Aerco BMK 3.0 LN Nat. Gas Jan 2011 Bedienungsanleitung

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

SAFETY PRECAUTIONS 1.2 EMERGENCY SHUTDOWN If over heating occurs or th e gas s upply f ails to shut of f, c lose the m anual g as s hutoff val ve

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/

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

APPENDIX F F-12 59434245CSEE DETAIL C37B5657IRI GAS TRAIN(NON DUAL FUEL)DETAIL B:TERMINAL COVER ARE HIDEN4849504652646590DETAIL C: FUEL SELECTOR SWITC

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

APPENDIX G G-1 AIRSEPARATORAUTOMATICAIR VENTLINESIZEBYPASSBACKFLOW PREVENTERDIAPHRAGM TYPEEXPANSION TANKWATERSUPPLYPRESSUREREDUCINGFILL VALVECHECKVAL

APPENDIX G G-2 NORTHVALE, NJ 07647INTERNATIONAL, INC.APPD.DWN.BYSCALEDATEMCDATESD061506AERCOSD-A-682 CREV.BENCHMARK 3 MIL. BTU LOW NOxGAS FIRED BOI

APPENDIX G G-3

SAFETY PRECAUTIONS Extracted Information From 248 CMR 5.08 (2) – Continued a. In the event that the side wall horizontally vented gas fueled equipmen

APPENDIX G G-4 NORTHVALE, NJ 07647INTERNATIONAL, INC.APPD.DWN.BYSCALEDATEDATESD072606AERCOSD-A-691 CREV.BENCHMARK 3 MIL. BTU LOW NOxGAS FIRED BOILE

APPENDIX G G-5

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

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 2502472522542539 68 7 5 4 3

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 BENCHMARK CONTROL PANEL EXPLODED VIEW

APPENDIX J J-2 P1P2P3P4P5P6 BENCHMARK CONTROL PANEL REAR VIEW

APPENDIX K RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix F for the locations of the r ecommended an d opt

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 2-1 CHAPTER 2 INSTALLATION 2.1 INTRODUCTION This Chapt er pr ovides t he d escriptions a nd procedures nec essary t o unpack, ins pect

INSTALLATION 2-2 Figure 2-1 Benchmark 3.0 Boiler Clearances WARNING KEEP T HE UNIT AREA CLEAR AND FREE FRO M ALL C OMBUSTIBLE MATERIALS AND FLAMMAB

INSTALLATION 2-3 2.4.3 Removal of Support Rod Prior to ins tallation of w ater supply a nd return piping, the 24” threaded rod shown in Figure 2-3 mu

INSTALLATION 2-4 The pr ocedures to install and c onnect b oth of the c ondensate drains ar e pr ovided i n paragraphs 2.6.1 and 2.6.2. SHELL DRAINVA

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

INSTALLATION 2-6 NATURALGASSUPPLYDIRTTRAP2" MANUALSHUTOFFVALVEMANDATORY REGULATOR FOR MASSACHUSSETTS INSTALLATIONS ONLY Figure 2-7 Manual Gas Shu

INSTALLATION 2-7 GNDNEUL2L3L1208 VAC, 3 PHASE208 VAC, 3 PhaseGNDL2L3L1460 VAC, 3 PHASE460 VAC, 3 Phase Figure 2-9 AC Terminal Block Configurations 2.

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

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

INSTALLATION 2-9 While it is pos sible to c ontrol a bo iler or boi lers using on e of the previously described m odes of operation, it m ay not be

INSTALLATION 2-10 22 AWG, s uch as Bel den 9 841 ( see Figure 2-11). Polarity must be m aintained. T he shield must be connected only at the source

INSTALLATION 2-11 2.10.11 FAULT RELAY The f ault r elay is a s ingle pol e do uble thr ow (SPDT) relay ha ving a normally op en and normally c lose

INSTALLATION 2-12 2.13.2 Combustion Air From Inside the Building When combustion air is provided from within the building, it m ust be s upplied t

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

CONTENTS GF-116 - AERCO BENCHMARK 3.0LN GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions FOREWORD A Chapter 1 – SAFETY PRECAUTION

CONTROL PANEL OPERATING PROCEDURES Table 3-3. Setup Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Passsword 0 99

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

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 B

INITIAL START-UP 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 the

INITIAL START-UP 10. Next, verify that the gas pressure downstream of the SSOV is 1.8” W.C. for both FM and IRI gas trains. If gas pressure adjustment

INITIAL START-UP NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. Th

INITIAL START-UP 37. Press the ▼ arrow key until CAL Voltage 40% is displayed. 38. Press the CHANGE key. CAL Voltage 40% will begin to flash. 39. Th

CONTENTS Chapter 5 – MODE OF OPERATION 5-1 Para. Subject Page5.1 Introduction 5-1 5.2 Indoor/Outdoor Reset Mode 5-1 5.3 Constant Setpoint Mode

INITIAL START-UP 4-6 4.4 UNIT REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service oper

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

SAFETY DEVICE TESTING 6.3 HIGH GAS PRESSURE TEST To simulate a high gas pressure fault, refer to Figure 6-1 and proceed as follows: 1. Remove the 1

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

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 3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV) and the Air/Fuel Valve (see Figure 6-3).

SAFETY DEVICE TESTING 5. Re-enable the blower output drive voltage by performing the following steps: (a) Press the MENU key until CONFIGUR-ATION ME

SAFETY DEVICE TESTING 6-6 4. Initiate a unit start sequence. 5. The unit should begin it’s start sequence, then shut down and display PRG SWITCH OP

MAINTENANCE CHAPTER 7 MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit r equires regular routine maintenance to keep up efficiency a nd r eliability

MAINTENANCE 5. Next, lo osen an d r emove the i gnitor-injector from the burner housing using a 1" open-end wrench. 6. Check the ign itor-inje

MAINTENANCE 7.3 FLAME DETECTOR The flame detector, part no. 66006, is located in the body of the b urner ( see F igure 7- 1). T he flame detec tor

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 t he f our ( 4) thum bscrews s ecuring the c over on the c ondensate tr ap. Rem ove the cover. 4. Remove the float from the co

MAINTENANCE 7-6 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be tak en out of s ervice f or an extended per io

TROUBLESHOOTING Chapter 8- TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This tr oubleshooting guide is intended to aid service/maintenance per sonnel i

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

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. Del

TROUBLESHOOTING 8-5 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 7. Carbon o

TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH GAS PRESSURE 1. Incorre

TROUBLESHOOTING 8-7 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH WATER TEMPERATURE

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

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

TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION RESIDUAL FLAME 1. SSOV not fu

TROUBLESHOOTING 8- 11 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Air/F

FOREWORD Foreword The AERCO Benchmark 3.0LN Boiler is a modulating unit. It represents a true industry advance that meets the needs of today&

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

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

RS232 COMMUNICATION (c) Menu c hanges wil l be s tored in non-volatile memory. 9. To r edisplay th e m enu and vie w t he opt ion which was j ust

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

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.

SAFETY PRECAUTIONS CHAPTER 1 SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and o perating p ersonnel M UST, at all times, obs erve a

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 (

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 REVAERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647BENCHMARK 3.0 LOW NOxFM GAS TRAINAP - A - 844 BDRWN BY: SJDDATE: 3/09/09*NOT TO SCALE*HIGH GA

APPENDIX F IRI GAS TRAINAP-A-803CZ 072806APPD.CHKD.DWN.BYSIZESCALEDATE REV.NORTHVALE, NJ 07647INTERNATIONAL, INC.AERCO1"-SCH.40 PIPE2"-SCH

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