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Aerco Benchmark 2.0 User Manual

Aerco Benchmark 2.0
122 pages
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Printed in U.S.A. REVISED JUNE 14, 2010
Instruction
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
GF-123
Installation, Operation
& Maintenance Instructions
Benchmark
2.0 Low NOx
Gas Fired
Boiler System
Natural Gas or Propane Fired
Condensing, Modulating,
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Applicable for Serial Numbers G-10-0927 and above

Table of Contents

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Aerco Benchmark 2.0 Specifications

General IconGeneral
ModelBenchmark 2.0
CategoryBoiler
Fuel TypeNatural Gas or Propane
TypeCondensing
Input Capacity2, 000, 000 BTU/h
NOx Emissions<20 ppm
Operating Pressure160 psi
Vent Diameter6 inches

Summary

CHAPTER 1 SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

General warnings and cautions for safe installation and operation of the boiler unit.

1.2 EMERGENCY SHUTDOWN

Procedures for emergency shutdown and identifying critical shutoff devices.

CHAPTER 2 INSTALLATION

2.4 SITE PREPARATION

Requirements for selecting a suitable installation site, including power and gas access.

2.4.1 Installation Clearances

Minimum clearances required around the boiler for service and maintenance.

2.7 GAS SUPPLY PIPING

Guidelines for gas supply piping design, installation, and safety precautions.

2.8 AC ELECTRICAL POWER WIRING

Instructions for connecting AC power wiring to the unit, consulting wiring guides.

2.12 FLUE GAS VENT INSTALLATION

Guidelines for flue gas vent and combustion air system design and installation.

2.13 COMBUSTION AIR

Requirements for supplying combustion air, including types and locations.

CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES

3.3 CONTROL PANEL MENUS

Explanation of the menu structure, options, and password protection.

3.3.1 Menu Processing Procedure

Step-by-step guide on navigating and using the control panel menus.

3.6 CONFIGURATION MENU

Explanation of the Configuration Menu for adjusting operating parameters.

3.8 COMBUSTION CAL MENU

Details on the Combustion Calibration Menu for optimizing efficiency.

3.9 START SEQUENCE

Step-by-step description of the boiler's start sequence and safety checks.

CHAPTER 4 INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

Key requirements for initial start-up, including installation and calibration.

4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION

List of necessary tools and instruments for performing combustion calibration.

4.3 NATURAL GAS COMBUSTION CALIBRATION

Procedure for performing natural gas combustion calibration and verifying readings.

4.4 PROPANE COMBUSTION CALIBRATION

Procedure for performing propane combustion calibration, similar to natural gas.

4.6 OVER-TEMPERATURE LIMIT SWITCHES

Description of automatic and manual reset over-temperature limit switches.

CHAPTER 5 MODE OF OPERATION

CHAPTER 6 SAFETY DEVICE TESTING

6.1 TESTING OF SAFETY DEVICES

Importance of periodic testing for controls and safety devices to ensure proper operation.

6.2 LOW GAS PRESSURE FAULT TEST

Procedure to simulate and test the low gas pressure fault condition.

6.3 HIGH GAS PRESSURE TEST

Procedure to simulate and test the high gas pressure fault condition.

6.4 LOW WATER LEVEL FAULT TEST

Procedure to simulate and test the low water level fault condition.

6.5 WATER TEMPERATURE FAULT TEST

Procedure to simulate and test high water temperature fault conditions.

6.7 FLAME FAULT TESTS

Procedures to simulate and test flame faults during ignition and run.

6.8 AIR FLOW FAULT TESTS

Tests for blower proof switch and blocked inlet switch operation.

CHAPTER 7 MAINTENANCE

Chapter 8- TROUBLESHOOTING GUIDE

CHAPTER 9 RS232 COMMUNICATION

APPENDIX H

APPENDIX I RECOMMENDED PERIODIC TESTING CHECK LIST

WARNING

Safety precautions to be observed during testing and maintenance.

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