Aerco BMK 3.0 LN Dual Fuel Jan 2011 Bedienungsanleitung

Printed in U.S.A. REVISED JANUARY 27, 2011 Instruction No. AERCO INTERNATIONAL, Inc., Northvale, New Jersey,

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

APPENDIX F FRONT REAR26 (66.0)AERCO061506061506ANCHOR BOLT LOCATIONSBENCHMARK 3 MIL. LOW NOx BTUGAS FIRED BOILERSCALEDWN.BYAPPD.GSMCDATEDATESD-A-680R

APPENDIX F TOP VIEWSIDE VIEWINSTALLATION CLEARANCES1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING24"24"24"79"18"

APPENDIX F TOP VIEWSIDE VIEWINSTALLATION CLEARANCES1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING2) MINIMUM CLEARANCES TO ADJACENT CONSTRU

APPENDIX F 2" SCH.40 PIPE2" SCH.40 PIPEBMK3.0 LN FM DUAL FUEL GAS TRAIN ASSY. P/N 22040-1*NOT TO SCALE*DATE: 3/23/09DRWN BY: SJDAAP - A - 84

APPENDIX F DUAL FUEL IRI GAS TRAINJK 071307APPD.CHKD.DWN.BYSIZESCALEDATE REV.NORTHVALE, NJ 07647INTERNATIONAL, INC.AERCONTSCBENCHMARK 3.0 LOW NOxLOW

APPENDIX F F-7 BENCHMARK 3.0 LOW NOxBURNER ACCESSORIESCZ072606PL-A-151 DDATEAPPD.SIZECHKD.DWN.BYSCALEREV.AERCONORTHVALE, NJ 07647INTERNATIONAL, INC.

APPENDIX F AERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647BENCHMARK 3.0 LOW NOxBOILER PARTS LIST(3)HPL - A - 150(SHEET 1 OF 7)DRAWN BY SJDDATE 2/1

APPENDIX F (1)(4)(4)(4)(4)(1)(7)(1)(2)(1)(8)(6)PART OF GAS TRAIN ASSY.(5) ONLY NEEDED ON DUAL FUELFOR 460 V OPTION ONLYFOR PICTORAL PURPOSES ONLY,FM

APPENDIX F APL - A - 150(SHEET 3 OF 7)DATE 2/18/0913212131415211292DETAIL A SCALE 1 : 1069101718222324252658165344554139386140BLOWER PROOF SWITCH47A

APPENDIX F 1920702829303132333434 34BB7213527626367SECTION B-B SCALE 1 : 1871436AERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647BENCHMARK 3.0 LOW NOx

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

APPENDIX F 59434245CSEE DETAIL C37B5657IRI GAS TRAIN(NON DUAL FUEL)DETAIL B:TERMINAL COVER ARE HIDEN4849504652646590DETAIL C: FUEL SELECTOR SWITCH(DUA

APPENDIX F 8081848382AERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647BENCHMARK 3.0 LOW NOxBOILER PARTS LISTHPL - A - 150(SHEET 6 OF 7)DRAWN BY SJDDA

APPENDIX F F-14 85 89868887AERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647BENCHMARK 3.0 LOW NOxBOILER PARTS LISTHPL - A - 150(SHEET 7 OF 7)DRAWN BY

APPENDIX G G-1

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

APPENDIX G G-3

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

APPENDIX H H-1 T1 T2 T4T3 T6T5B2 B4 B5JUMPER # 368JUMPER # 367SOLENOID6 PIN CONNECTOR195194193192191190208209202203206204201AUTO RESETOVER TEMPERATU

APPENDIX H H-2 CONTROL BOX CONNECTORS1210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 242243244245251246 250247252 2542539 68 7 5 4

APPENDIX H H-3 ENCLOSURETO CONTROL BOXSOLENOID6 PIN CONNECTOR195194193192191190208209202203206204201AUTO RESETOVER TEMPERATURE SWITCHESMANUAL RESET1

INSTALLATION 2-2 43"24"24"24"4" HIGH PADREARFRONT77"18"101"79" Figure 2-1 Benchmark 3.0 Dual Fuel Boi

APPENDIX H H-4 CONTROL BOX CONNECTORS1210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 242243244245251246 250247252 2542539 68 7 5 4

APPENDIX H H-5 123456789123456789101112131415123456789101112CONTROL BOX CONNECTORSBLOWER PROOF SW.OVER TEMPERATURE SWITCHESIGNITORTRANSFORMERWATER L

APPENDIX H H-6 CONTROL BOX CONNECTORS1210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 242243244245251246 2502472522542539 68 7 5 4 3 1

APPENDIX H H-7 123456789123456789101112131415123456789101112CONTROL BOX CONNECTORSBLOWER PROOF SW.OVER TEMPERATURE SWITCHESIGNITORTRANSFORMERWATER LE

APPENDIX H H-8 CONTROL BOX CONNECTORS1210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 242243244245 251246 250247252 2542539 68 7 5 4 3

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

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,

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

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

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-

APPENDIX L RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix F for the locations of the recommended and optio

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 2-4 The procedures to install and connect both of the condensate drains are provided in paragraphs 2.6.1 and 2.6.2. UNITFRAMECONNECTINGMA

INSTALLATION 2-5 CONDENSATE TRAPCONNECTING MANIFOLDDRAIN PIPE3/4" NPTNIPPLESTOFLOORDRAINCLAMP1" I.D.HOSEADAPTOR Figure 2-6 Condensate Tr

INSTALLATION 2-6 NATURALGASSUPPLYDIRTTRAP2" MANUALSHUTOFFVALVESPROPANESUPPLYDIRTTRAP Figure 2-7 Manual Gas Shut-Off Valve Location 2.7.3 IRI Ga

INSTALLATION 2-7 Figure 2-9 AC Terminal Block Configurations 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 3.0 Dual-Fuel Boiler

INSTALLATION 2-8 mA OUTRS-485 COMM.+-+-ANALOG INSENSOR COMMONOUTDOOR SENSOR INREMOTE INTL'K INB.M.S. (PWM) INSHIELD+-+-(AIR) AUX SENSOR INN

INSTALLATION 2-9 that you consult with your local AERCO representative or the factory for the mode of operation that will work best with your applica

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

INSTALLATION 2-10 must be left floating (not connected) at the Boiler’s I/O Box. Regardless of whether voltage or current is used for the drive signa

INSTALLATION 2-11 2.10.11 FAULT RELAY The fault relay is a single pole double throw (SPDT) relay having a normally open and normally closed set of r

INSTALLATION 2-12 2.13.3 Sealed Combustion The AERCO Benchmark 3.0 Dual-Fuel Boiler is UL listed for 100%-sealed combustion. For sealed combustion i

CONTROL PANEL OPERATING PROCEDURES 3-1 CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES 3.1 INTRODUCTION The information in this Chapter provides a

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 NOTE The following paragraphs provide brief descriptions of the options contained in each menu. Refer to Appe

CONTROL PANEL OPERATING PROCEDURES Table 3-3. Setup Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Passsword 0 9

CONTROL PANEL OPERATING PROCEDURES 3-7 Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum

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

CONTROL PANEL OPERATING PROCEDURES 3.7 TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change these

CONTROL PANEL OPERATING PROCEDURES 1. The DEMAND LED status indicator will light. 2. The unit checks to ensure that the Proof of Closure (POC) switch

CONTROL PANEL OPERATING PROCEDURES 3-10 8. With the unit firing properly, it will be controlled by the temperature controller circuitry. The boiler’s

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 5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 inch W.C. manometer. Figure 4-1 1/8 I

INITIAL START-UP 8. Ensure that the Fuel Selector Switch (Figure 4-3 is in the NATURAL GAS position. In addition, ensure that the Fuel Type option in

INITIAL START-UP 15. If necessary, adjust the iris air damper shown in Figure 4-5 until the oxygen level is within the range specified in Table 4-1.

INITIAL START-UP 27. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. 28. Press the CHANGE key. SET Valve Position wil

INITIAL START-UP 51. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. 52. Press the CHANGE key. SET Valve Position wi

INITIAL START-UP 9. Locate the Fuel Selector Switch on the front of the unit behind the panel door (Figure 4-3). 10. Set the ON/OFF switch on the un

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

INITIAL START-UP Combustion Oxygen Level at 60% Valve Position Oxygen % ± 0.2 Carbon Monoxide NOx 5.5 % <150 ppm <100 ppm 26. If the oxyge

INITIAL START-UP 4-9 47. Press the ▼ arrow key until CAL Voltage 18% is displayed. 7. Remove the combustion analyzer probe from the vent hole. Repl

MODE OF OPERATION 5-1 CHAPTER 5 MODE OF OPERATION 5.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The f

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 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 of

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

CONTENTS Chapter 9 - RS232 COMMUNICATION 9-1 Para. Subject Page9.1 Introduction 9-19-2 RS232 Communication Setup 9-1 Para. Subject Page9-3

SAFETY DEVICE TESTING 6.3 PROPANE LOW GAS PRESSURE SWITCH TEST Refer to Figure 6-1 and ensure that the leak detection ball valve located at the top o

SAFETY DEVICE TESTING 10. The fault message should clear and the FAULT indicator should go off. The unit should restart. 11. Upon test completion, cl

SAFETY DEVICE TESTING RESET BUTTON FOR MANUALRESET TEMPERATURE LIMIT SWITCHADJUSTABLETEMPERATURE LIMIT SWITCHMOUNTING PLATEON SHELLHIGH LIMIT Figure

SAFETY DEVICE TESTING PARTIAL LEFT SIDE VIEWBLOWERAIRINLETBLOCKED AIR INLETSWITCHAIR/FUELVALVEMANUAL GASSHUTOFF VALVEHANDLEPROPANEPART OF FRAMEGAS IN

SAFETY DEVICE TESTING 6. Once the unit has proved flame, turn off the blower by going to the Configuration Menu, Analog Output menu item and selec

SAFETY DEVICE TESTING 6-7 5. The unit should begin it’s start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE. 172171169170 6. Re

MAINTENANCE CHAPTER 7 MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability. Fo

MAINTENANCE 5. Next, loosen and remove the ignitor-injector from the burner housing using a 1" open-end wrench. 6. Check the ignitor-injector

MAINTENANCE 7.3 FLAME DETECTOR The flame detector, part no. 66006, is located in the body of the burner (see Figure 7-1). The flame detector may be

MAINTENANCE STAGED IGNITION ASSEMBLY3/8-16 NUTS (8)BURNERHOUSING1/4-20 SCREWS (6)GROUNDINGSCREW Figure 7-3 Burner Disassembly Diagram - Top View NOTE

MAINTENANCE 3. Loosen the four (4) thumbscrews securing the cover on the condensate trap. Remove the cover. 4. Remove the float from the condensate

MAINTENANCE 7-6 7.8 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 ti

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

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

TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING PURGE 1

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

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

TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 3. Defective Hi

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

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

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

TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION REMOTE SETPT SIGNAL FAULT (co

TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION STEPPER MOTOR FAILURE 1. Air

TROUBLESHOOTING 8-12 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a sp

TROUBLESHOOTING Figure 8-1 High Pressure Gas Switch & Snubber Locations Figure 8-2 Staged Ignition Solenoid Location NATURALGAS SSOVPROPA

RS232 COMMUNICATION CHAPTER 9 RS232 COMMUNICATION 9.1 INTRODUCTION The RS232 port on the front panel of the C-More Control Box (Figure 3-1) can be

RS232 COMMUNICATION (c) Menu changes will be stored in non-volatile memory. 9. To redisplay the menu and view the option which was just changed in s

RS232 COMMUNICATION Table 9-1. Sample Fault Log Display No. Fault Message Cycle Date Time 0 Direct Drive Signal F

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

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

APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Reset Ratio Pe

APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Setpt EN

APPENDIX A A-5 MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate based on the error that exists between the setpoi

APPENDIX B APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DEMAND DELAY XX sec Disp

APPENDIX B TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge, or ai

APPENDIX B B-3 TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Out

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

APPENDIX C C-1 TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART (BALCO) TEMP (°F) RES (OHMS) VOLTS* -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90

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 BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Address

APPENDIX E E-2 BOILER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Configuration Menu --Continued Network Timeout 30 seconds

APPENDIX F 79 (201.4)36 11/16 (93.2)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 5/8 (