What does Heat Demand Failure mean for Aerco Boiler?
If your Aerco Boiler displays a Heat Demand Failure, it means that the Heat Demand Relays on the Ignition/Stepper (IGST) board failed to activate when commanded. Press CLEAR button and restart the unit. If the fault persists, replace Ignition/Stepper (IGST) Board. It could also mean that the relay is activated when not in Demand, in which case you should replace the IGST Board.
What causes a Residual Flame error in my Aerco Benchmark 1500?
A Residual Flame error in your Aerco Boiler can be caused by a defective Flame Detector, so replace the Flame Detector. It can also be caused by the SSOV not fully closed. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator. Close the 2” Gas Shut-Off Valve downstream of SSOV (Figure 2-7). Install a manometer or gauge at the leak detection port between the SSOV and Gas Shut Off Valve. If a gas pressure reading is observed replace the SSOV Valve and/or Actuator.
Why does my Aerco Boiler experience flame loss during run?
Flame loss during run in your Aerco Boiler can occur due to several reasons: * A worn flame detector or cracked ceramic: inspect the flame detector for wear or cracks and replace if necessary. * A defective regulator: check gas pressure readings using a gauge or manometer into and out of the air/fuel valve to ensure that the gas pressure into and out of the valve is correct. * Poor combustion calibration: check combustion calibration. * Debris on burner: remove the burner and inspect for any carbon build-up or debris. Clean and reinstall. * A blocked condensate drain: remove any blockage in the condensate drain.
What does 'Direct Drive Signal Fault' mean on my Aerco Boiler?
A 'Direct Drive Signal Fault' on your Aerco Boiler indicates that the direct drive signal is not present because it is not yet installed, has the wrong polarity, the signal is defective at the source, or there is broken or loose wiring. Check I/O Box to ensure signal is hooked up. Hook up if not installed. If installed, check polarity. Measure signal level. Check wiring continuity between source and unit. It could also mean that the signal is not isolated (floating), so check the signal at the source to ensure it is isolated. Finally, the Control Box signal type selection switches may not be set for the correct signal type (voltage or current). Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. Check control signal type set in Configuration Menu.
What to do if PRG SWTCH is Open During Purge in Aerco Benchmark 1500?
If the PRG SWTCH is Open During Purge in your Aerco Boiler: * Defective purge switch: If the air-fuel valve does rotate, check purge switch for continuity when closing. Replace switch if continuity does not exist. * No voltage present at switch: Measure for 24 VAC from each side of the switch to ground. If 24 VAC is not present, refer fault to qualified service personnel. * Switch wired incorrectly: Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). * Defective Power Supply Board or fuse: Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board. * Defective IGST Board: Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.
What to check if Aerco Boiler shows a Low Water Level?
If your Aerco Boiler indicates a Low Water Level, check the system for sufficient water level. If the water level is adequate, test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons. Replace water level circuitry if it does not respond. Also, check continuity of probe end to the shell, change probe if there is no continuity.
What causes High Exhaust Temperature in Aerco Benchmark 1500 Boiler?
High Exhaust Temperature in your Aerco Boiler can be caused by poor combustion calibration. If exhaust temperature is greater than 200o F, check combustion calibration. Calibrate or repair as necessary or carboned heat exchanger due to incorrect combustion calibration.
Why is the SSOV Switch Open on my Aerco Boiler?
The SSOV switch might be open on your Aerco Boiler because: * Actuator not allowing for full closure of gas valve: Observe operation of the Safety Shut-Off Valve (SSOV) through indicator on the Valve actuator and ensure that the valve is fully and not partially closing. * SSOV powered when it should not be: If the SSOV never closes, it may be powered continuously. Close the gas supply and remove power from the unit. Refer fault to qualified service personnel. * Defective Switch or Actuator: Remove the electrical cover from the SSOV and check switch continuity. If the switch does not show continuity with the gas valve closed, either adjust or replace the switch or actuator. * Incorrectly wired switch: Ensure that the SSOV Proof of Closure switch is correctly wired.
What should I do if my Aerco Benchmark 1500 displays a Stepper Motor Failure?
If your Aerco Boiler displays a Stepper Motor Failure, consider the following: * Air/Fuel Valve out of calibration: Refer to GF-112 (C-More O & M) and perform the Stepper Feedback Calibration procedure in Section 6, section 6.2.1. * Air/Fuel Valve unplugged: Check that the Air/Fuel Valve is connected to the Control Box. * Loose wiring connection to the stepper motor: Inspect for loose connections between the Air/Fuel Valve motor and the wiring harness. * Defective Air/Fuel Valve stepper motor: Replace stepper motor. * Defective Power Supply Board or fuse: Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board. * Defective IGST Board: Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.
What causes a High Gas Pressure fault in my Aerco Benchmark 1500 Boiler?
A High Gas Pressure fault in your Aerco Boiler may be due to: * Incorrect supply gas pressure: Check to ensure gas pressure at inlet of SSOV does not exceed 14” W.C. * Defective SSOV Actuator: If gas supply pressure downstream of SSOV Actuator cannot be lowered to the range of 3.6” ± 0.2” W.C. for BMK1500 or 3.9” ± 0.2” W.C. for BMK2000 using the gas pressure adjustment screw (see section 4.3.1 or 4.3.2, step 10), the SSOV Actuator may be defective. * Defective High Gas Pressure Switch: Remove the leads from the high gas pressure switch. Measure continuity across the common (C) and normally closed (NC) terminals with the unit not firing. Replace the switch if continuity does not exist.
General warnings and cautions for installers and operators.
Procedure for emergency shutdown.
Recommendations for prolonged shutdown and restart.
Ensures the site selected for installation meets requirements.
Details minimum required clearances for unit installation and service.
Details water piping, gas supply piping, and related installations.
Details AC electrical power connections to the unit's power box.
Describes field wiring connections for additional control features.
Describes the C-More Control Panel, its controls, indicators, and displays.
Allows entry of unit password, date, time, and communication settings.
Permits adjustment of internal setpoint and other configuration settings.
Details the sequence of events when starting the unit.
Lists requirements for initial unit start-up, including installation and testing.
Outlines necessary tools and their attachment for combustion calibration.
Step-by-step procedure for calibrating natural gas combustion.
Describes the three types of over-temperature limit switches.
Operation based on outside air temperature to adjust supply header temperature.
Mode for a fixed header temperature, used for heat pump loops or indirect heat exchangers.
Allows setpoint control via Energy Management System (EMS) or BAS.
Periodic testing to ensure control system and safety devices operate properly.
Procedure to simulate and test the low gas pressure fault.
Procedure to simulate and test the high gas pressure fault.
Simulates flame faults during ignition or running.
Outlines routine maintenance procedures and schedules for optimal performance.
Procedures for inspecting and maintaining the igniter-injector assembly.
Detailed steps for inspecting and maintaining the burner assembly.
Maintenance procedures for inspecting and cleaning the condensate drain trap.
Introduces the guide for isolating and correcting faults in the boilers.
Provides troubleshooting information for faults not displayed with specific messages.
Guidelines for setting up the RS-232 communication link, including baud rate and data format.
How to view/change menus and data logs using RS-232 communication.
Introduces the Boiler Sequencing Technology (BST) system for efficient boiler operation.
Detailed instructions for implementing various BST options and configurations.
Descriptions of menu items available in the Operating Menu.
Descriptions of menu items available in the Setup Menu.
Descriptions of menu items available in the Configuration Menu.
Describes startup and status messages displayed on the control panel.
Lists fault messages and their descriptions for troubleshooting.
Provides resistance and voltage data for the Balco temperature sensor.
Default settings for the Setup Menu options.
Default settings for the Configuration Menu options.
Visual checks of instruments, controls, and settings.
Testing critical safety devices and interlocks.
Charts showing header temperature based on air temp and reset ratio.
Visual representations of unit dimensions and installation clearances.
Comprehensive list of all parts for the boilers.
Details connections for the control box.
Wiring diagram for the input/output box.
Visual representations of piping configurations for various setups.
Exploded and rear views of the Benchmark control panel components.
Lists of recommended emergency, maintenance, and optional spare parts.
General| Model | Benchmark 1500 |
|---|---|
| Category | Boiler |
| Input Capacity | 1500 MBH |
| Input BTU/hr | 1, 500, 000 BTU/hr |
| Efficiency | 95% |
| Fuel Type | Natural Gas or Propane |
| Heat Exchanger | Stainless Steel |
| Dimensions | Varies by model configuration; consult manufacturer specifications |
| Weight | Varies by model configuration; consult manufacturer specifications |
| Operating Pressure | 160 psi |
| Type | Condensing |
| Output BTU/h | 1, 425, 000 BTU/hr |
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