMER(460 VAC UNITS ONLY)VFDFUELSELECTORSWITCH FIGURE K-1. BENCHMARK 3.0 DUAL FRONT VIEW – D

APPENDIX K K-3 SWITCHOVER FROM PROPANE TO NATURAL GAS To switch from Propane to Natural Gas operation, proceed as follows: 1. Refer to Figure K-

INSTALLATION 2-2 Figure 2-1 Benchmark 3.0 Dual Fuel Boiler Clearances WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS

Standard Warranty: Benchmark Gas-Fired Hydronic Boiler International, Inc. Rev. 02/04/08 W-1 C103.0 PRESSURE VESSEL/HEAT EXCHANGER: 10 YEA

Standard Warranty: Benchmark Gas-Fired Hydronic Boiler International, Inc. Rev. 02/04/08 W-2 C103.1 CONDITIONS OF WARRANTY Should an AER

INSTALLATION 2-3 2.4.3 Removal of Support Rod Prior to installation of water supply and return piping, the 24” threaded rod shown in Figure 2-3 must

INSTALLATION 2-4 UNITFRAMECONNECTINGMANIFOLDDRAINVALVECONDENSATEDRAIN PIPETOCONDENSATETRAPSHELLVIEW “B - B”VIEW “A - A”UNITFRAMEEXHAUSTMANIFOLDCONDE

INSTALLATION 2-5 2.7 GAS SUPPLY PIPING The AERCO Benchmark 3.0 Gas Components and Supply Design Guide, GF-3030 must be consulted prior to designing

INSTALLATION 2-6 2.7.3 IRI Gas Train Kit The IRI gas train is an optional gas train configuration which is required in some areas for code complianc

INSTALLATION 2-7 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 3.0 Dual-Fuel Boiler is available in several different modes of oper

INSTALLATION 2-8 2.9.1 Constant Setpoint Mode The Constant Setpoint Mode is used when it is desired to have a fixed setpoint that does not deviate.

INSTALLATION 2-9 This feature allows the boiler to be enabled or disabled based on the outdoor air temperature. The factory default for the outdoor

Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday): 1-800-526-0288

INSTALLATION 2-10 louvers. These interlocks are called the Remote Interlock and Delayed Interlock (Figure 2-11). The wiring terminals for these inte

INSTALLATION 2-11 The combustion air must be free of chlorine, halogenated hydrocarbons, or other chemicals that can become hazardous when used i

CONTROL PANEL OPERATING PROCEDURES CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES 3.1 INTRODUCTION The information in this Chapter provides a guide

CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 LED Sta

CONTROL PANEL OPERATING PROCEDURES 3-3 Table 3-1 Operating Controls, Indicators and Displays – Continued ITEM NO. CONTROL, INDICATOR OR DISPLAY FUN

CONTROL PANEL OPERATING PROCEDURES 3.3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to

CONTROL PANEL OPERATING PROCEDURES 3-5 3.4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in

CONTROL PANEL OPERATING PROCEDURES 3.6 CONFIGURATION MENU The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint (Set

CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Def

CONTENTS i GF-117 - AERCO BENCHMARK 3.0 DUAL-FUEL LOW NOx BOILER Operating & Maintenance Instructions FOREWORD A Chapter 1 – SAFETY PRECAUTIO

CONTROL PANEL OPERATING PROCEDURES PROPANESSOV 4(UPSTREAM)NATURAL GASINLETPROPANEINLETPROPANESSOV 3(DOWNSTREAM)NATURAL GASSSOV 1(DOWNSTREAM)NATURAL GA

CONTROL PANEL OPERATING PROCEDURES 3-9 5. Upon completion of the purge cycle, the Control Box initiates an ignition cycle and the following events o

INITIAL START-UP 4-1 CHAPTER 4 INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 3.0 D

INITIAL START-UP 4-2 4. Install a NPT-to-barbed fitting into the tapped plug port. 5. Attach one end of the plastic tubing to the barbed fitting and

INITIAL START-UP 4-3 5. Set the unit to the Manual Mode by pressing the AUTO/MAN key on the control panel. A flashing Manual Fire Rate message will

INITIAL START-UP 4-4 15. Compare the measured oxygen level to the oxygen range for the inlet air temperature shown in Table 4-1. Also, ensure that the

INITIAL START-UP 4-5 22. Press the M key again and observe the frequency shown in the right part of the display. The oxygen level at the 85% firing

INITIAL START-UP 4-6 1. Open the water supply and return valves to the unit and ensure that the system pumps are running. 2. Open the propane supply

INITIAL START-UP 4-7 19. Press the M key again and observe the frequency shown in the right part of the display. The oxygen level at the 75% firing

CONTENTS ii Chapter 5 – MODE OF OPERATION 5-1 Para. Subject Page5.1 Introduction 5-15.2 Indoor/Outdoor Reset Mode 5-15.3 Constant Setpoint Mod

INITIAL START-UP 4-8 6. Install the correct VFD Logic Stick for the fuel being used. 7. Remove the manometer and barbed fittings and reinstall the N

MODE OF OPERATION 5-1 CHAPTER 5 MODE OF OPERATION 5.1 INTRODUCTION The Benchmark 3.0 Dual-Fuel Boiler is capable of being operated in any one of si

MODE OF OPERATION 7. Press the CHANGE key. The display will begin to flash. 8. Use the ▲ and ▼ arrow keys to select the desired Building Reference Te

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 Modb

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 Modb

MODE OF OPERATION 5-5 5.7 COMBINATION CONTROL SYSTEM (CCS) NOTE Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5R

SAFETY DEVICE TESTING 6-1 CHAPTER 6 SAFETY DEVICE TESTING 6.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that

SAFETY DEVICE TESTING 6-2 8. Fully open the external manual gas shut-off valve and press the CLEAR button on the Control Box. 9. The fault message s

SAFETY DEVICE TESTING 6-3 5. Start the unit in Manual mode at a firing rate between 25 and 30%. 6. Slowly increase the gas pressure using the adjust

CONTENTS iii APPENDICES App Subject PageA Boiler Menu Item Descriptions A-1B Startup, Status and Fault Messages B-1C Temperature Sensor Resist

SAFETY DEVICE TESTING 6-4 Figure 6-2 Temperature Limit Switch Setting 6.8 INTERLOCK TESTS The unit is equipped with two interlock circuits called

SAFETY DEVICE TESTING 6-5 8. Once flame is proven, close the manual gas valve located between the SSOV and the Air/Fuel Valve. 9. The unit should sh

SAFETY DEVICE TESTING 6-6 9. Remove the wire again when the unit reaches the purge cycle and PURGING is displayed. 10. The unit should shut down and

SAFETY DEVICE TESTING 6-7 172169 Figure 6-6 Air/Fuel Valve Purge and Ignition Switch Locations 6.14 SAFETY PRESSURE RELIEF VALVE TEST Test the s

MAINTENANCE 7-1 CHAPTER 7 MAINTENANCE 5. The igniter is gapped at 1/8-inch. If there is a substantial erosion of the spark gap or ground electrode

MAINTENANCE Table 7-1 - Maintenance Schedule PARAGRAPH ITEM 6 Mos. 12 Mos. 24 Mos. Labor Time 7.2 Spark Igniter (GP-122435-S) *Inspect Inspect

MAINTENANCE 7-3 7.5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they

MAINTENANCE 7-4 7.7 CONDENSATE DRAIN TRAPS The Benchmark 3.0 Dual-Fuel Boiler contains two condensate traps as shown in Figure 2-5. One trap is loca

MAINTENANCE 7-5 7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN UNITFRAMEEXHAUSTMANIFOLDCONDENSATETRAPDRAINHOSECLAMP1" I.D.H

TROUBLESHOOTING 8-1 Chapter 8- TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel i

TROUBLESHOOTING 8-2 TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. Blower

TROUBLESHOOTING 8-3 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 17.Fuel Sele

TROUBLESHOOTING 8-4 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OPEN 1.

TROUBLESHOOTING 8-5 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 8. Carbon o

TROUBLESHOOTING 8-6 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 3. Defective H

TROUBLESHOOTING 8-7 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED DURING

TROUBLESHOOTING 8-8 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE OUT OF PHA

TROUBLESHOOTING 8-9 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION PRG SWTCH OPEN DURING

FOREWORD A Foreword The AERCO Benchmark 3.0 Dual-Fuel Boiler is a modulating unit. It represents a true industry advance that meets the needs

TROUBLESHOOTING 8-10 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Defectiv

TROUBLESHOOTING 8-11 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a s

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

TROUBLESHOOTING 8-13 Table 8-3 BMK 3.0 LN (3.3 KΩ) Temperature Sensor and Temperature Transmitter Outputs TEMP ºC TEMP ºF UA33 Resistance Ohm Volts

APPENDIX A A-1 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpo

APPENDIX A A-2 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password

APPENDIX A A-3 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Reset Ratio Permits setting of Reset R

APPENDIX A A-4 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a f

APPENDIX B B-1 APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DISABLED HH:MM pm MM

APPENDIX B B-2 TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION HIGH WATER TEMP SWITCH OPEN The High Water Temperature Limit Switch is o

APPENDIX B B-3 TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION RESIDUAL FLAME The Flame signal was seen for more than 60 sec

APPENDIX C C-1 TEMPERATURE SENSORAERCO PART NO. 123449R = RESISTANCE (OHMS) T = TEMPERATURE (°F) R=.00161T^2+1.961T+854.841TEMP (°F) RES. (OHMS)-

APPENDIX D D-1 APPENDIX D. - INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1. Header Temperature for a Building Reference Temperature of 50F RESET RAT

APPENDIX D D-2 Table D-3. Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.

APPENDIX D D-3 Table D-5. Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.

APPENDIX D D-4 Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2

APPENDIX E E-1 BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Addre

SAFETY PRECAUTIONS 1-1 CHAPTER 1 SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe al

APPENDIX F F-1 79 (201.4)36 1/4 (92.2)15 (38.0)33 (84.7)6 7/8 (17.4)7 7/16 (18.9)42 1/8 (107.0)69 5/8 (176.9)5 1/4 (13.3)12 3/4 (32.4)13.5 (34.3)2 5/

APPENDIX F F-2 FRONT REAR26 (66.0)AERCO061506061506ANCHOR BOLT LOCATIONSBENCHMARK 3 MIL. LOW NOx BTUGAS FIRED BOILERSCALEDWN.BYAPPD.GSMCDATEDATESD-A-6

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DRAWN BY ESD(SHEET 1 OF 7)PL - A - 150DATE 12/02/08BOILER PARTS LISTAERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647TOP MANIFOLD INSULATION2(3)BENCHMA

(SHEET 2 OF 7)DRAWN BY PL - A - 150SDEDATE 12/02/08AERCO24065-3(4)59DUAL FUEL, PROPANE - STICKTOP PANELBOILER PARTS LIST2(4)(4)(4)(5)(1)(7)(1)(2)(1)(8

DRAWN BY ESD(SHEET 3 OF 7)PL - A - 150DATE 12/02/08NORTHVALE, NJ 07647AERCOINTERNATIONAL, INC.BENCHMARK 3.0 LOW NOxBOILER PARTS LIST516533839DET