AERCO Boiler Benchmark 3.0

Instruction
No.
GF-116
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
Benchmark 3.0LN
Series
Gas Fired
Low NOx
Boiler System
Condensing, Modulating
Forced Draft, Hot Water Boiler
3,000,000 BTU/H Input
Applicable for Serial Numbers G-10-1031 and above
Printed in U.S.A. REVISED JUNE 15, 2010

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

installation, operation and mainte-
nance manual is subject to
change without notice from
AERCO International, Inc.
AERCO makes no warranty of any
kind with respect to this material,
including but not limited to implied
warranties of merchantability and
fitness for a particular application.
AERCO International is not liable
AERCO International, Inc. for errors appearing in this
159 Paris Avenue manual. Nor for incidental or
Northvale, NJ 07647-0128 consequential damages occurring
www.aerco,com in connection with the furnishing,
performance, or use of this
material.
© AERCO International, Inc., 2010
CONTENTS
GF-116 - AERCO BENCHMARK 3.0LN GAS FIRED LOW NOx BOILER

Operating & Maintenance Instructions
FOREWORD A
Chapter 1 – SAFETY PRECAUTIONS 1-1
Para. Subject Page Para. Subject Page

1-1 Warnings & Cautions 1-1 1-3 Prolonged Shutdown 1-2
1-2 Emergency Shutdown 1-2
Chapter 2 – INSTALLATION 2-1

2.1 Introduction 2-1 2.9 Modes of Operation and Field 2-7
2.2 Receiving the Unit 2-1 Control Wiring
2.3 Unpacking 2-1 2.10 I/O Box Connections 2-9
2.4 Site Preparation 2-1 2.11 Auxiliary Relay Contacts 2-11
2.5 Supply and Return Piping 2-3 2.12 Flue Gas Vent Installation 2-11
2.6 Condensate Drains 2-3 2.13 Combustion Air 2-11
2.7 Gas Supply Piping 2-5
2.8 AC Electrical Power Wiring 2-6
Chapter 3 – CONTROL PANEL OPERATING PROCEDURES 3-1

3.1 Introduction 3-1 3.6 Configuration Menu 3-6
3.2 Control Panel Description 3-1 3.7 Tuning Menu 3-8
3.3 Control Panel Menus 3-4 3.8 Combustion Cal Menu 3-8
3.4 Operating Menu 3-5 3.9 Start Sequence 3-8
3.5 Setup Menu 3-5 3.10 Start/Stop Levels 3-10
Chapter 4 – INITIAL START-UP 4-1

4.1 Initial Startup Requirements 4-1 4.4 Unit Reassembly 4-6
4.2 Tools and Instruments for 4-1 4.5 Over-Temperature Limit Switch 4-6
Combustion Calibration
4.3 Natural Gas Combustion 4-2
Calibration
i
CONTENTS
Chapter 5 – MODE OF OPERATION 5-1

5.1 Introduction 5-1 5.6 Boiler Management System 5-4
5.2 Indoor/Outdoor Reset Mode 5-1 (BMS)
5.3 Constant Setpoint Mode 5-2 5.7 Combination Control System 5-5
5.4 Remote Setpoint Mode 5-2 (CCS)
5.5 Direct Drive Modes 5-3
Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1

6.1 Testing of Safety Devices 6-1 6.8 Air Flow Fault Test 6-4
6.2 Low Gas Pressure Fault Test 6-1 6.9 SSOV Proof of Closure Switch 6-4
6.3 High Gas Pressure Test 6-2 6.10 Purge Switch Open During 6-5
6.4 Low Water Level Fault Test 6-2 Purge
6.5 Water Temperature Fault Test 6-2 6.11 Ignition Switch Open During 6-5
6.6 Interlock Tests 6-3 Ignition
6.7 Flame Fault Test 6-3 6.12 Safety Pressure Relief Valve 6-6
Test
Chapter 7 – MAINTENANCE REQUIREMENTS 7-1

7.1 Maintenance Schedule 7-1 7.7 Condensate Drain Trap 7-4
7.2 Ignitor-Injector 7-1 7.8 Shutting the Boiler Down For An 7-6
7.3 Flame Detector 7-2 Extended Period of Time
7.4 Combustion Calibration 7-3 7.9 Placing The Boiler Back In 7-6
7.5 Safety Device Testing 7-3 Service After A Prolonged
7.6 Burner Assembly Inspection 7-3 Shutdown
Chapter 8 – TROUBLESHOOTING GUIDE 8-1

8.1 Introduction 8-1
ii
CONTENTS
Chapter 9 - RS232 COMMUNICATION 9-1

9.1 Introduction 9-1 9-3 Menu Processing Utilizing 9-1
9-2 RS232 Communication Setup 9-1 RS232 Communication
9-4 Data Logging 9-2
APPENDICES
App Subject Page App Subject Page

A Boiler Menu Item Descriptions A-1 G Piping Drawings G-1
B Startup, Status and Fault B-1 H Wiring Schematics H-1
Messages I Recommended Periodic Testing I-1
C Temperature Sensor Resistance C-1 Checklist
Chart J Benchmark Control Panel Views J-1
D Indoor/Outdoor Reset Ratio D-1 K Recommended Spare Parts K-1
Charts
E Boiler Default Settings E-1
F Dimensional and Part Drawings F-1
WARRANTIES W-1
iii
FOREWORD
Foreword
The AERCO Benchmark 3.0LN Boiler is a modulating unit. It represents a true industry advance
that meets the needs of today's energy and environmental concerns. Designed for application
in any closed loop hydronic system, the Benchmark's modulating capability relates energy input
directly to fluctuating system loads. The Benchmark 3.0, with its 15:1 turn down ratio and
condensing capability, provides extremely high efficiencies and makes it ideally suited for
modern low temperature, as well as, conventional heating systems.
The Benchmark 3.0 operates at inputs ranging from 200,000 BTU/hr. to 3,000,000 BTU/hr. The
output of the boiler is a function of the unit’s firing rate and return water temperature. Output
ranges from 198,000 BTU/hr. to 2,900,000 BTU/hr., depending on operating conditions.
When installed and operated in accordance with this Instruction Manual, the Benchmark 3.0
Boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.1
Whether used in singular or modular arrangements, the Benchmark 3.0 offers the maximum
flexibility in venting with minimum installation space requirements. The Benchmark's advanced
electronics are available in several selectable modes of operation offering the most efficient
operating methods and energy management system integration.
For service or parts, contact your local sales representative or AERCO INTERNATIONAL.
NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________
A
SAFETY PRECAUTIONS
CHAPTER 1 SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS WARNING!

Installers and operating personnel MUST, at all DO NOT USE MATCHES, CANDLES,
times, observe all safety regulations. The FLAMES, OR OTHER SOURCES OF
following warnings and cautions are general and IGNITION TO CHECK FOR GAS
must be given the same attention as specific LEAKS.
precautions included in these instructions. In
addition to all the requirements included in this WARNING!
AERCO Instruction Manual, the installation of
FLUIDS UNDER PRESSURE MAY
units MUST conform with local building codes,
or, in the absence of local codes, ANSI Z223.1 CAUSE INJURY TO PERSONNEL
(National Fuel Gas Code Publication No. NFPA- OR DAMAGE TO EQUIPMENT
54). Where ASME CSD-1 is required by local WHEN RELEASED. BE SURE TO
jurisdiction, the installation must conform to SHUT OFF ALL INCOMING AND
CSD-1. OUTGOING WATER SHUTOFF
VALVES. CAREFULLY DECREASE
Where applicable, the equipment shall be ALL TRAPPED PRESSURES TO
installed in accordance with the current ZERO BEFORE PERFORMING
Installation Code for Gas Burning Appliances
MAINTENANCE.
and Equipment, CGA B149, and applicable
Provincial regulations for the class; which should
WARNING!
be carefully followed in all cases. Authorities
having jurisdiction should be consulted before ELECTRICAL VOLTAGES UP TO
installations are made. 120 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE
COVER ON THE UNIT’S POWER
IMPORTANT BOX (LOCATED BEHIND THE
This Instruction Manual is an integral FRONT PANEL DOOR) MUST BE
part of the product and must be INSTALLED AT ALL TIMES, EXCEPT
maintained in legible condition. It must DURING MAINTENANCE AND
be given to the user by the installer SERVICING.
and kept in a safe place for future
reference. CAUTIONS!
Must be observed to prevent
WARNINGS!
equipment damage or loss of
MUST BE OBSERVED TO PREVENT operating effectiveness.
SERIOUS INJURY.
CAUTION!
WARNING!
Many soaps used for gas pipe leak
BEFORE ATTEMPTING TO PER- testing are corrosive to metals. The
FORM ANY MAINTENANCE ON THE piping must be rinsed thoroughly with
UNIT, SHUT OFF ALL GAS AND clean water after leak checks have
ELECTRICAL INPUTS TO THE UNIT. been completed.
WARNING! CAUTION!
THE EXHAUST VENT PIPE OF THE DO NOT use this boiler if any part has
UNIT OPERATES UNDER A been under water. Call a qualified
POSITIVE PRESSURE AND THERE- service technician to inspect and
FORE MUST BE COMPLETELY replace any part that has been under
SEALED TO PREVENT LEAKAGE water.
OF COMBUSTION PRODUCTS INTO
LIVING SPACES.
1-1
SAFETY PRECAUTIONS
1.2 EMERGENCY SHUTDOWN

If overheating occurs or the gas supply fails to
shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
IMPORTANT MANUAL GAS SHUTOFF VALVE

The Installer must identify and indicate
the location of the emergency shutdown
manual gas valve to operating personnel.
VALVE OPEN VALVE CLOSED
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended
that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of
this manual be performed, to verify all system-
operating parameters. If there is an emergency,
turn off the electrical power supply to the
AERCO boiler and close the manual gas valve
located upstream the unit. The installer must
identify the emergency shut-off device. Figure 1-1
Manual Gas Shutoff Valve
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY

Boiler Installations within the Commonwealth of Massachusetts must conform to the following
requirements:
• Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of
Massachusetts.
• Prior to unit operation, the complete gas train and all connections must be leak tested using a
non-corrosive soap.
• If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed
upstream of the Fill/Makeup Valve.
• The vent termination must be located a minimum of 4 feet above grade level.
• If side-wall venting is used, the installation must conform to the following requirements extracted
from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or
structure used in whole or in part for residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above
finished grade in the area of the venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the

side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe
that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the
floor level where the gas equipment is to be installed. In addition, the installing plumber or
gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for the installation of hard wired carbon
monoxide detectors.
1-2
SAFETY PRECAUTIONS
Extracted Information From 248 CMR 5.08 (2) – Continued
a. In the event that the side wall horizontally vented gas fueled equipment is installed in
a crawl space or an attic, the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as

required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior
of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust
vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign
shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the
most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or
structure separate from the dwelling, building or structure used in whole or in part for residential
purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When

the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting
system design or venting system components with the equipment, the instructions provided by the
manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system
components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does
not provide the parts for venting the flue gases, but identifies "special venting systems", the following
requirements shall be satisfied by the manufacturer:
1. The identification of each "special venting system" shall include the listing of either the
website, phone number or manufacturer’s address where the venting system installation
instructions can be obtained, and
2. The "special venting systems" shall be Product Approved by the Board, and the instructions
for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for the Product Approved side wall horizontally vented gas fueled
equipment and all the venting instructions, parts lists and/or design instructions for the venting system
shall remain with the appliance or equipment at the completion of the installation.
_______________________________ [End of Extracted Information From 248 CMR 5.08 (2)]
1-3
INSTALLATION
CHAPTER 2 INSTALLATION
2.1 INTRODUCTION • Pressure/Temperature Gauge

This Chapter provides the descriptions and • Spare Ignitor-Injector
procedures necessary to unpack, inspect and
install the AERCO Benchmark 3.0 Boiler. Brief • Spare Flame Detector
descriptions are also provided for each available
• ASME Pressure Relief Valve
mode of operation. Detailed procedures for
implementing these modes are provided in • Condensate Drain Trap & Adapter `
Chapter 5.
• 2” Gas Supply Shutoff Valve
2.2 RECEIVING THE UNIT When ordered, optional accessories may be
Each Benchmark 3.0 System is shipped as a packed separately, packed within the boiler
single crated unit. The shipping weight is shipping container, or may be installed on the
approximately 2,170 pounds. The unit must be boiler. Any standard or optional accessories
moved with the proper rigging equipment for shipped loose should be identified and stored in
safety and to avoid equipment damage. The unit a safe place until ready for installation or use.
should be completely inspected for evidence of
shipping damage and shipment completeness at 2.4 SITE PREPARATION.
the time of receipt from the carrier and before Ensure that the site selected for installation of
the bill of lading is signed. the Benchmark 3.0 Boiler includes:
NOTE • Access to AC Input Power corresponding to

the ordered power configuration. The
AERCO is not responsible for lost or
available power configurations are:
damaged freight.
• 208 VAC, 3-Phase, 60 Hz @ 20 A
Each unit has a Tip-N-Tell indicator on the • 460 VAC, 3-Phase, 60 Hz @ 15 A
outside of the crate. This indicates if the unit has
• Access to Natural Gas line at a minimum
been turned on its side during shipment. If the
static pressure of 3.5” W.C.(FM) or 4.0” W.C.
Tip-N-Tell indicator is tripped, do not sign for the
(IRI). Maximum static pressure must not
shipment. Note the information on the carrier’s
exceed 2 psi.
paperwork and request a freight claim and
inspection by a claims adjuster before 2.4.1 Installation Clearances
proceeding. Any other visual damage to the The unit must be installed with the prescribed
packaging materials should also be made clear clearances for service as shown in Figure 2-1.
to the delivering carrier. The minimum clearance dimensions, required by
AERCO, are listed below. However, if Local
2.3 UNPACKING
Building Codes require additional clearances,
Carefully unpack the unit taking care not to these codes shall supersede AERCO’s
damage the unit enclosure when cutting away requirements. Minimum acceptable clearances
packaging materials required are:
A close inspection of the unit should be made to • Sides: 24 inches
ensure that there is no evidence of damage not
indicated by the Tip-N-Tell indicator. The freight • Front : 24 inches
carrier should be notified immediately if any
• Rear: 43 inches
damage is detected.
• Top: 18 inches
The following accessories come standard with
each unit and are either packed separately All gas piping, water piping and electrical conduit
within the unit’s packing container or are factory or cable must be arranged so that they do not
installed on the boiler: interfere with the removal of any panels, or
inhibit service or maintenance of the unit.
2-1
INSTALLATION
Figure 2-1 Benchmark 3.0 Boiler Clearances
WARNING Remove the four (4) lag screws securing the unit
KEEP THE UNIT AREA CLEAR AND to the shipping skid. Lift the unit off the shipping
FREE FROM ALL COMBUSTIBLE skid and position it on the 4 inch to 6 inch
MATERIALS AND FLAMMABLE housekeeping concrete pad (required) in the
desired location.
VAPORS OR LIQUIDS.
BURNER
ASSEMBLY
CAUTION
While packaged in the shipping LIFTING LIFTING
container, the boiler must be moved TAB 1 TAB 2
by pallet jack or forklift from the
FRONT ONLY. LIFTING
TAB 3
FOR MASSACHUSETTS ONLY

For Massachusetts installations, the PRIMARY HEAT
boiler must be installed by a plumber EXCHANGER
or gas fitter who is licensed within the Figure 2-2
Commonwealth of Massachusetts. In Lifting Lug Locations
addition, the installation must comply
with all requirements specified in In multiple unit installations, it is important to
Chapter 1 (Safety Precautions), pages plan the position of each unit in advance.
1-2 & 1-3. Sufficient space for piping connections and
future service/maintenance requirements must
also be taken into consideration. All piping must
2.4.2 Setting the Unit include ample provisions for expansion.
The unit must be installed on a 4 inch to 6 inch
housekeeping pad to ensure proper condensate If installing a Combination Control Panel (CCP)
drainage. If anchoring the unit, refer to the system, it is important to identify the
dimensional drawings in Appendix F for anchor Combination Mode Boilers in advance and place
locations. A total of 3 lifting tabs are provided at them in the proper physical location. Refer to
the top of the primary heat exchanger as shown Chapter 5 for information on Combination Mode
in Figure 2-2. However, USE ONLY TABS 1 Boilers.
AND 2 SHOWN IN FIGURE 2-2 TO MOVE THE
ENTIRE UNIT. Tabs 1 and 3 are used only
when removing or replacing the unit’s primary
heat exchanger. Remove the front top panel
from the unit to provide access to the lifting tabs.
2-2
INSTALLATION
2.4.3 Removal of Support Rod This can be easily accomplished by removing

the top panel nearest to the front of the unit.
Prior to installation of water supply and return
piping, the 24” threaded rod shown in Figure 2-3 2.5 SUPPLY AND RETURN PIPING
must be removed. This rod is installed prior to
The Benchmark 3.0 Boiler utilizes 4” 150#
shipment from the factory to prevent damage to
flanges for the water system supply and return
the insulated metal flex hose on the hot water
piping connections. The physical location of the
supply outlet of the boiler. In order to install the
supply and return piping connections are on the
water supply piping, this rod must be removed
rear of the unit as shown in Figure 2-4. Refer to
as follows:
Appendix F, Drawing AP-A-811 for additional
dimensional data.
1. Refer to Figure 2-3 and back off the hex nut
on the outlet side of the flex hose. BOILER SUPPLY
4" – 150# FLANGED
CONNECTION
2. Next, disconnect the coupling nut from the
flange stud.
3. Completely remove the threaded rod, hex
BOILER RETURN
nut and coupling nut from the boiler. EXHAUST
4" – 150# FLANGED
CONNECTION
MANIFOLD
5/8-11 x 24" LONG 5/8-11 5/8-11
THREADED ROD HEX NUT COUPLING NUT
OUTLET
FLANGE
SHELL DRAIN
VALVE
INSULATED
FLEX HOSE 2" GAS INLET
(SEE IMPORTANT CONNECTION
NOTE BELOW)
EXHAUST
MANIFOLD
REAR VIEW
PARTIAL TOP VIEW - REAR
Figure 2-4
Figure 2-3 Supply and Return Locations
Location of Threaded Support Rod
2.6 CONDENSATE DRAINS
IMPORTANT The Benchmark 3.0 Boiler is designed to
THE INSULATED FLEX HOSE condense water vapor from the flue products.
SHOWN IN FIGURE 2-3 MUST BE Therefore, the installation must have provisions
LEVEL OR SLOPING UPWARD AS for suitable condensate drainage or collection.
IT EXITS THE BOILER. FAILURE TO Two condensate drain connections are provided
PROPERLY POSITION THIS HOSE on the rear of the unit as shown in Figure 2-5.
MAY CAUSE INEFFECTIVE AIR One drain connection is located on the exhaust
ELIMINATION RESULTING IN ELE- manifold and the other is located on the
VATED TEMPERATURES THAT connecting manifold.
COULD COMPROMISE THE TOP
The drain at the bottom of the exhaust manifold
HEAD GASKET. also includes a condensate trap containing a
2.4.4 Removal of Strap and Packing float assembly. When condensate collects in the
exhaust manifold, the float rises, thereby
Material From Heat Exchanger
allowing it to discharge through the drain
Prior to connecting the external gas supply or opening. The drain pipe located on the
electrical power to the unit. the strap and connecting manifold must be connected to a
packing material must be removed from the top second condensate trap which is packed
of the primary heat exchanger. This material is separately within the unit’s shipping container.
located in the area of the ignitor-injector and
staged ignition solenoid on the burner assembly
2-3
INSTALLATION
The procedures to install and connect both of 2.6.2 Connecting Manifold Condensate
the condensate drains are provided in Drain
paragraphs 2.6.1 and 2.6.2.
The connecting manifold drain pipe shown in
Figure 2-5, View B – B must be connected to a
separate condensate drain trap external to the
unit. This condensate trap (part no. 24060) is
supplied with the unit along with a trap adapter
EXHAUST
MANIFOLD and a 3/4” NPT x 5” long nipple. Refer to Figure
A 2-6 and install the trap as follows:
NOTE
CONDENSATE
The condensate trap described in the
TRAP following steps can be installed on the
DRAIN
A floor behind the unit as shown in Figure 2-
6. Ensure that the condensate trap inlet is
SHELL DRAIN level with or below the connecting
VALVE
manifold drain pipe. Ensure that the outlet
B hose from the trap slopes away (down)
CONNECTING
MANIFOLD
from the trap.
1. Apply Teflon tape to the threads of the 3/4” x

DRAIN
5” long nipple provided with the boiler.
B
2. Attach the 3/4” NPT nipple between the
REAR VIEW
condensate trap inlet and the trap adaptor
UNIT (Figure 2-6).
UNIT FRAME
EXHAUST FRAME 3. Attach another 3/4” NPT nipple (not sup-
MANIFOLD SHELL plied) to the condensate trap outlet on the
lower part of the trap.
CONDENSATE DRAIN
4. Connect the condensate trap and adaptor to
TRAP VALVE the connecting manifold drain pipe. Position
DRAIN
CONNECTING
the trap so it is level and then tighten the
HOSE
CLAMP MANIFOLD thumb screw on the adaptor.
1" I.D. TO
HOSE CONDENSATE 5. Place a suitable support under the
TRAP condensate trap to maintain the trap in the
TO FLOOR
DRAIN
CONDENSATE level position.
DRAIN PIPE
VIEW “A - A” VIEW “B - B” 6. Connect a length of 1” I.D. polypropylene hose

to the outlet side of the condensate trap and
Figure 2-5 route it to a nearby floor drain.
Condensate Drain Connection Location
If desired, a Tee fitting may be used to connect the
two drain hoses from the exhaust manifold and the
2.6.1 Exhaust Manifold Condensate outlet side of the of the condensate trap attached to
Drain the connecting manifold.
Refer to Figure 2-5, View A – A and install as
follows: If a floor drain is not available, a condensate pump
can be used to remove the condensate to drain.
1. Connect a length of 1 inch I.D. hose (part no. The maximum condensate flow rate is 20 GPH.
91030) to the drain on the exhaust manifold The condensate drain trap, associated fittings and
and secure it in place with a hose clamp. drain lines must be removable for routine
maintenance.
2. Route the hose to a nearby floor drain.
2-4
INSTALLATION
A suitable piping compound, approved for use

with natural gas, should be used. Any excess
CONNECTING
must be wiped off to prevent clogging of
CONDENSATE
MANIFOLD components.
TRAP
ADAPTOR To avoid unit damage when pressure testing gas
piping, isolate the unit from the gas supply
CLAMP piping. At no time should the gas pressure
applied to the unit exceed 2 psi. Leak test all
TO
FLOOR
DRAIN
external piping thoroughly using a soap and
DRAIN
PIPE water solution or suitable equivalent. The gas
1" I.D. 3/4" NPT
piping used must meet all applicable codes.
HOSE NIPPLES
2.7.1 Gas Supply Specification
The gas supply input specifications to the unit
Figure 2-6 for Natural Gas are as follows:
Condensate Trap Installation
The maximum static pressure to the unit must
not exceed 2 psi. The gas supply pressure to the
2.7 GAS SUPPLY PIPING unit must be of sufficient capacity to provide
The AERCO Benchmark 3.0 Gas Components 3000 cfh while maintaining the gas pressure at
and Supply Design Guide, GF-3030 must be 3.5” W.C. for FM or 4.0” for IRI gas trains.
consulted prior to designing or installing any gas
supply piping. 2.7.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the
gas supply line upstream of the Boiler as shown
WARNING in Figure 2-7. Maximum allowable gas pressure
NEVER USE MATCHES, CANDLES, to the Boiler is 2 psi
FLAMES OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS NOTE
LEAKS. Paragraph 2.7.3 applies only to bolier
installations within the Commonwealth of
CAUTION Massachusetts.
Many soaps used for gas pipe leak
testing are corrosive to metals. There- 2.7.3 External Gas Supply Regulator
fore, piping must be rinsed thoroughly For Massachusetts installations, a mandatory
with clean water after leak checks external gas supply regulator must be positioned
as shown in Figure 2-7. The gas supply
have been completed.
regulator must be properly vented to outdoors.
Consult the local gas utility for detailed
NOTE requirements concerning venting of the the
All gas piping must be arranged so that it supply gas regulator.
does not interfere with removal of any
covers, inhibit service/maintenance, or
restrict access between the unit and NOTE
walls, or another unit. The external regulator must be capable of
regulating 3,00,000 BTU/HR of natural
A 2 inch gas inlet connection is located on the gas while maintaining a gas pressure to
rear of the unit as shown in Figure 2-4. the boiler of 3.5” W.C. for FM or 4.0” W.C.
for IRI gas trains.
Prior to installation, all pipes should be de-
burred and internally cleared of any scale, metal
chips or other foreign particles. Do Not install CAUTION
any flexible connectors or unapproved gas
fittings. Piping must be supported from the floor,
A lock-up style regulator MUST be
ceiling or walls only and must not be supported used when gas supply pressure will
by the unit. exceed 14” W.C.
2-5
INSTALLATION
TERMINAL BLOCK
NATURAL
GAS
SUPPLY
2" MANUAL
SHUTOFF
VALVE
UPPER RIGHT CORNER OF FRONT PANEL

MANDATORY
REGULATOR FOR
MASSACHUSSETTS
INSTALLATIONS ONLY
DIRT
TRAP
Figure 2-8
AC Input Terminal Block Location
Figure 2-7
Manual Gas Shut-Off Valve Location 2.8.1 Electrical Power Requirements
The AERCO Benchmark 3.0 Boiler is available
in two different AC power configurations:
2.7.4 IRI Gas Train Kit
The IRI gas train is an optional gas train • 208 VAC/3-Phase/60 @20 amps
configuration which is required in some areas for
• 460 VAC/3-Phase/60 Hz @ 15 amps
code compliance or for insurance purposes.
The IRI gas train is factory pre-piped and wired. Each of the power configurations utilize a Power
See Appendix F, Drawing AP-A-803 for details. Box with a terminal block that matches the
configuration ordered. The two different terminal
2.8 AC ELECTRICAL POWER WIRING block configurations are shown in Figure 2-9. A
The AERCO Benchmark 3.0 Electrical Power wiring diagram showing the required AC power
Wiring Guide, GF-3060, must be consulted prior connections is provided on the front cover of the
to connecting any AC power wiring to the unit. Power Box.
External AC power connections are made to the
unit inside the Power Box on the front panel of Each Benchmark 3.0 Boiler must be connected
the unit. Remove the front door of the unit to to a dedicated electrical circuit. NO OTHER
access the Power Box mounted directly above DEVICES SHOULD BE ON THE SAME
the Control Box. Loosen the four Power Box ELECTRICAL CIRCUIT AS THE BENCHMARK
cover screws and remove cover to access the BOILER. A means for disconnecting AC power
AC terminal connections inside the Power Box from the unit (such as a service switch) must be
(Figure 2-8). installed near the unit for normal operation and
maintenance. All electrical connections should
NOTE be made in accordance with the National
Electrical Code and/or with any applicable local
All electrical conduit and hardware must codes.
be installed so that it does not interfere
with the removal of any unit covers, inhibit For electrical power wiring diagrams, see the
service/maintenance, or prevent access AERCO Benchmark 3.0 Electrical Power Wiring
between the unit and walls or another Guide, (GF-3060).
unit.
2-6
INSTALLATION
208 VAC, 3 PHASE 460 VAC, 3 PHASE

TERMINAL
STRIPS
GND GND
NEU
L3 L3
L2 L2
L1 L1
208 VAC, 3 Phase 460 VAC, 3 Phase
Figure 2-9
AC Terminal Block Configurations
LOWER RIGHT CORNER

2.9 MODES OF OPERATION AND FIELD OF FRONT PANEL
CONTROL WIRING
Figure 2-10.
The Benchmark 3.0 Boiler is available in several
different modes of operation. While each unit is
Input/Output (I/O) Box Location
factory configured and wired for its intended
mode, some additional field wiring may be Refer to the wiring diagram provided on the
required to complete the installation. This wiring cover of the I/O Box (Figure 2-11) when making
is typically connected to the Input/Output (I/O) all wiring connections.
Box located on the lower portion of the unit front
panel (Figure 2-10) behind the removable front
door. Brief descriptions of each mode of operation,
and their wiring requirements, are provided in
To access the I/O Box terminal strips shown in the following paragraphs. Additional information
Figure 2-10, loosen the four cover screws and concerning field wiring is provided in paragraphs
remove the cover. All field wiring is installed 2.9.1 through 2.9.9. Refer to Chapter 5 for
from the rear of the panel by routing the wires detailed information on the available modes of
through one of the four bushings provided. operation
2-7
INSTALLATION
OUTDOOR SENSOR IN
REMOTE INTL'K IN
SENSOR COMMON
(AIR) AUX SENSOR IN
EXHAUST SWITCH IN
DELAYED INTL'K IN
NOT USED NOT USED
NC
COM FAULT RELAY
NO 120 VAC, 5A, RES
+ NC
ANALOG IN- COM AUX RELAY
+ NO 120 VAC, 5A, RES
B.M.S. (PWM) IN -
SHIELD NOT USED
+ RELAY CONTACTS:
mA OUT
- 120 VAC, 30 VDC
+ 5 AMPS RESISTIVE
RS-485
G
COMM.
- DANGER
NOT USED 120 VAC USED
0 – 10V IN THIS BOX
AGND
Figure 2-11. I/O Box Terminal Strip
2.9.1 Constant Setpoint Mode utilize either pulse width modulation (PWM)
signaling, or RS485 Modbus signaling. For PWM
The Constant Setpoint Mode is used when it is signaling, connections are made from the
desired to have a fixed setpoint that does not AERCO Boiler Management System to the
deviate. No wiring connections, other than AC B.M.S. (PWM) IN terminals on the I/O Box
electrical power connections, are required for terminal strip. For RS485 Modus signaling,
this mode. However, if desired, fault monitoring connections are made from the BMS to the
or enable/disable interlock wiring can be utilized RS485 COMM terminals on the I/O Box terminal
(see paragraphs 2.9.9.1 and 2.9.10). strip. Polarity must be maintained and the shield
must be connected only at the AERCO BMS.
2.9.2 Indoor/Outdoor Reset Mode
The boiler end of the shield must be left floating.
This mode of operation increases supply water For additional instructions, refer to Chapter 5,
temperature as outdoor temperatures decrease. paragraph 5.6 in this manual. Also, refer to GF-
An outside air temperature sensor (AERCO Part 108M (BMS Model 168) and GF-124 (BMS II
No. 122790) is required. The sensor MUST BE Model 5R5-384), BMS -Operations Guides.
wired to the I/O Box wiring terminals (see Figure
2-11). Refer to paragraph 2.10.1 for additional
information on outside air temperature sensor 2.9.4 Remote Setpoint and Direct Drive
installation. Modes
2.9.3 Boiler Management System Mode The Benchmark 3.0 Boiler can accept several
types of signal formats from an Energy
NOTE Management System (EMS), Building
BMS Model 168 can utilize either pulse Automation System (BAS) or other source, to
width modulation (PWM) or RS485 control either the setpoint (Remote Setpoint
Modbus signaling to the Boiler. BMS II Mode) or firing rate (Direct Drive Mode) of the
Model 5R5-384 can utilize only RS485 Boiler. These formats are:
signaling to the Boiler. • 4 to 20 mA/1 to 5 VDC
When using an AERCO Boiler Management • 0 to 20 mA/0 to 5 VDC
System (BMS), the field wiring is connected • PWM – (Pulse Width Modulated signal. See
between the BMS Panel and each Boiler’s I/O para. 2.10.4)
Box terminal strip (Figure 2-11). Twisted
shielded pair wire from 18 to 22 AWG must be • Network (RS485 Modbus. See para. 2.10.8)
utilized for the connections. The BMS Mode can
2-8
INSTALLATION
While it is possible to control a boiler or boilers SENSOR IN and SENSOR COMMON terminals
using one of the previously described modes of in the I/O Box (see Figures 2-10 and 2-11). Wire
operation, it may not be the method best suited the sensor using a twisted shielded pair wire
for the application. Prior to selecting one of from 18 to 22 AWG. There is no polarity to
these modes of operation, it is recommended observe when terminating these wires. The
that you consult with your local AERCO shield is to be connected only to the terminals
representative or the factory for the mode of labeled SHIELD in the I/O Box. The sensor end
operation that will work best with your of the shield must be left free and ungrounded.
application. For more information on wiring the
4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5 When mounting the sensor, it must be located
VDC, see paragraph 2.9.3. on the North side of the building where an
average outside air temperature is expected.
The sensor must be shielded from direct sunlight
2.9.5 Combination Mode as well as impingement by the elements. If a
shield is used, it must allow for free air
NOTE circulation.
Only BMS Model 168 can be utilized for
the Combination Mode, not the BMS II 2.10.2 AIR SENSOR IN
(Model 5R5-384). The AIR SENSOR IN is connected to the AUX
SENSOR IN and SENSOR COMMON terminals
With a Combination Mode unit, field wiring is on the I/O board. The AIR SENSOR measures
between the unit’s I/O Box wiring terminals, the the temperature of the air input to the Air/Fuel
CCP (Combination Control Panel), and the BMS Valve. This temperature reading is one of the
Model 168 (Boiler Management System). The components used to calculate the rotational
wiring must be accomplished using twisted- speed of the blower used in the combustion
shielded pair wire from 18 to 22 AWG. Polarity Calibration process (Chapter 4).
must be maintained. For further instructions and
wiring diagrams, refer to the GF-108 Boiler The AUX SENSOR IN terminals can be used to
Management System Operations Guide and the add an additional temperature sensor for
CCP-1 data sheet. monitoring purposes. This input is always
enabled and is a view-only input that can be
2.10 I/O BOX CONNECTIONS seen in the Operating Menu. The sensor must
The types of input and output signals and be wired to the AUX SENSOR IN and SENSOR
devices to be connected to the I/O Box terminals COMMON terminals and must be similar to
shown in Figure 2-11 are described in the AERCO BALCO wire sensor Part No. 12449. A
following paragraphs. resistance chart for this sensor is provided in
Appendix C.
CAUTION
DO NOT make any connections to the 2.10.3 ANALOG IN
I/O Box terminals labeled “NOT The ANALOG IN + and – terminals are used
USED”. Attempting to do so may when an external signal is used to drive the
firing rate (Direct Drive Mode) or change the
cause equipment damage.
setpoint (Remote Setpoint Mode) of the Boiler.
2.10.1 OUTDOOR SENSOR IN Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA
An outdoor air temperature sensor (AERCO Part / 0 to 5 VDC signal may be used to vary the
No. 122790) will be required primarily for the setpoint or firing rate. The factory default setting
Indoor/Outdoor reset mode of operation. It can is for 4 to 20 mA / 1 to 5 VDC, however this may
also be used with another mode if it is desired to be changed to 0 to 20 mA / 0 to 5 VDC using the
use the outdoor sensor enable/disable feature. Configuration Menu described in Chapter 3. If
This feature allows the boiler to be enabled or voltage rather than current is selected as the
disabled based on the outdoor air temperature. drive signal, a DIP switch must be set on the
PMC Board located inside the Control Box.
The factory default for the outdoor sensor is Contact the AERCO factory for information on
DISABLED. To enable the sensor and/or select setting DIP switches.
an enable/disable outdoor temperature, see the
Configuration menu in Chapter 3. All of the supplied signals must be floating
(ungrounded) signals. Connections between the
The outdoor sensor may be wired up to 200 feet signal source and the Boiler’s I/O Box must be
from the boiler. It is connected to the OUTDOOR made using twisted shielded pair wire from 18 to
2-9
INSTALLATION
22 AWG, such as Belden 9841 (see 2.10.9 EXHAUST SWITCH IN

Figure 2-11). Polarity must be maintained. The These terminals permit an external exhaust
shield must be connected only at the source end switch to be connected to the exhaust manifold
and must be left floating (not connected) at the of the boiler. The exhaust switch should be a
Boiler’s I/O Box. normally open type switch (such as AERCO Part
Regardless of whether voltage or current is used No. 123463) that closes (trips) at 500°F.
for the drive signal, they are linearly mapped to
2.10.10 INTERLOCKS
a 40°F to 240°F setpoint or a 0% to 100% firing
rate. No scaling for these signals is provided The unit offers two interlock circuits for
interfacing with Energy Management Systems
2.10.4 B.M.S. (PWM) IN and auxiliary equipment such as pumps or
louvers. These interlocks are called the Remote
NOTE Interlock and Delayed Interlock (Figure 2-11).
Only BMS Model 168 can utilize Pulse The wiring terminals for these interlocks are
Width Modulation (PWM), not the BMS II located inside the I/O Box on the unit front
(Model 5R5-384). panel. The I/O Box cover contains a wiring
diagram which shows the terminal strip locations
These terminals are used to connect the for these interlocks (REMOTE INTL’K IN and
AERCO Boiler Management System (BMS) DELAYED INTL’K IN). Both interlocks,
Model 168 to the unit. The BMS Model 168 described below, are factory wired in the closed
utilizes a 12 millisecond, ON/OFF duty cycle. position.
This duty cycle is Pulse Width Modulated (PWM)
to control firing rate. A 0% firing rate = a 5% ON IMPORTANT
pulse and a 100% firing rate = a 95% ON pulse. Both the Remote Interlock and Delayed
Interlock MUST be in the closed position
2.10.5 SHIELD to allow the unit to fire.
The SHIELD terminals are used to terminate any
shields used on sensor wires connected to the 2.10.10.1 REMOTE INTERLOCK IN
unit. Only shields must be connected to these The remote interlock circuit is provided to
terminals. remotely start (enable) and stop (disable) the
Boiler, if desired. The circuit is labeled
IMPORTANT REMOTE INTL’K IN and is located inside the I/O
DO NOT USE the mA OUT output to Box on the front panel. The circuit is 24 VAC
remotely monitor Setpoint, Outlet Temp or and is factory pre-wired in the closed (jumpered)
Fire Rate Out. position.
2.10.6 mA OUT 2.10.10.2 DELAYED INTERLOCK IN

These terminals provide a 4 to 20 mA output to The delayed interlock is typically used in
the VFD (if so equipped) to control the rotational conjunction with the auxiliary relay described in
speed of the blower. This function is enabled in paragraph 2.10. This interlock circuit is located
the Configuration Menu (Chapter 3, Table 3-4). in the purge section of the start string. It can be
connected to the proving device (end switch,
2.10.7 0 – 10V OUT flow switch etc.) of an auxiliary piece of
These terminals provide a 0 to 10V output to equipment started by the Boiler’s auxiliary relay.
control the rotational speed of the blower. This The delayed interlock must be closed for the
function is enabled in the Configuration Menu boiler to fire.
(Chapter 3, Table 3-4).
If the delayed interlock is connected to a proving
2.10.8 RS-485 COMM device that requires time to close (make), a time
These terminals are used for RS-485 MODBUS delay (Aux Start On Dly) that holds the start
serial communication between the unit and an sequence of the boiler long enough for a proving
external “Master” such as a Boiler Management switch to make can be programmed. Should the
System (BMS), Energy Management System proving switch not prove within the programmed
(EMS), Building Automation System (BAS) or time frame, the boiler will shut down. The Aux
other suitable device. Start On Dly can be programmed from 0 to 120
seconds. This option is locate in the
Configuration Menu (Chapter 3, Table 3-4).
2-10
INSTALLATION
2.10.11 FAULT RELAY For Massachusetts boiler installations, the

Heatfab Division of the Selkirk Corporation
The fault relay is a single pole double throw provides vent systems which conform to all
(SPDT) relay having a normally open and applicable requirements for installations within
normally closed set of relay contacts that are the Commonwealth of Massachusetts. Contact
rated for 5 amps at 120 VAC and 5 amps at 30 information for this supplier is as follows:
VDC. The relay energizes when any fault
condition occurs and remains energized until the Selkirk Corporation
fault is cleared and the CLEAR button is Heatfab Division
depressed. The fault relay connections are 130 Industrial Blvd.
shown in Figure 2-11. Turners Falls, MA 01376
Phone: 1-800-772-0739
2.11 AUXILIARY RELAY CONTACTS www.heat-fab.com
Each Boiler is equipped with a single pole
2.13 COMBUSTION AIR
double throw (SPDT) relay that is energized
when there is a demand for heat and de- The AERCO Benchmark Venting and Combus-
energized after the demand for heat is satisfied. tion Air Guide, GF-2050 MUST be consulted
The relay is provided for the control of auxiliary before any flue or combustion supply air venting
equipment, such as pumps and louvers, or can is designed or implemented. Combustion air
be used as a Boiler status indictor (firing or not supply is a direct requirement of ANSI 223.1,
firing). Its contacts are rated for 120 VAC @ 5 NFPA-54, and local codes. These codes should
amps. Refer to Figure 2-11 to locate the AUX be consulted before a permanent design is
RELAY terminals for wiring connections. determined.
The combustion air must be free of chlorine,
halogenated hydrocarbons, or other chemicals
2.12 FLUE GAS VENT INSTALLATION that can become hazardous when used in gas-
fired equipment. Common sources of these
The minimum allowable vent diameter for a compounds are swimming pools, degreasing
single Benchmark 3.0 Boiler is 8 inches. compounds, plastic processing and refrigerants.
Whenever the environment contains these types
The AERCO Benchmark Venting and
of chemicals, combustion air must be supplied
Combustion Air Guide, GF-2050, must be
from a clean area outdoors for the protection
consulted before any flue gas vent or inlet air
and longevity of the equipment.
venting is designed or installed. U/L listed,
positive pressure, watertight vent materials as The AERCO Benchmark 3.0 Boiler is UL listed
specified in AERCO’s GF-2050, must be used for 100% sealed combustion. It can also be
for safety and code compliance. Since the unit is installed using room air, provided there is an
capable of discharging low temperature exhaust adequate supply. (See paragraph 2.13.3 for
gases, horizontal sections of the flue vent more information concerning sealed combustion
system must be pitched back to the unit a air). If the sealed combustion air option is not
minimum of 1/4 inch per foot to avoid being used, an inlet screen will be attached at
condensate pooling and allow for proper the air inlet on the top of the unit
drainage.
The more common methods of supplying
The combined pressure drop of vent and combustion air are outlined below. For more
combustion air systems must not exceed 140 information concerning combustion air, consult
equivalent feet of 8 inch ducting. Fittings as well the AERCO Benchmark Venting and
as pipe lengths must be calculated as part of the Combustion Air Guide, GF-2050.
equivalent length.
2.13.1 Combustion Air From Outside the
For a natural draft installation the draft must not Building
exceed ±0.25 inch W.C. These factors must be
Air supplied from outside the building must be
planned into the vent installation. If the
provided through two permanent openings. Each
maximum allowable equivalent lengths of piping
opening must have a free area of not less than
are exceeded, the unit will not operate properly
one square inch for each 4000 BTU/H boiler
or reliably.
input. The free area must take into account
restrictions such as louvers and bird screens.
2-11
INSTALLATION
2.13.2 Combustion Air From Inside the 2.13.4 Temporary Combustion Air
Building Filtering During Construction
When combustion air is provided from within the When the AERCO Benchmark 3.0 Boiler is used
building, it must be supplied through two to provide heat temporarily during ongoing
permanent openings in an interior wall. Each building construction, accumulated drywall dust,
opening must have a free area of not less than sawdust and similar particles can accumulate in
one square inch per 1000 BTU/H of total boiler the unit’s combustion air intake filter and block
input. The free area must take into account any combustion air flow. In these situations, AERCO
restrictions such as louvers. recommends that a disposable air intake filter be
installed, temporarily, above the boiler
2.13.3 Sealed Combustion combustion air inlet.
The AERCO Benchmark 3.0 Boiler is UL listed
for 100%-sealed combustion. For sealed AERCO recommends that the temporary air filter
combustion installations, the screen on the air be cut from a McMaster-Carr part no. 2122K315
inlet duct of the unit must be removed. The inlet Polyester Air Filter Roll Tackfield, 1/2” thick, 16”
air ductwork must then be attached directly to wide, or equivalent. Cover the Benchmark 3.0
the unit’s air inlet. air inlet with the blue side of the filter material
facing outward to hold the dust on the outside
In a sealed combustion air application, the surface. Maximize the surface area of the filter
combustion air ducting pressure losses must be covering the 8" diameter opening by creating a
taken into account when calculating the total dome out of the filter material.
maximum allowable venting run. See the
AERCO Benchmark Venting and Combustion During construction, check the filter for dust
Air Guide, GF-2050. When using the boiler in a accumulation and replace it when the
sealed combustion air configuration, each unit accumulation becomes noticeable.
must have a minimum 8-inch diameter
connection at the unit.
2-12
CONTROL PANEL OPERATING PROCEDURES
CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES
3.1 INTRODUCTION
The information in this Chapter provides a guide
to the operation of the Benchmark 3.0 Boiler
using the Control Panel mounted on the front of
the unit. It is imperative that the initial startup of
this unit be performed by factory trained
personnel. Operation prior to initial startup by
factory trained personnel will void the equipment 2
warranty. In addition, the following WARNINGS
and CAUTIONS must be observed at all times.
CAUTION 1
3
All of the installation procedures in
Chapter 2 must be completed before
attempting to start the unit. 4
12
WARNING 5
ELECTRICAL VOLTAGES IN THIS

SYSTEM MAY INCLUDE 460, 208 11 6
AND 24 VOLTS AC. IT MUST BE
SERVICED ONLY BY FACTORY
CERTIFIED SERVICE TECHNICIANS 7
10
WARNING 8
DO NOT ATTEMPT TO DRY FIRE
THE BOILER. STARTING THE UNIT
WITHOUT A FULL WATER LEVEL
9
CAN SERIOUSLY DAMAGE THE
UNIT AND MAY RESULT IN INJURY
TO PERSONNEL OR PROPERTY
DAMAGE. THIS SITUATION WILL
VOID ANY WARRANTY.
3.2 CONTROL PANEL DESCRIPTION

The Benchmark 3.0 Control Panel shown in
Figure 3-1.
Figure 3-1 contains all of the controls, indicators
and displays necessary to operate, adjust and Control Panel Front View
troubleshoot the Benchmark 3.0 Boiler. These
operating controls, indicators and displays are
listed and described in Table 3-1. Additional
information on these items are provided in the
individual operating procedures provided in this
Chapter.
3-1
Table 3-1 Operating Controls, Indicators and Displays

ITEM CONTROL, INDICATOR
NO. OR DISPLAY FUNCTION
1 LED Status Indicators Four Status LEDs indicate the current operating status as
follows:
COMM Lights when RS-232 communication is occurring
MANUAL Lights when the unit is being controlled using the front panel
keypad.
REMOTE Lights when the unit is being controlled by an external signal
from an Energy Management System
DEMAND Lights when there is a demand for heat.
2 OUTLET 3–Digit, 7–Segment LED display continuously displays the
TEMPERATURE outlet water temperature. The °F or °C LED next to the
Display display lights to indicate whether the displayed temperature is
in degrees Fahrenheit or degrees Celsius. The °F or °C blinks
when operating in the Deadband Mode.
3 VFD Display Vacuum Fluorescent Display (VFD) consists of 2 lines each
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
Startup Messages
Fault Messages
Operating Status Messages
Menu Selection
4 RS-232 Port Port permits a Laptop Computer or External Modem to be
connected to the unit’s Control Panel.
5 FAULT Indicator Red FAULT LED indicator lights when a boiler alarm
condition occurs. An alarm message will appear in the VFD.
6 CLEAR Key Turns off the FAULT indicator and clears the alarm message
if the alarm is no longer valid. Lockout type alarms will be
latched and cannot be cleared by simply pressing this key.
Troubleshooting may be required to clear these types of
alarms.
Lights ON/OFF switch is set to ON and all Pre-Purge
7 READY Indicator
conditions have been satisfied.
8 ON/OFF Switch Enables and disables boiler operation.
9 LOW WATER LEVEL Allows operator to test operation of the water level monitor.
TEST/RESET Switches Pressing TEST opens the water level probe circuit and
simulates a Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
3-2
Table 3-1 Operating Controls, Indicators and Displays – Continued

ITEM CONTROL, INDICATOR
NO. OR DISPLAY FUNCTION
10 MENU Keypad Consists of 6 keys which provide the following functions for
the Control Panel Menus:
MENU Steps through the main menu categories shown in Figure 3-
2. The Menu categories wrap around in the order shown.
BACK Allows you to go back to the previous menu level without
changing any information. Continuously pressing this key
will bring you back to the default status display in the VFD.
Also, this key allows you to go back to the top of a main
menu category.
▲ (UP) Arrow When in one of the main menu categories (Figure 3-2),
pressing the ▲ arrow key will select the displayed menu
category. If the CHANGE key was pressed and the menu
item is flashing, pressing the ▲ arrow key will increment the
selected setting.
▼ (DOWN) Arrow When in one of the main menu categories (Figure 3-2),
pressing this key will select the displayed menu category. If
the CHANGE key was pressed and the menu item is
flashing, pressing the ▼ arrow key will decrement the
selected setting.
CHANGE Permits a setting to be changed (edited). When the
CHANGE key is pressed, the displayed menu item will begin
to flash. Pressing the ▲ or ▼ arrow key when the item is
flashing will increment or decrement the displayed setting.
ENTER Saves the modified menu settings in memory. The display
will stop flashing.
11 AUTO/MAN Switch This switch toggles the boiler between the Automatic and
Manual modes of operation. When in the Manual (MAN)
mode, the front panel controls are enabled and the
MANUAL status LED lights.
When in the Automatic (AUTO) mode, the MANUAL status
LED will be off and the front panel controls disabled.
12 VALVE POSITION 20 segment red LED bargraph continuously shows the
Bargraph Air/Fuel Valve position in 5% increments from 0 to 100%
3-3
available menu options in the Top-Down
3.3 CONTROL PANEL MENUS sequence. Pressing the ▼ arrow key will
The Control Panel incorporates an extensive display the options in the Bottom-Up
menu structure which permits the operator to set sequence. The menu options will wrap-
up, and configure the unit. The menu structure around after the first or last available option
consists of five major menu categories which are is reached.
applicable to this manual. These categories are
shown in Figure 3-2. Each of the menus shown, 6. To change the value or setting of a
contain options which permit operating displayed menu option, press the CHANGE
parameters to be viewed or changed. The key. The displayed option will begin to flash.
menus are protected by a password levels to Press the ▲ or ▼ arrow key to scroll
prevent unauthorized use. through the available menu option choices
for the option to be changed. The menu
Prior to entering the correct password, the option choices do not wrap around.
options contained in the Operation, Setup, 7. To select and store a changed menu item,
Configuration and Tuning Menu categories can press the ENTER key.
be viewed. However, with the exception of
Internal Setpoint Temperature (Configuration
Menu), none of the viewable menu options can
be changed.
Once the valid level 1 password (159) is

entered, the options listed in the Setup.
Configuration and Tuning Menus can be viewed
and changed, if desired. The Combustion Cal
Menu is protected by the level 2 password which
is used in Chapter 4 to perform combustion
calibration prior to service use.
3.3.1 Menu Processing Procedure

Accessing and initiating each menu and option
is accomplished using the Menu Keys shown in
Figure 3-1. Therefore, it is imperative that you
be thoroughly familiar with the following basic
steps before attempting to perform specific
menu procedures.
1. The Control Panel will normally be in the

Operating Menu and the VFD will display the
current unit status. Pressing the ▲ or ▼
arrow key will display the other available
data items in the Operating Menu.
2. Press the MENU key. The display will show
the Setup Menu, which is the next menu
category shown in Figure 3-2. This menu
contains the Password option which must be
entered if other menu options will be
changed.
3. Continue pressing the MENU key until the
desired menu is displayed.
4. With the desired menu displayed, press the
▲ or ▼ arrow key. The first option in the
selected menu will be displayed.
5. Continue to press the ▲ or ▼ arrow key
until the desired menu option is displayed. Figure 3-2. Menu Structure
Pressing the ▲ arrow key will display the
3-4
NOTE 3.5 SETUP MENU
The following paragraphs provide brief The Setup Menu (Table 3-3) permits the
descriptions of the options contained in each operator to enter the unit password (159) which
menu. Refer to Appendix A for detailed is required to change the menu options. To
descriptions of each menu option. Refer to prevent unauthorized use, the password will
Appendix B for listings and descriptions of time-out after 1 hour. Therefore, the correct
displayed startup, status and error password must be reentered when required. In
messages. addition to permitting password entries, the
Setup Menu is also used to enter date and time,
units of temperature measurements and entries
3.4 OPERATING MENU required for external communication and control
The Operating Menu displays a number of key of the unit via the RS-232 port. A view-only
operating parameters for the unit as listed in software version display is also provided to
Table 3-2. This menu is “Read-Only” and does indicate the current Control Box software
not allow personnel to change or adjust any version.
displayed items. Since this menu is “Read-Only”,
it can be viewed at any time without entering a NOTE
password. Pressing the ▲ arrow key to display The Outdoor Temp display item shown with
the menu items in the order listed (Top-Down). an asterisk in Table 3-2 will not be displayed
Pressing the ▼ arrow key will display the menu unless the Outdoor Sensor function has
items in reverse order (Bottom-Up). been enabled in the Configuration Menu
(Table 3-4).
Table 3-2. Operating Menu

Available Choices or Limits
Menu Item Display Minimum Maximum Default
Status Message
Active Setpoint 40°F 240°F
AIR Temp -70°F 245°F
Outdoor Temp* -70°F 130°F
Valve Position In 0% Max Valve
Position
Flame Strength 0% 100%
Run Cycles 0 999,999,999
Run Hours 0 999,999,999
Fault Log 0 9 0
3-5
Table 3-3. Setup Menu

Passsword 0 9999 0
Language English English
Time 12:00 am 11:59 pm
Date 01/01/00 12/31/99
Unit of Temp Fahrenheit or Celsius Fahrenheit
Comm Address 0 127 0
Baud Rate 2400, 4800, 9600, 19.2K 9600
Software Ver 0.00 Ver 9.99
3.6 CONFIGURATION MENU NOTE

The Configuration Menu shown in Table 3-4 The Configuration Menu settings shown in
permits adjustment of the Internal Setpoint Table 3-4 are Factory-Set in accordance
(Setpt) temperature regardless of whether the with the requirements specified for each
valid password has been entered. Setpt is individual order. Therefore, under normal
required for operation in the Constant Setpoint operating conditions, no changes will be
mode. The remaining options in this menu required.
require the valid password to be entered, prior to
changing existing entries. This menu contains a
number of other configuration settings which
may or may not be displayed, depending on the
current operating mode setting.
Table 3-4. Configuration Menu

Internal Setpt Lo Temp Limit Hi Temp Limit 130°F
Unit Type KC Boiler, KC Boiler LN, BMK Boiler
BMK Boiler, BMK Boiler LN, LN
BMK Boiler Dual, KC Water
Heater, KC Water Heater LN,
Water Heater 2010
Unit Size 0.5 MBTU, 1.0 MBTU 1.0 MBTU
1.5 MBTU, 2.0 MBTU
3.0 MBTU, 3.5 MBTU
4.0 MBTU, 5.0 MBTU
6.0 MBTU
Fuel Type Natural Gas, Propane Natural Gas
Boiler Mode Constant Setpoint, Constant
Remote Setpoint, Setpoint
Direct Drive
Combination
Outdoor Reset
3-6
Table 3-4. Configuration Menu - Continued

Remote Signal 4 – 20 mA/1 – 5V 4 – 20 mA,
(If Mode = Remote 0 -20 mA/0 – 5V 1-5V
Setpoint, Direct Drive PWM Input (BMS)
or Combination) Network
Bldg Ref Temp 40°F 230°F 70°F
(If Mode = Outdoor
Reset)
Reset Ratio 0.1 9.9 1.2
(If Mode = Outdoor
Reset)
Outdoor Sensor Enabled or Disabled Disabled
System Start Tmp 30°F 100°F 60°F
(If Outdoor Sensor =
Enabled)
Setpt Lo Limit 40°F Setpt Hi Limit 60°F
Setpt Hi Limit Setpt Lo Limit 220°F 200°F
Temp Hi Limit 40°F 240°F 210°F
Max Fire Rate 40% 100% 100%
Pump Delay Timer 0 min. 30 min. 0 min.
Aux Start On Dly 0 sec. 120 sec. 0 sec.
Failsafe Mode Shutdown or Constant Setpt Shutdown
*Analog Output Off, Setpoint, Outlet Temp, *Valve
(See CAUTION at Valve Position 4-20 mA, Position
end of Table 3-4 ) Valve Position 0-10V 0-10V
Low Fire Timer 2 sec. 600 sec. 2 sec.
Setpt Limiting Enabled or Disabled Disabled
Setpt Limit Band 0°F 10°F 5°F
Network Timeout 5 Sec 999 Sec 30 Sec
HI DB Setpt EN 0% 100% 30%
Demand Offsert 0 25 10
Deadband High 0 25 2
Deadband Low 0 25 2
*CAUTION:
1. DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve
Position 0-10V).
3-7
3.7 TUNING MENU positions (% open). This is accomplished by

providing a DC drive voltage to the motor which
The Tuning Menu items in Table 3-5 are Factory
adjusts the rotational speed of the blower to
set for each individual unit. Do not change
maximize combustion efficiency and ensure the
these menu entries unless specifically requested
unit conforms to the Nitrogen Oxide (NOx) and
to do so by Factory-Trained personnel.
Carbon Monoxide (CO) emissions specified in
Chapter 4. The firing rates (%) and default drive
3.8 COMBUSTION CAL MENU voltages are listed in Table 3-6.
The Combustion Cal (Calibration) Menu items in
Table 3-6 are used to vary the speed of the
unit’s blower motor based on air temperature
and air density at prescribed Air/Fuel Valve
Table 3-5. Tuning Menu

Prop Band 1°F 120°F 70°F
Integral Gain 0.00 2.00 1.00
Derivative Time 0.0 min 2.00 min 0.00 min
Reset Defaults? Yes, No, Are You Sure? No
Table 3-6. Combustion Cal Menu

CAL Voltage 16% .25 8.20 1.80v
CAL Voltage 30% .25 8.20 3.20v
CAL Voltage 45% .25 8.20 3.70v
CAL Voltage 60% .25 8.20 3.80
CAL Voltage 80% .25 8.20 4.60
CAL Voltage 100% .25 8.20 6.00
SET Valve Position 0% 100% 0%
Blower Output Monitor Blower Output Voltage .00
3.9 START SEQUENCE If all of the above switches are closed, the
When the Control Box ON/OFF switch is set to READY light above the ON/OFF switch will light
the ON position, it checks all pre-purge safety and the unit will be in the Standby mode.
switches to ensure they are closed. These
switches include: When there is a demand for heat, the following
events will occur:
• Safety Shut-Off Valve Proof of Closure
(POC) switch
NOTE
• Low Water Level switch
If any of the Pre-Purge safety device
• High Water Temperature switch switches are open, the appropriate fault
• High Gas Pressure switch message will be displayed. Also, the
• Low Gas Pressure switch appropriate fault messages will be displayed
throughout the start sequence, if the
• Blower Proof switch
required conditions are not observed.
3-8
1. The DEMAND LED status indicator will light. Valve (Figure 3-6) will read between 25
and 35 to indicate that the valve is in
2. The unit checks to ensure that the Proof of
the low-fire position.
Closure (POC) switch in the downstream
Safety Shut-Off Valve (SSOV) is closed. (b) The igniter relay is activated and
See Figure 3-3 for SSOV location. provides ignition spark.
(c) The gas Safety Shut-Off Valve (SSOV)
is energized (opened) allowing gas to
flow into the Air/Fuel Valve.
Figure 3-3.
SSOV Location
3. With all required safety device switches Figure 3-4.

closed, a purge cycle will be initiated and the
Air/Fuel Valve In Purge Position
following events will occur:
(a) The Blower relay energizes and turns
on blower.
(b) The Air/Fuel Valve rotates to the full-
open purge position and closes purge
position switch. The dial on the Air/Fuel
Valve (Figure 3-4) will read 100 to
indicate that it is full-open (100%).
(c) The VALVE POSITION bargraph will
show 100%.
4. Next, the blower proof switch on the Air/Fuel
Valve (Figure 3-5) closes. The display will
show Purging and indicate the elapsed time
of the purge cycle in seconds. The normal
(default) time for the purge cycle is 7
seconds.
5. Upon completion of the purge cycle, the
Control Box initiates an ignition cycle and
the following events occur:
(a) The Air/Fuel Valve rotates to the low- Figure 3-5.
fire ignition position and closes the Blower Proof Switch
ignition switch. The dial on the Air/Fuel
3-9
8. With the unit firing properly, it will be

controlled by the temperature controller
circuitry. The boiler’s VALVE POSITION will
be continuously displayed on the front panel
bargraph.
Once the demand for heat has been satisfied,

the Control Box will turn off the dual SSOV gas
valves. The blower relay will be deactivated and
the Air/Fuel Valve will be closed. Standby will
be displayed.
3.10 START/STOP LEVELS

The start and stop levels are the Air/Fuel Valve
positions (% open) that start and stop the unit,
based on load. These levels are Factory preset
as follows:
Start Level: 20%

Figure 3-6.
Air/Fuel Valve In Ignition Position Stop Level: 14%
Normally, these settings should not require

6. Up to 7 seconds will be allowed for ignition adjustment.
to be detected. The igniter relay will be
turned off one second after flame is Note that the energy input of the boiler is not
detected. linearly related to the Air/Fuel Valve position.
Refer to Table 3-7 for the relationship between
7. After 2 seconds of continuous flame, Flame
the boiler energy input and the Air/Fuel Valve
Proven will be displayed and the flame
position (% open) for a unit running on Natural
strength will be indicated. After 5 seconds,
Gas.
the current date and time will be displayed in
place of the flame strength.
Table 3-7
Relationship Between Air/Fuel Valve Position and Energy Input
Air/Fuel Valve Energy Input Boiler Energy Input
Position (% Open) (BTU/HR) (% Of Full Capacity)
0% 0 0
10% 0 0
14%
6.67%
(Stop Level) 200,000
20% 287,000 10%
30% 486,000 16%
40% 802,000 27%
50% 1,180,000 39%
60% 1,720,000 57%
70% 2,300,000 77%
80% 2,550,000 85%
90% 2,720,000 91%
100% 3,000,000 100%
3-10
INITIAL START-UP
CHAPTER 4 INITIAL START-UP
4.1 INITIAL START-UP REQUIREMENTS CAUTION

The requirements for the initial start-up of the
All applicable installation procedures
Benchmark 3.0 Boiler consists of the following:
in Chapter 2 must be completed
before attempting to start the unit.
• Complete installation
• Perform combustion calibration 4.2 TOOLS AND INSTRUMENTATION
• Set proper controls and limits FOR COMBUSTION CALIBRATION
• Set up mode of operation (see Chapter 5)
To properly perform combustion calibration, the
• Test safety devices (see Chapter 6)
proper instruments and tools must be used and
correctly attached to the unit. The following
Installation should be fully completed before paragraphs outline the necessary tools and
performing initial start-up; and the start-up must instrumentation as well as their installation.
be complete prior to putting the unit into service.
Starting a unit without the proper piping, venting,
or electrical systems can be dangerous and may 4.2.1 Required Tools & Instrumentation
void the product warranty. The following start-up The following tools and instrumentation are
instructions should be followed precisely in order necessary to perform combustion calibration of
to operate the unit safely and at a high thermal the unit:
efficiency, with low flue gas emissions.
• Digital Combustion Analyzer: Oxygen
accuracy to ± 0.4%; Carbon Monoxide
Initial unit start-up is to be performed ONLY by (CO) and Nitrogen Oxide (NOx) resolution
AERCO factory trained start-up and service to 1PPM.
personnel. After following the steps in this • 16 inch W.C. manometer or equivalent
chapter, it will be necessary to perform the Mode gauge and plastic tubing.
of Operation settings in Chapter 5, and the
Safety Device Testing procedures in Chapter 6 • 1/8 inch NPT-to-barbed fittings for use with
to complete the initial unit start-up. gas supply manometer or gauge.
• Small and large flat blade screwdrivers.
An AERCO Gas Fired Startup Sheet, included • Tube of silicone adhesive
with each Benchmark Boiler, must be completed
for each unit for warranty validation and a copy
must be returned promptly to AERCO at: 4.2.2 Installing Gas Supply Manometer
The gas supply manometer is installed in the
gas train as follows:
AERCO International, Inc.
159 Paris Ave.
Northvale, NJ 07647 1. Close the main manual gas supply shut-off
valve upstream of the unit.
WARNING 2. Remove the front door and left side panels
DO NOT ATTEMPT TO DRY FIRE from the boiler to access the gas train
components.
THE BOILER. STARTING THE UNIT
WITHOUT A FULL WATER LEVEL 3. Remove the 1/8 inch NPT pipe plug from the
CAN SERIOUSLY DAMAGE THE leak detection ball valve on the downstream
UNIT AND MAY RESULT IN INJURY side of the Safety Shut Off Valve (SSOV) as
TO PERSONNEL OR PROPERTY shown in Figure 4-1.
DAMAGE. THIS SITUATION WILL
VOID ANY WARRANTY.
4-1
INITIAL START-UP
4. Install a NPT-to-barbed fitting into the

tapped plug port.
Prepare the port for the combustion analyzer
5. Attach one end of the plastic tubing to the probe as follows:
barbed fitting and the other end to the 16
inch W.C. manometer.
1. Remove the plug from the probe port on the
left or right side of the exhaust manifold.
1/8" NPT PLUG 2. If necessary, adjust the stop on the

(INSTALL MANOMETER HERE) combustion analyzer probe so that it will
extend mid-way into the flue gas flow. DO
LEAK DETECTION
HIGH GAS BALL VALVE NOT install the probe at this time.
PRESSURE
SWITCH
4.3 NATURAL GAS COMBUSTION
CALIBRATION
TO The Benchmark 3.0LN Boiler is combustion
AIR/FUEL
VALVE calibrated at the factory prior to shipping.
However, recalibration as part of initial start-up
SSOV
is necessary due to changes in the local altitude,
LOW GAS
PRESSURE gas BTU content, gas supply piping and supply
SWITCH regulators. Factory Test Data sheets are
shipped with each unit. These sheets must be
filled out and returned to AERCO for proper
Warranty Validation.
GAS
INLET
It is important to perform the following procedure
as outlined. This will keep readjustments to a
minimum and provide optimum performance.
1. Open the water supply and return valves to
the unit and ensure that the system pumps
Figure 4-1. are running.
1/8 Inch Gas Plug Location
2. Open the natural gas supply valve(s) to the
unit.
4.2.3 Accessing the Vent Probe Port 3. Set the control panel ON/OFF switch to the
OFF position.
The unit contains NPT plugs on both the left and
right side of the exhaust manifold at the rear of 4. Turn on external AC power to the unit. The
the unit as shown in Figure 4-2. display will show LOSS OF POWER and the
time and date.
5. Set the unit to the Manual Mode by pressing
the AUTO/MAN key. A flashing Manual
Valve Position message will be displayed
showing the present air/fuel valve % open
position. Also, the MANUAL LED will light.
6. Adjust the air/fuel valve position to 0% by
pressing the ▼ arrow key.
7. Ensure that the leak detection ball valve
downstream of the SSOV is open.
8. Set the ON/OFF switch to the ON position.
9. Change the valve position to 29% using the
▲ arrow key. The unit should begin its start
sequence and fire.
Figure 4-2
Analyzer Probe Hole Location
4-2
INITIAL START-UP
10. Next, verify that the gas pressure

Table 4-1
downstream of the SSOV is 1.8” W.C. for Combustion Oxygen Levels for a 100%
both FM and IRI gas trains. If gas pressure Open Air/Fuel Valve Position
adjustment is required, remove the brass Inlet Air Oxygen % Carbon
hex nut covering the SSOV gas pressure Temp ± 0.2 Monoxide NOx
adjustment screw (Figure 4-3). Make gas >100°F 4.8 % <100 ppm <30 ppm
pressure adjustments using a flat-tip
screwdriver to obtain 1.8” W.C. 90°F 5.0 % <100 ppm <30 ppm
80°F 5.2 % <100 ppm <30 ppm
<70°F 5.3 % <100 ppm <30 ppm
14. If necessary, adjust the iris air damper

shown in Figure 4-4 until the oxygen level is
within the range specified in Table 4-1.
15. Once the oxygen level is within the specified
range at 100%, decrease the valve position
to 70%.
Figure 4-3
Regulator Adjustment Screw Location
11. Increase the valve open position to 100%

and verify that the gas pressure downstream
of the SSOV remains at 1.8” W.C. Readjust
pressure if necessary. -
12. With the valve position at 100%, insert the
combustion analyzer probe into the flue
probe opening and allow enough time for the
combustion analyzer to settle.
13. Compare the measured oxygen level to the
oxygen range for the inlet air temperature
shown in Table 4-1. Also, ensure that the
carbon monoxide (CO) and nitrogen oxide
(NOx) readings do not exceed the values
shown.
Figure 4-4
Iris Air Damper Location/Adjustment
4-3
INITIAL START-UP
NOTE NOTE
The remaining combustion calibration steps are The remaining steps basically repeat the
performed using the Combustion Cal Menu procedures in steps 18 through 25 for air/fuel
included in the C-More Control System. The valve positions of 50%, 40%, 30% and 14%
combustion calibration control functions will be open. However, since oxygen levels vary, these
used to adjust the oxygen level (%) at air/fuel steps are repeated in their entirety. When
valve positions of 80%, 60%, 45%, 30% and performing these steps, also ensure that the
16% as described in the following steps. These carbon monoxide (CO) and nitrogen oxide (NOx)
steps assume that the inlet air temperature is readings do not exceed the values shown for
within the range of 50°F to 100°F. each valve position.
16. Press the MENU Key on the front panel of

the C-MORE and access the Setup menu. 26. Press the ▲ arrow key until SET Valve
Enter password 6817 and then press the Position appears on the C-MORE display.
ENTER key. 27. Press the CHANGE key. SET Valve Position
17. Press the MENU Key on the front panel of will begin to flash.
the C-MORE until Combustion Cal Menu 28. Press the ▼ arrow key until the SET Valve
appears on the C-More display. Position reads 50% and then press the
18. Press the ▲ arrow key until SET Valve ENTER key.
Position appears on the C-MORE display. 29. Press the down ▼ arrow key until CAL
19. Press the CHANGE key. SET Valve Position Voltage 50% is displayed.
will begin to flash. 30. Press the CHANGE key. CAL Voltage 50%
20. Press the ▲ arrow key until the SET Valve will begin to flash.
Position reads 70%. Press the ENTER key. 31. The oxygen level at the 50% Valve Position
21. Next, press the down (▼) arrow key until should be as shown below. Also, ensure that
CAL Voltage 70% is displayed. the carbon monoxide (CO) and nitrogen
oxide (NOx) readings do not exceed the
22. Press the CHANGE key and observe that values shown.
CAL Voltage 70% is flashing.
Combustion Oxygen Level at
23. The oxygen level at the 70% valve position
should be as shown below. Also, ensure that 50% Valve Position
the carbon monoxide (CO) and nitrogen Oxygen % Carbon
oxide (NOx) readings do not exceed the ± 0.2 Monoxide NOx
values shown. 7.0 % <50 ppm <20 ppm

32. If the oxygen level is not within the specified
70% Valve Position
range, adjust the level using the ▲ and ▼
Oxygen % Carbon arrow keys. This will adjust the output
± 0.2 Monoxide NOx voltage to the blower motor as indicated on
6.0 % <100 ppm <30 ppm the display. Pressing the ▲ arrow key
increases the oxygen level and pressing the
▼ arrow key decreases the oxygen level.
range, adjust the level using the ▲ and ▼ 33. Once the oxygen level is within the specified
arrow keys. This will adjust the output range at 50%, press the ENTER key to store
voltage to the blower motor as indicated on the selected blower output voltage for the
the display. Pressing the ▲ arrow key 50% Valve Position.
increases the oxygen level and pressing the 34. Press the ▲ arrow key until SET Valve
down ▼ arrow key decreases the oxygen Position appears on the C-MORE display.
level.
35. Press the CHANGE key. SET Valve Position
25. Once the oxygen level is within the specified will begin to flash.
range at 70%, press the ENTER key to store
the selected blower output voltage for the 36. Press the ▼ arrow key until the SET Valve
70% valve position. Position reads 40%, then press the ENTER
key.
4-4
INITIAL START-UP
37. Press the ▼ arrow key until CAL Voltage arrow keys. This will adjust the output
40% is displayed. voltage to the blower motor as indicated on
the display. Pressing the ▲ arrow key
38. Press the CHANGE key. CAL Voltage 40%
will begin to flash.
▼ arrow key decreases the oxygen level.
39. The oxygen level at the 40% valve position
49. Once the oxygen level is within the specified
should be as shown below. Also, ensure that
range at 30%, press the ENTER key to store
the carbon monoxide (CO) and nitrogen
the selected blower output voltage for the
oxide (NOx) readings do not exceed the
30% valve position.
values shown.
50. Press the ▲ arrow key until SET Valve
Combustion Oxygen Level at Position appears on the C-MORE display.
40% Valve Position 51. Press the CHANGE key. SET Valve Position
Oxygen % Carbon will begin to flash.
± 0.2 Monoxide NOx 52. Press the ▼ arrow key until the SET Valve
7.8 % <50 ppm <20 ppm Position reads 14%, then press the ENTER
key.
range, adjust the level using the ▲ and ▼ 53. Press the ▼ arrow key until CAL Voltage
arrow keys. This will adjust the output 14% is displayed.
voltage to the blower motor as indicated on 54. Press the CHANGE key. CAL Voltage 14%
the display. Pressing the ▲ arrow key will begin to flash.
▼ arrow key decreases the oxygen level. 55. The oxygen level at the 14% Valve Position
should be as shown below. Also, ensure that
41. Once the oxygen level is within the specified the carbon monoxide (CO) and nitrogen
range at 40%, press the ENTER key to store oxide (NOx) readings do not exceed the
the selected blower output voltage for the values shown.
40% valve position.
42. Press the ▲ arrow key until SET Valve
Position appears on the C-MORE display. 14% Valve Position
43. Press the CHANGE key. SET Valve Position Oxygen % Carbon
will begin to flash. ± 0.2 Monoxide NOx
8.5 % <50 ppm <30 ppm
44. Press the ▼ arrow key until the SET Valve
Position reads 30%, then press the ENTER
key. range, adjust the level using the ▲ and ▼
45. Press the ▼ arrow key until CAL Voltage arrow keys. This will adjust the output
30% is displayed. voltage to the blower motor as indicated on
the display. Pressing the ▲ arrow key
46. Press the CHANGE key. CAL Voltage 30% increases the oxygen level and pressing the
will begin to flash. ▼ arrow key decreases the oxygen level.
47. The oxygen level at the 30% Valve Position 57. Once the oxygen level is within the specified
should be as shown below. Also, ensure that range at 14%, press the ENTER key to store
the carbon monoxide (CO) and nitrogen the selected blower output voltage for 14%
oxide (NOx) readings do not exceed the Valve Position.
values shown.
Combustion Oxygen Level at IMPORTANT

30% Valve Position Repeat steps 18 through 57 until the
blower output voltage does not require
Oxygen % Carbon adjustment when sequencing from 70% to
± 0.2 Monoxide NOx 14%.
8.0 % <50 ppm <20 ppm
58. This completes the natural gas combustion
48. If the oxygen level is not within the specified calibration procedure.
range, adjust the level using the ▲ and ▼
4-5
INITIAL START-UP
4.4 UNIT REASSEMBLY RESET button before the boiler can be

Once the combustion calibration adjustments restarted. The automatic reset over-temperature
are properly set, the unit can be reassembled for switch is adjustable and allows the boiler to
service operation. restart, once the temperature drops below its
temperature setting. Set the automatic over-
temperature switch to the desired setting.
1. Set the ON/OFF switch in the OFF position.
2. Disconnect AC power from the unit.
3. Shut off the gas supply to the unit.
4. Remove the manometer and barbed fittings
and reinstall the NPT plug using a suitable
pipe thread compound.
5. Remove the combustion analyzer probe
from the vent hole. Replace the NPT plug in
the vent hole using a suitable pipe joint
compound.
6. Replace the unit’s side panels and front
door.
4.5 OVER-TEMPERATURE LIMIT

SWITCHES
The unit contains both automatic and manual
reset over-temperature limit switches. These
switches are mounted on a plate attached to the
boiler shell as shown in Figure 4-6. The switches
can be accessed by removing the left side
panels of the unit. The manual reset switch is
not adjustable and is permanently fixed at
210°F. This switch will shut down and lock out
the boiler if the water temperature exceeds Figure 4-6
210°F. Following an over-temperature condition, Over Temperature Limit Switch
it must be manually reset by pressing the Locations
4-6
MODE OF OPERATION
CHAPTER 5 MODE OF OPERATION
5.1 INTRODUCTION 5.2.3 Outdoor Air Temperature Sensor

The boiler is capable of being operated in any Installation
one of six different modes. The following The outdoor air temperature sensor must be
paragraphs in this Chapter provide descriptions mounted on the North side of the building in an
of each of these operating modes. Each boiler is area where the average outside air temperature
shipped from the factory tested and configured is expected. The sensor must be shielded from
for the ordered mode of operation. All the sun's direct rays, as well as direct
temperature related parameters are at their impingement by the elements. If a cover or
factory default values which work well in most shield is used, it must allow free air circulation.
applications. However, it may be necessary to The sensor may be mounted up to two hundred
change certain parameters to customize the unit feet from the unit. Sensor connections are
to the system environment. A complete listing made at the Input/Output (I/O) Box on the front
and descriptions of the temperature related of the boiler. Connections are made at the
parameters are included in Appendix A. Factory terminals labeled OUTDOOR SENSOR IN and
defaults are listed in Appendix E. After reading SENSOR COMMON inside the I/O Box. Use
this chapter, parameters can be customized to shielded 18 to 22 AWG wire for connections. A
suit the needs of the specific application. wiring diagram is provided on the cover of the
I/O Box. Refer to Chapter 2, paragraph 2.9.1 for
5.2 INDOOR/OUTDOOR RESET MODE additional wiring information.
This mode of operation is based on outside air
temperatures. As the outside air temperature 5.2.4 Indoor/ Outdoor Startup
decreases, the supply header temperature will Startup in the Indoor/Outdoor Reset Mode is
increase and vice versa. For this mode, it is accomplished as follows:
necessary to install an outside air sensor as well
as select a building reference temperature and a 1. Refer to the Indoor/Outdoor reset ratio
reset ratio. charts in Appendix D.
2. Choose the chart corresponding to the
5.2.1 Reset Ratio desired Building Reference Temperature.
Reset ratio is an adjustable number from 0.1 to
3. Go down the left column of the chart to the
9.9. Once adjusted, the supply header
coldest design outdoor air temperature
temperature will increase by that number for
expected in your area.
each degree that the outside air temperature
decreases. For instance, if a reset ratio of 1.6 is
used, for each degree that outside air NOTE
temperature decreases the supply header A design engineer typically provides
temperature will increase by 1.6 degrees. design outdoor air temperature and
supply header temperature data
5.2.2 Building Reference Temperature
4. Once the design outdoor air temperature is
This is a temperature from 40°F to 230°F. Once chosen, go across the chart to the desired
selected, it is the temperature that the system supply header temperature for the design
references to begin increasing its temperature. temperature chosen in step 3.
For instance, if a reset ratio of 1.6 is used, and
we select a building reference temperature of 5. Next, go up that column to the Reset Ratio
70°F, then at an outside temperature of 69°F, row to find the corresponding reset ratio.
the supply header temperature will increase by
6. Access the Configuration Menu and scroll
1.6° to 71.6°F.
through it until the display shows Bldg Ref
Temp. (Building Reference Temperature).
5-1
MODE OF OPERATION
7. Press the CHANGE key. The display will

5.4 REMOTE SETPOINT MODES
begin to flash. The unit’s setpoint can be remotely controlled by
an Energy Management System (EMS) or
8. Use the ▲ and ▼ arrow keys to select the Building Automation System (BAS). The Remote
desired Building Reference Temperature. Setpoint can be driven by a current or voltage
9. Press ENTER to save any changes. signal within the following ranges:
10. Next, scroll through the Configuration Menu 4-20 mA/1-5 Vdc
until the display shows Reset Ratio.
0-20 mA/0-5 Vdc
11. Press the CHANGE key. The display will
begin to flash. The factory default setting for the Remote
12. Use the ▲ and ▼ arrow keys to select the Setpoint mode is 4 - 20 mA/1 - 5 Vdc. With this
Reset Ratio determined in step 5. setting, a 4 to 20 mA/1 to 5 Vdc signal, sent by
an EMS or BAS, is used to change the unit's
13. Press ENTER to save the change. setpoint. The 4 mA/1V signal is equal to a 40°F
Refer to paragraph 3.3 for detailed instructions setpoint while a 20 mA /5V signal is equal to a
on menu changing. 240°F setpoint. When a 0 to 20 mA/0 to 5 Vdc
signal is used, 0 mA is equal to a 40°F setpoint.
5.3 CONSTANT SETPOINT MODE In addition to the current and voltage signals
The Constant Setpoint mode is used when a described above, the Remote Setpoint mode
fixed header temperature is desired. Common can also driven by a RS485 Modbus Network
uses of this mode of operation include water signal from an EMS or BAS.
source heat pump loops, and indirect heat
exchangers for potable hot water systems or The Remote Setpoint modes of operation can be
processes. used to drive single as well as multiple units.
No external sensors are required to operate in

this mode. While it is necessary to set the
NOTE
desired setpoint temperature, it is not necessary If a voltage, rather than current signal is
to change any other temperature-related used to control the remote setpoint, a DIP
functions. The unit is factory preset with settings switch adjustment must be made on the
that work well in most applications. Prior to CPU Board located in the Control Panel
changing any temperature-related parameters, Assembly. Contact your local AERCO
other than the setpoint, it is suggested that an representative for details.
AERCO representative be contacted. For
descriptions of temperature-related functions In order to enable the Remote Setpoint Mode,
and their factory defaults, see Appendices A and the following menu setting must be made in the
E. Configuration Menu:
MENU OPTION SETTING

5.3.1 Setting the Setpoint
The setpoint temperature of the unit is Boiler Mode Remote Setpoint
adjustable from 40°F to 240°F. To set the unit Remote Signal 4-20mA/1-5V,
for operation in the Constant Setpoint Mode, the
following menu settings must be made in the 0-20mA/0-5V, or
Configuration Menu: Network
MENU OPTION SETTING Refer to paragraph 3.3 for detailed instructions
on changing menu options.
Boiler Mode Constant Setpoint
Internal Setpt Select desired setpoint
using ▲ and ▼ arrow
keys (40°F to 240°F)
Refer to paragraph 3.3 for detailed instructions

on changing menu options.
5-2
MODE OF OPERATION
If the Network setting is selected for RS485 5.5 DIRECT DRIVE MODES
Modbus operation, a valid Comm Address must The unit’s air/fuel valve position (% open) can be
be entered in the Setup Menu. Refer to Modbus changed by a remote signal which is typically
Communication Manual GF-114 for additional sent from an Energy Management System
information. (EMS) or from a Building Automation System
(BAS). The Direct Drive mode can be driven by
While it is possible to change the settings of a current or voltage signal within the following
temperature related functions, the unit is factory ranges:
preset with settings that work well in most
applications. It is suggested that an AERCO 4-20 mA/1-5 Vdc
representative be contacted, prior to changing
any temperature related function settings. For 0-20 mA/0-5 Vdc
descriptions of temperature-related functions
and their factory defaults, refer to Appendices A The factory default setting for the Direct Drive
and E. mode is 4-20 mA/1-5 Vdc. With this setting, a 4
to 20 mA signal, sent by an EMS or BAS is used
to change the unit’s valve position from 0% to
5.4.1 Remote Setpoint Field Wiring 100%. A 4 mA/1V signal is equal to a 0% valve
The only wiring connections necessary for the position, while a 20 mA /5V signal is equal to a
Remote Setpoint mode are connection of the 100% valve position. When a 0-20 mA/0-5 Vdc
remote signal leads from the source to the unit’s signal is used, zero is equal to a 0% valve
I/O Box. The I/O Box is located on the front position.
panel of the boiler. For either a 4-20mA/0-5V or
a 0-20mA/0-5V setting, the connections are In addition to the current and voltage signals
made at the ANALOG IN terminals in the I/O described above, the Direct Drive mode can also
Box. For a Network setting, the connections are driven by a RS485 Modbus Network signal from
made at the RS-485 COMM terminals in the I/O an EMS or BAS.
Box. The signal must be floating, (ungrounded)
at the I/O Box and the wire used must be a two When in a Direct Drive mode, the unit is a slave
to the EMS or BAS and does not have a role in
wire shielded pair from 18 to 22 AWG. Polarity
temperature control. Direct Drive can be used to
must be observed. The source end of the shield
drive single, or multiple units.
must be connected at the source. When driving
multiple units, each unit’s wiring must conform to
the above. NOTE
If a voltage, rather than current signal is
5.4.2 Remote Setpoint Startup used to control the remote setpoint, a DIP
Since this mode of operation is factory preset switch adjustment must be made on the
and the setpoint is being externally controlled, CPU Board located in the Control Box
no startup instructions are necessary. In this Assembly. Contact your local AERCO
mode, the REMOTE LED will light when the representative for details.
external signal is present.
To enable the Direct Drive Mode, the following
To operate the unit in the Manual mode, press menu setting must be made in the Configuration
the AUTO/MAN switch. The REMOTE LED will Menu:
go off and the MANUAL LED will light.
MENU OPTION SETTING
To change back to the Remote Setpoint mode, Boiler Mode Direct Drive
simply press the AUTO/MAN switch. The
REMOTE LED will again light and the MANUAL Remote Signal 4-20mA/1-5V,
LED will go off.
0-20mA/0-5V, or
Network
Refer to paragraph 3.3 for instructions on

changing menu options.
5-3
MODE OF OPERATION
If the Network setting is selected for RS485 header. The BMS can control up to 40 boilers; 8
Modbus operation, a valid Comm Address must via pulse width modulation (PWM) and up to 32
be entered in the Setup Menu. Refer to Modbus via Modbus (RS485) network communication.
Communication Manual GF-114 for additional For BMS programming, operation, and Header
information. Sensor installation details, see GF-108M (BMS
Model 168) and GF-124 (BMS II Model 5R5-
5.5.1 Direct Drive Field Wiring 384), BMS Operations Guides. For operation via
an RS485 Modbus network, refer to Modbus
The only wiring connections necessary for Direct Communication Manual GF-114.
Drive mode are connection of the remote signal
leads from the source to the unit’s I/O Box. For To enable the BMS Mode, the following menu
either a 4-20mA/0-5V or a 0-20mA/0-5V setting, settings must be made in the Configuration
the connections are made at the ANALOG IN Menu:
terminals in the I/O Box. For a Network setting,
the connections are made at the RS-485 COMM MENU OPTION SETTING
terminals in the I/O Box. The signal must be
Boiler Mode Direct Drive
floating, (ungrounded) at the I/O Box and the
wire used must be a two wire shielded pair from Remote Signal BMS (PWM Input)
18 to 22 AWG. Polarity must be observed. The or
source end of the shield must be connected at Network (RS485)
the source. When driving multiple units, each
unit’s wiring must conform to the above. Refer to paragraph 3.3 for instructions on
changing menu options.
5.5.2 Direct Drive Startup
Since this mode of operation is factory preset
5.6.1 BMS External Field Wiring
and the valve position is being externally Wiring connections for BMS control using PWM
controlled, no startup instructions are necessary. signaling are made between connector JP2 on
In this mode, the REMOTE LED will light when the BMS panel (boilers 1 through 8), and the
the signal is present. B.M.S. (PWM) IN terminals in the I/O Box on the
front of the boilers. Refer to the wiring diagram
To operate the unit in manual mode, press the provided on the cover of the I/O Box.
AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light. Wiring connections for RS485 Modbus control
are made between connector JP11 on the BMS
To change back to the Direct Drive mode, simply (boilers 9 through 40) and the RS485 COMM
press the AUTO/MAN switch. The REMOTE terminals in the I/O Box on the front of the
LED will again light and the MANUAL LED will boilers.
go off.
Wire the units using shielded twisted pair wire
between 18 and 22 AWG. Observe the proper
5.6 BOILER MANAGEMENT SYSTEM
polarity for the B.M.S. (PWM) IN and/or RS485
(BMS) COMM wiring connections. Shields should be
NOTE terminated only at the BMS and the boiler end
must be left floating. Each unit’s wiring must
BMS Model 168 can utilize either pulse
conform to the above.
width modulation (PWM) or RS485
Modbus signaling to the Boiler. BMS II
Model 5R5-384 can utilize only RS485 5.6.2 BMS Setup and Startup
signaling to the Boiler. This mode of operation is factory preset and the
AERCO BMS controls the firing rate (air/fuel
The BMS mode of operation is used in valve % open position). There are no setup
conjunction with an AERCO Boiler Management instructions for each individual unit.
System. The BMS mode is used when it is
desired to operate multiple units in the most To operate the unit in manual mode, press the
efficient manner possible. For this mode of AUTO/MAN switch. The REMOTE LED will go
operation, a BMS Header Sensor must be off and the MANUAL LED will light
installed between 2 and 10 feet downstream of
the LAST boiler in the boiler plant's supply water
5-4
MODE OF OPERATION
To change back to the BMS mode, simply press Combination Control Panel see the AERCO
the AUTO/MAN switch. The REMOTE LED will CCP-1 literature.
again light and the MANUAL LED will go off.
5.7.1 Combination Control System Field
5.7 COMBINATION CONTROL SYSTEM Wiring
(CCS) Wiring for this system is between the BMS
NOTE Model 168 panel, the CCP and the B.M.S.
Only BMS Model 168 can be utilized for (PWM) IN terminals in the I/O Box. Wire the
the Combination Mode, not the BMS II units using a shielded twisted pair of 18 to 22
(Model 5R5-384). AWG wire. When wiring multiple units, each
unit’s wiring must conform to the above. For a
A Combination Control System (CCS) is one complete CCP system-wiring diagram see the
that uses multiple boilers to cover both space- AERCO CCP-1 literature.
heating and domestic hot water needs. An
AERCO Boiler Management System (BMS) 5.7.2 Combination Control System Setup
Model 168 and a Combination Control Panel and Startup
(CCP) are necessary to configure this system.
Typically, an adequate number of boilers are Setup for the Combination Mode requires entries
installed to cover the space-heating load on the to be made in the Configuration Menu for boiler
design day, however one or more units are used mode, remote signal type and setpoint. The
for the domestic hot water load. setpoint is adjustable from 40°F to 240°F.
The theory behind this type of system is that the Enter the following settings in the Configuration
maximum space-heating load and the maximum Menu:
domestic hot water load do not occur simul- MENU OPTION SETTING
taneously.+ Therefore, boilers used for the
domestic hot water are capable of switching Boiler Mode Combination
between constant setpoint and BMS modes of
operation. These boilers are the combination Remote Signal BMS (PWM Input)
units and are referred to as the combo boilers. Internal Setpt 40°F to 240°F
The combo boilers heat water to a constant
setpoint temperature. That water is then Refer to paragraph 3.3 for instructions on
circulated through a heat exchanger in a changing menu options.
domestic hot water storage tank.
While it is possible to change other temperature-
When the space-heating load is such that all the related functions for combination mode, thes
space-heating boilers are at the 100% valve functions are preset to their factory default
position, the BMS will then ask the Combination values. These default settings work well in most
Control Panel for the domestic boilers to applications. It is suggested that AERCO be
become space-heating boilers. Provided the contacted prior to changing settings other than
domestic hot water load is satisfied, the combo the unit’s setpoint. For a complete listing of
(hot water) boilers will then become space- temperature related function defaults, see
heating boilers. If the domestic hot water load is Appendix E.
not satisfied, the combo boiler(s) remain on the
domestic hot water load. If the combo boilers To set the unit to the manual mode, press the
switch over to space heating, but there is a call AUTO/MAN switch. The MANUAL LED will
for domestic hot water, the CCP switches the light.
combo units back to the domestic load.
To set the unit back to the auto mode, press the
When the combo units are satisfying the AUTO/MAN switch. The MANUAL LED will go
domestic load they are in constant setpoint off and the REMOTE LED will light.
mode of operation. When the combo units
When the boiler is switched to BMS mode, the
switch over to space heating, their mode of
AERCO BMS controls the valve position. There
operation changes to the BMS mode. For more
are no setup requirements to the boiler(s) in this
information concerning the operation of the
mode.
5-5
SAFETY DEVICE TESTING
CHAPTER 6 SAFETY DEVICE TESTING
6.1 TESTING OF SAFETY DEVICES 4. Place the unit in Manual Mode and adjust the
air/fuel valve position (% open) between 25
Periodic safety device testing is required to and 30%.
ensure that the control system and safety
devices are operating properly. The Benchmark 5. While the unit is firing, slowly close the
3.0LN control system comprehensively monitors external manual gas shut-off valve.
all combustion-related safety devices before, 6. The unit should shut down and display a
during and after the start sequence. The LOW GAS PRESSURE fault message at
following tests check to ensure that the system approximately 2.6” W.C. The FAULT indi-
is operating as designed. cator should also start flashing.
Operating controls and safety devices should be
tested on a regular basis or following service or 1/8" NPT PLUG
replacement. All testing must conform to local (INSTALL MANOMETER HERE
FOR HIGH GAS PRESSURE
codes such as ASME CSD-1. FAULT TEST)
LEAK DETECTION
HIGH GAS BALL VALVE
NOTE PRESSURE
SWITCH
MANUAL and AUTO modes of operation
are required to perform the following
tests. For a complete explanation of these TO
AIR/FUEL
modes, see Chapter 3. VALVE
SSOV LOW GAS

NOTE PRESSURE
SWITCH
It will be necessary to remove the front
door and side panels from the unit to
perform the following tests.
GAS
INLET
WARNING
ELECTRICAL VOLTAGES IN THIS
SYSTEM MAY INCLUDE 460, 220,
120 AND 24 VOLTS AC. POWER 1/8" NPT PLUG BALL VALVE
MUST BE REMOVED PRIOR TO (INSTALL MANOMETER HERE
FOR LOW GAS PRESSURE
PERFORMING WIRE REMOVAL OR FAULT TEST)
OTHER TEST PROCEDURES THAT
CAN RESULT IN ELECTRICAL Figure 6-1
SHOCK. Low & High Gas Pressure Testing
6.2 LOW GAS PRESSURE FAULT TEST 7. Fully open the external manual gas shut-off
Refer to Figure 6-1 and ensure that the leak valve and press the CLEAR button on the
detection ball valve located at the high gas Control Box.
pressure switch is closed.
8. The fault message should clear and the
1. Remove the 1/8 “ plug from the ball valve at FAULT indicator should go off. The unit
the low gas pressure switch shown in the should restart.
lower portion of Figure 6-1. 9. Upon test completion, close the ball valve
2. Install a 0 – 16 “ W.C. manometer or a W.C. and remove the manometer. Replace the 1/8
gauge where the 1/8" plug was removed. “ plug removed in step 1.
3. Slowly open the ball valve near the low gas

pressure switch.
6-1
6. Set the ON/OFF switch to the ON position.

The READY light should remain off and the
6.3 HIGH GAS PRESSURE TEST unit should not start. If the unit does start,
To simulate a high gas pressure fault, refer to shut the unit off immediately and refer fault to
Figure 6-1 and proceed as follows: qualified service personnel.
1. Remove the 1/8 “ plug from the leak 7. Close the drain and pressure relief valve
detection ball valve shown in the upper used in draining the unit.
portion of Figure 6-1. 8. Open the water shut-off valve in the return
piping to the unit.
2. Install a 0 – 16” W.C. manometer (or W.C.
gauge) where the 1/8” plug was removed. 9. Open the water supply shut-off valve to the
unit to refill.
3. Slowly open the leak detection ball valve
10. After the shell is full, press the LOW WATER
4. Start the unit in Manual mode at a valve LEVEL RESET button to reset the low water
position (firing rate) between 25 and 30%. cutoff.
11. Press the CLEAR button to reset the FAULT
5. Slowly increase the gas pressure using the
LED and clear the displayed error message.
adjustment screw on the SSOV Actuator
(see Figure 4-3). 12. Set the ON/OFF switch to the ON position.
The unit is now ready for operation.
6. The unit should shut down and display a
HIGH GAS PRESSURE fault message
when the gas pressure exceeds 2.6” W.C. 6.5 WATER TEMPERATURE FAULT
The FAULT indicator should also start TEST
flashing.
A high water temperature fault is simulated by
7. Reduce the gas pressure back to 1.8” W.C. adjusting the automatic over-temperature switch.
This switch is accessible from the left side of the
8. Press the CLEAR button on the Control Box unit as shown in Figure 6-2.
to clear the fault.
1. Start the unit in the normal operating mode.
9. The fault message should clear and the Allow the unit to stabilize at its setpoint.
FAULT indicator should go off. The unit
should restart. Lower the adjustable over-temperature switch
setting to match the displayed OUTLET
10. Upon test completion, close the ball valve TEMPERATURE.
and remove the manometer. Replace the Once the adjustable over-temperature switch
1/8“ plug removed in step 1. setting is approximately at, or just below, the
actual outlet water temperature, the unit
should shut down. The FAULT indicator
6.4 LOW WATER LEVEL FAULT TEST should start flashing and a HIGH WATER
To simulate a low water level fault: TEMP SWITCH OPEN fault message should
be displayed. It should not be possible to
1. Set the ON/OFF switch to the OFF position restart the unit.
2. Close the water shut-off valves in the supply Reset the adjustable over-temperature switch to
and return piping to the unit. its original setting.
3. Slowly open the drain valve on the rear of the The unit should start once the adjustable
unit. If necessary the unit’s relief valve may temperature limit switch setting is above the
be opened to aid in draining. actual outlet water temperature.
4. Continue draining the unit until a LOW
WATER LEVEL fault message is displayed
and the FAULT indicator flashes.
5. Place the unit in the Manual Mode and raise
the valve position above 30%.
6-2
RESET BUTTON FOR MANUAL that a device such as a pump, gas booster, or
RESET TEMPERATURE LIMIT
SWITCH louver is operational.
6.6.1 REMOTE INTERLOCK

1. Remove the cover from the I/O Box and
locate the REMOTE INTL’K IN terminals.
HIGH LIMIT
2. Start the unit in the Manual Mode and set the
valve position between 25% and 30%.
3. If there is a jumper across the REMOTE
INTL’K IN terminals, remove one side of the
ADJUSTABLE jumper. If the interlock is being controlled by
TEMPERATURE
LIMIT SWITCH an external device, either open the interlock
via the external device or disconnect one of
the wires leading to the external device.
MOUNTING 4. The unit should shut down and display

PLATE INTERLOCK OPEN.
ON SHELL
5. Once the interlock connection is
reconnected, the INTERLOCK OPEN
message should automatically clear and the
unit should restart.
6.6.2 DELAYED INTERLOCK

Figure 6-2 Remove the cover from the I/O Box and locate
Temperature Limit Switch Setting the DELAYED INTL’K IN terminals.
Start the unit in the Manual Mode at a valve
Once the adjustable over-temperature switch position between 25% and 30%.
setting is approximately at, or just below, the If there is a jumper across the DELAYED INTL’K
actual outlet water temperature, the unit IN terminals, remove one side of the jumper. If
should shut down. The FAULT indicator the interlock is connected to a proving switch of
should start flashing and a HIGH WATER an external device, disconnect one of the wires
TEMP SWITCH OPEN fault message should leading to the proving switch.
be displayed. It should not be possible to
restart the unit. The unit should shut down and display a
DELAYED INTERLOCK OPEN fault message.
Reset the adjustable over-temperature switch to The FAULT LED should be flashing.
its original setting.
Reconnect the wire or jumper removed in step 3
The unit should start once the adjustable to restore the interlock.
temperature limit switch setting is above the
actual outlet water temperature. Press the CLEAR button to reset the fault
The unit should start.
6.6 INTERLOCK TESTS
The unit is equipped with two interlock circuits 6.7 FLAME FAULT TESTS
called the Remote Interlock and Delayed Flame faults can occur during ignition or while
Interlock. Terminal connections for these circuits the unit is already running. To simulate each of
are located in the I/O Box (Figure 2-9) and are these fault conditions, proceed as follows:
labeled REMOTE INTL’K IN and DELAYED
INTL’K IN. These circuits can shut down the
1. Set the ON/OFF switch to the OFF position.
unit in the event that an interlock is opened.
These interlocks are shipped from the factory 2. Place the unit in the Manual Mode and set
jumpered (closed). However, each of these the valve position between 25% and 30%.
interlocks may be utilized in the field as a remote
stop and start, an emergency cut-off, or to prove
6-3
3. Close the manual gas shutoff valve located (a) The unit will execute a shutdown purge
between the Safety Shut-Off Valve (SSOV) cycle for a period of 15 seconds and
and the Air/Fuel Valve (see Figure 6-3). display WAIT FAULT PURGE.
(b) The unit will execute a 30 second re-
AIR
INLET BLOWER PROOF ignition delay and display WAIT RETRY
BLOCKED SWITCH
INLET PAUSE.
SWITCH BLOWER
(c) The unit will then execute a standard
ignition sequence and display WAIT
IGNITION RETRY.
P/O FRAME
9. Open the valve previously closed in step 8.

10. Press the CLEAR button. The unit should
restart and fire.
6.8 AIR FLOW FAULT TESTS

These tests check the operation of the Blower
Proof Switch and Blocked Inlet Switch shown in
SSOV
AIR/FUEL Figure 6-3.

VALVE
1. Disable the blower output drive voltage as
MANUAL GAS
SHUTOFF VALVE follows:
HANDLE
(a) Press the MENU key until CONFIGUR-
ATION MENU is displayed.
GAS
INLET
(b) Press the ▲ arrow key until the ANA-
PARTIAL LEFT SIDE VIEW LOG OUTPUT function is displayed,
then press the CHANGE key.
Figure 6-3
Manual Gas Shut-Off Valve Location (c) Press the ▼ arrow key until OFF is
displayed, then press the ENTER key.
4. Set the ON/OFF switch to the ON position to 2. Start the unit in the Manual Mode at a valve
start the unit. position between 25% and 30%.
5. The unit should shut down after reaching the 3. The unit should shut down and execute an
Ignition cycle and display FLAME LOSS IGNITION RETRY cycle by performing the
DURING IGN. following steps:
6. Open the valve previously closed in step 3 (a) The unit will execute a 30 second re-
and press the CLEAR button. ignition delay and display WAIT RETRY
PAUSE.
7. Restart the unit and allow it to prove flame.
(b) The unit will then execute a standard
8. Once flame is proven, close the manual gas ignition sequence and display WAIT
valve located between the SSOV and the IGNITION RETRY.
Air/Fuel Valve.
4. The unit should perform two IGNITION
The unit should shut down and execute an RETRY cycles and then shut down on the
IGNITION RETRY cycle by performing the third successive ignition attempt. The unit will
following steps: display AIRFLOW FAULT DURING PURGE.
6-4
5. Disconnect wire #148 from the SSOV to

5. Re-enable the blower output drive voltage by
“open” the proof of closure switch circuit.
performing the following steps:
6. The unit should fault and display SSOV
(a) Press the MENU key until CONFIGUR-
SWITCH OPEN.
ATION MENU is displayed.
7. Replace wire #148 and press the CLEAR
(b) Press the ▲ arrow key until the ANA-
button.
LOG OUTPUT function is displayed,
then press the CHANGE key. 8. Set the ON/OFF switch to ON to start the
unit.
(c) Press the ▲ arrow key until VALVE
POSITION 0-10V is displayed, then 9. Remove the wire again when the unit
press the ENTER key. reaches the purge cycle and PURGING is
displayed.
6. Once the unit has proved flame, turn off the
blower by going to the Configuration Menu, 10. The unit should shut down and display SSOV
Analog Output menu item and select OFF. FAULT DURING PURGE.
7. The Blower Proof Switch will open and the 11. Replace the wire on the SSOV and press the
blower should stop. The unit should shut CLEAR button. The unit should restart.
down and display AIRFLOW FAULT
DURING RUN.
8. Go to the Configuration Menu, Analog Output
item and select Valve Position 0-10v.
restart.
10. Next, check the Blocked Inlet Switch by first
noting the current position of the Iris Air SSOV
ACTUATOR
Damper and then closing the Damper to COVER
position 8.
11. The unit should shut down and again display ACTUATOR
COVER
AIRFLOW FAULT DURING RUN. SCREW
12. Return the Iris Air Damper to its previous

setting.
restart. Figure 6-4
SSOV Actuator Cover Location
6.9 SSOV PROOF OF CLOSURE SWITCH 6.10 PURGE SWITCH OPEN DURING
The SSOV shown in Figure 6-1 contains a proof PURGE
of closure switch. The proof of closure switch The Purge Switch (and Ignition Switch) is
circuit is checked as follows: located on the Air/Fuel Valve. To check the
switch, proceed as follows:
1. Set the unit’s ON/OFF switch to the OFF
position. 1. Set the unit’s ON/OFF switch to the OFF
2. Place the unit in Manual Mode and set the position. Place the unit in manual mode and
valve position between 25% and 30% set the valve position between 25% and
30%.
3. Refer to Figure 6-1 and locate the SSOV.
2. Remove the Air/Fuel Valve cover by rotating
4. Remove the cover from the SSOV by the cover counterclockwise to unlock it and
loosening the screw shown in Figure 6-4. Lift then lift up (see Figure 6-5).
off the cover to access the terminal wiring
connections. 3. Remove one of the two wires (#171 or #172)
from the Purge Switch (Figure 6-6).
6-5
4. Initiate a unit start sequence.

5. The unit should begin it’s start sequence,
then shut down and display PRG SWITCH STEPPER
OPEN DURING PURGE. MOTOR DIAL
6. Replace the wire on the Purge Switch and

depress the CLEAR button. The unit should
restart. TO AIR
BLOWER IN
6.11 IGNITION SWITCH OPEN DURING
IGNITION
The Ignition Switch (and the Purge Switch) is
located on the Air/Fuel Valve. To check the
switch, proceed as follows:
1. Set the unit’s ON/OFF switch to the OFF
17
16
position.
2
170
171
2. Place the unit in Manual Mode and set the
valve position between 25% and 30%. IGNITION PURGE
POSITION POSITION
3. Remove the Air/Fuel Valve cover (Figure SWITCH SWITCH
6-5) by rotating the cover counterclockwise to
unlock and lift up to remove. Figure 6-6
4. Remove one of the two wires (#169 or #170) Air/Fuel Valve Purge and Ignition Switch
from the Ignition Switch (Figure 6-6). Locations
5. Initiate a unit start sequence.
6. The unit should begin its start sequence and 6.12 SAFETY PRESSURE RELIEF
then shut down and display IGN SWITCH
VALVE TEST
OPEN DURING IGNITION.
Test the safety Pressure Relief Valve in
7. Replace the wire on the Ignition Switch and accordance with ASME Boiler and Pressure
press the CLEAR button. The unit should Vessel Code, Section VI.
restart.
AIR/FUEL VALVE COVER

(ROTATE CCW TO REMOVE)
Figure 6-5
Air/Fuel Valve Cover Location
6-6
MAINTENANCE
CHAPTER 7 MAINTENANCE
7.1 MAINTENANCE SCHEDULE 7.2 IGNITOR-INJECTOR

The unit requires regular routine maintenance to The ignitor-injector (part no. 58023) is located in
keep up efficiency and reliability. For best the body of the burner (see Figure 7-1). In
operation and life of the unit, the following addition to providing the ignition spark required
routine maintenance procedures should be to light the burner, this component also contains
carried out in the time periods specified in Table a gas injector tube which connects to the staged
7-1. See Appendix I for a complete CSD-1 ignition assembly. The ignitor-injector may be
inspection check list. hot, therefore, care should be exercised to avoid
burns. It is easier to remove the ignitor-injector
In order to perform the maintenance tasks
from the unit after the unit has cooled to room
specified in Table 7-1, the following
temperature.
maintenance kits are available through your
local AERCO Sales Representative:
• Annual Maintenance Kit, Part No. 58025-01
• 24-Month Waterside/Fireside Inspection Kit,
Part No. 58025-04 (See NOTE below) BURNER
HOUSING
NOTE
The 24-Month Waterside/Fireside Inspec-
tion Kit also includes the items contained STAGED
IGNITION
in the Annual Maintenance Kit. Therefore, ASSY
only Kit Part No. 58025-04 is required
when performing the waterside/fireside
inspections.
IGNITOR- FLAME DETECTOR
INJECTOR & GASKET (SECURED
WITH 2 SCREWS)
Appendix K contains recommended spare parts
Figure 7-1.
lists for maintenance of the boiler.
Burner Assembly – Top View
To inspect/replace the Ignitor-injector, proceed

WARNING as follows:
TO AVOID PERSONAL INJURY, 1. Set the ON/OFF switch on the control panel,
PRIOR TO SERVICING: to the OFF position. Disconnect AC power
• DISCONNECT THE AC SUPPLY BY from the unit
TURNING OFF THE SERVICE 2. Remove the top and side panels from the
SWITCH AND AC SUPPLY CIRCUIT unit.
BREAKER. 3. Disconnect the cable from the ignitor-injector.
• SHUT OFF THE GAS SUPPLY AT
4. Using a 7/16” open-end wrench, disconnect
THE MANUAL SHUT-OFF VALVE
the compression nut securing the gas injector
PROVIDED WITH THE UNIT tube of the ignitor-injector to the elbow of the
• ALLOW THE UNIT TO COOL TO A staged ignition assembly. Disconnect the
SAFE WATER TEMPERATURE TO staged ignition assembly from the ignitor-
PREVENT BURNING OR SCALDING injector.
7-1
MAINTENANCE
BURNER
HOUSING
5. Next, loosen and remove the ignitor-injector HOUSING
CENTERLINE
from the burner housing using a 1" open-end IGNITOR-
wrench. INJECTOR
6. Check the ignitor-injector for evidence of

erosion or carbon build-up. If there is
evidence of substantial erosion or carbon
build-up, the ignitor-injector should be 120
replaced. If carbon build-up is present, clean

the component using fine emery cloth. 120
Repeated carbon build-up is an indication DEG. GAS INJECTOR TUBE
that the combustion settings of the unit MUST BE WITHIN
THIS RANGE
should be checked. Refer to Chapter 4 for
combustion calibration procedures.
Fgurei 7-2
7. Prior to reinstalling the ignitor-injector, a high
temperature, conductive, anti-seize com- Burner Assembly – Top View
pound must be applied to the threads. 8. Reinstall the ignitor-injector in the burner
housing and torque to 80 to 90 in-lbs.
NOTE However, if the burner housing was replaced
If a replacement ignitor-injector (part no. just prior to replacing the ignitor-injector,
58023) is being installed, a compression torque to 180 in-lbs, then loosen and re-
nut containing a built-in ferrule will be tighten to 80 to 90 in-lbs.
included with the replacement part. If
9. Connect the staged ignition assembly to the
needed, 3 indexing washers are also
gas injector tube of the ignitor-injector by
included. These washers may be needed
securing the compression nut to the elbow of
to properly position the gas injector tube
the staged ignition assembly.
of the ignitor-injector within the 120° angle
shown in Figure 7-2. 10. Reconnect the ignitor-injector cable.
11. Reinstall the side and top panels on the unit.
Table 7-1 - Maintenance Schedule

Labor
PARAGRAPH ITEM 6 Mos. 12 Mos. 24 Mos.
Time
Ignitor-Injector
7.2 *Inspect Inspect Replace 15 mins.
(58023)
Flame Detector
7.3 *Inspect Inspect Replace 15 mins.
(66006)
Combustion
7.4 *Check Check 1 hr.
Calibration
See CSD-1
Testing of
7.5 Chart in 20 mins.
Safety Devices
Appendix I
7.6 Burner Inspect 2 hrs.
Condensate Inspect &
7.7 *Inspect 1 hr.
Drain Traps Clean
* Only performed after initial 6 month period after initial startup.
7-2
MAINTENANCE
7.3 FLAME DETECTOR 7.6 BURNER ASSEMBLY INSPECTION

The flame detector, part no. 66006, is located in The burner assembly is located at the top front
the body of the burner (see Figure 7-1). The of the unit. The burner assembly may be hot.
flame detector may be HOT. Allow the unit to Allow the unit to cool sufficiently before
cool sufficiently before removing the flame removing the burner assembly.
detector.
The following replacement parts will be
To inspect or replace the flame detector: necessary for reassembly following inspection:
1. Set the ON/OFF switch on the control panel,

to the OFF position. Disconnect AC power
from the unit.
Part No. Description
81030 Burner Gaskets (Qty=2)
2. Remove the top panels from the unit. 81048 Flame Detector Gasket
3. Disconnect the lead wire from the flame
detector. To inspect or replace the burner assembly:
4. Remove the two (2) screws securing the

flame detector to the burner housing (Figure 1. Set the ON/OFF switch on the control panel,
7-1). The flame detector is secured to the to the OFF position. Disconnect AC power
burner housing with one (1) #10-32 screw from the unit and turn off the gas supply.
and one (1) #8-32 screw. 2. Remove the side and top panels from the
5. Remove the flame detector and gasket from unit.
the burner housing. 3. Disconnect the lead wire from the flame
6. Inspect the detector thoroughly. If eroded, detector (see Figure 7-1).
the detector should be replaced. Otherwise 4. Remove the two (2) screws securing the
clean the detector with a fine emery cloth. flame detector to the burner housing. The
7. Reinstall the flame detector and flame flame detector is secured to the burner
detector gasket. housing with one (1) #10-32 screw and one
(1) #8-32 screw.
8. Reconnect the flame detector lead wire.
5. Remove the flame detector and gasket from
9. Reinstall the top and side panels on the unit. the burner housing.
6. Disconnect the cable from the ignitor-injector.
7.4 COMBUSTION CALIBRATION
7. Using a 7/16” open-end wrench, disconnect
Combustion settings must be checked at the the compression nut securing the gas injector
intervals shown in Table 7-1 as part of the tube of the ignitor-injector to the elbow of the
maintenance requirements. Refer to Chapter 4 staged ignition assembly. Disconnect the
for combustion calibration instructions. staged ignition assembly from the ignitor-
injector.
7.5 SAFETY DEVICE TESTING
8. Loosen and remove the ignitor-injector from
Systematic and thorough tests of the operating
the burner plate using a 1" wrench.
and safety devices should be performed to
ensure that they are operating as designed. 9. Disconnect the burner housing from the
Certain code requirements, such as ASME blower by removing the six (6) 1/4-20 screws
CSD-1, require that these tests be performed on using a 3/8” wrench.
a scheduled basis. Test schedules must
10. Remove the eight (8) 3/8-16 nuts from the
conform to local jurisdictions. The results of the
burner flange (Figure 7-3) using a 9/16”
tests should be recorded in a log book. See
wrench.
Chapter 6-Safety Device Testing Procedures.
7-3
MAINTENANCE
BURNER
HOUSING
3/8-16 STAGED STAGED IGNITION
NUTS (8) IGNITION ASSEMBLY
ASSEMBLY
FLAME
DETECTOR
GROUNDING
SCREW
IGNITOR-
INJECTOR
BURNER GASKET
BURNER
HOUSING
BURNER
BURNER GASKET
1/4-20
SCREWS
(6)
Figure 7-3
Burner Disassembly Diagram - Top View Figure 7-4
Burner Assembly - Exploded View
NOTE
The burner housing is heavy, weighing 7.7 CONDENSATE DRAIN TRAPS
approximately 25 pounds.
The Benchmark 3.0 Boiler contains two
11. Refer to the exploded view in Figure 7-4. condensate traps as shown in Chapter 2, Figure
Remove the burner housing from burner 2-5. One trap is located external to the unit and
flange by pulling straight up. attached to the drain pipe from the connecting
manifold. The other trap is an integral part of the
12. Remove the grounding screw. exhaust manifold. These traps should be
inspected and, if necessary, cleaned to ensure
13. Remove the burner by pulling straight up.
proper operation. Follow the procedures in
14. Remove and replace the burner gaskets. paragraphs 7.7.1 and 7.7.2.
15. Beginning with the burner removed in step
13, reinstall all the components in the reverse 7.7.1 Connecting Manifold Condensate
order that they were removed. Trap
To inspect and clean the condensate trap (part
16. Make sure to align the burner housing with
no. 24060) attached to the connecting manifold,
the blower and the heat exchanger top head.
proceed as follows:
17. Check to ensure that the grounding screw is
reinstalled. Also, ensure that conductive, 1. Loosen the thumbscrew securing the trap
high-temperature, anti-seize compound is adaptor (Figure 2-6) to the condensate drain
applied to the threads of the ground screw pipe on the connecting manifold.
and the ignitor-injector. Torque the ignitor-
2. Remove the nipples and connections on the
injector to 80 to 90 in-lbs. However, if the
inlet and outlet sides of the condensate trap
burner housing was replaced during
shown in Figure 7-5.
inspection, torque to 180 in-lbs, then loosen
and re-tighten to 80 to 90 in-lbs.
7-4
MAINTENANCE
3. Loosen the four (4) thumbscrews securing

1. Loosen the clamp securing the hose to the
the cover on the condensate trap. Remove
condensate drain (Figure 7-6). Disconnect
the cover.
the hose.
4. Remove the float from the condensate trap.
2. Remove the four bolts securing the flue to
5. Remove the orifice gasket from the trap. the top of the exhaust manifold. Separate the
flue from the exhaust manifold.
6. Thoroughly clean the trap, float and gasket.
Also inspect the drain piping for blockage. If 3. From the top of the exhaust manifold,
the trap cannot be thoroughly cleaned, remove the float and orifice gasket from the
replace the trap. condensate trap.
7. After the above items have been inspected 4. Thoroughly clean the trap, float and gasket.
and thoroughly cleaned, replace the orifice Also, inspect the drain hose for blockage.
gasket and float in the condensate trap and
5. After the above items have been inspected
replace the trap cover.
and cleaned, replace the gasket and float in
8. Reassemble all piping and hose connections the condensate trap.
to the condensate trap inlet and outlet.
6. Replace the four bolts securing the flue to the
9. Reconnect the condensate trap adaptor to exhaust manifold and connect the hose to
connecting manifold drain pipe, Ensure that the manifold condensate drain.
the trap is level and then tighten the adaptor
thumbscrew. Place a suitable support under
FLUE
the trap to maintain it in the level position. UNIT
FRAME
BOLTS
(4)
THUMB
SCREWS
COVER (4) EXHAUST
MANIFOLD
O-RING
FLOAT CONDENSATE
TRAP
INLET
ORIFICE
GASKET DRAIN
3/4 NPT
PORT HOSE
3/4 NPT CLAMP
PORT
1" I.D.
OUTLET HOSE
Figure 7-5
External Condensate Trap
7.7.2 Exhaust Manifold Condensate Trap

TO FLOOR
The exhaust manifold condensate trap also DRAIN
contains a float and orifice gasket similar to
those shown in Figure 7-5. The only difference is Figure 7-6
that the orifice gasket in the exhaust manifold
Exhaust Manifold Condensate Trap &
trap has a 0.75" I.D. opening and the gasket
shown in Figure 7-5 has a 0.25" I.D. To inspect Drain
and clean the trap, refer to Figure 7-6 and
proceed as follows:
7-5
MAINTENANCE
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 time (one year or more), the
following instructions must be followed.
1. Set ON/OFF switch on the front panel to the

OFF position to shut down the boiler’s
operating controls.
2. Disconnect AC power from the unit.
3. Close the water supply and return valves to
isolate boiler.
4. Close external gas supply valve.
5. Open relief valve to vent water pressure.
7.9 PLACING THE BOILER BACK IN

SERVICE AFTER A PROLONGED
SHUTDOWN
After a prolonged shutdown (one year or more),
the following procedures must be followed:
1. Review installation requirements included in

Chapter 2.
2. Inspect all piping and connections to the

unit.
3. Inspect exhaust vent, air duct (if applicable).
4. Perform initial startup per Chapter 4.
5. Perform safety device testing and the

scheduled maintenance procedures per
Chapters 6 and 7 of this manual.
7-6
TROUBLESHOOTING
Chapter 8- TROUBLESHOOTING GUIDE
8.1 INTRODUCTION
This troubleshooting guide is intended to aid When a fault occurs in the Benchmark Boiler,
service/maintenance personnel in isolating the proceed as follows to isolate and correct the
cause of a fault in a Benchmark 3.0 Boiler. The fault:
troubleshooting procedures contained herein are
presented in tabular form on the following pages.
These tables are comprised of three columns 1. Observe the fault messages displayed in the
labeled: Fault Indication, Probable Cause and Control Box display.
Corrective Action. The numbered items in the
Probable Cause and Corrective Action columns 2. Refer to the Fault Indication column in
correspond to each other. For example, Troubleshooting Table 8-1 which follows and
Probable Cause No. 1 corresponds to Corrective locate the Fault that best describes the
Action No. 1, etc. existing conditions.
3. Proceed to the Probable Cause column and

start with the first item (1) listed for the Fault
Indication.
NOTE:
The front panel of the C-More Control Box 4. Perform the checks and procedures listed in
contains an RS232 port which can be interfaced the Corrective Action column for the first
to a laptop computer or other suitable device. Probable Cause candidate.
This RS232 communication feature permits 5. Continue checking each additional Probable
service personnel to view menu items and data Cause for the existing fault until the fault is
logs which can be useful in isolating faults. Refer corrected.
to Chapter 9 of this manual for detailed RS232
communication set-up and procedures. 6. Paragraph 8.2 and Table 8-2 contain
additional troubleshooting information which
may apply when no fault message is
displayed.
7. If the fault cannot be corrected using the

information provided in the Troubleshooting
Tables, contact your local AERCO
Representative.
8-1
APPENDIX B
TABLE 8-1. BOILER TROUBLESHOOTING
FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

AIRFLOW FAULT 1. Blower stopped running due to 1. Check combustion blower for signs of excessive heat or high current
DURING IGNITION thermal or current overload drain that may trip thermal or current overload devices.
2. Blocked Blower inlet or inlet ductwork 2. Inspect the inlet to the combustion blower including any ductwork
leading up to the combustion blower for signs of blockage.
3. Blocked Blower proof switch 3. Remove the Blower proof switch and inspect for signs of blockage,
clean or replace as necessary.
4. Blocked blocked-air inlet switch 4. Remove the blocked-air inlet switch and inspect for signs of
blockage, clean or replace as necessary.
5. Defective Blower proof switch 5. Measure the Blower proof switch for continuity with the combustion
blower running. If there is an erratic resistance reading or the
resistance reading is greater than zero ohms, replace the switch.
6. Defective blocked-air inlet switch 6. Measure the blocked-air inlet switch for continuity with the
combustion blower running. If there is an erratic resistance reading
or the resistance reading is greater than zero ohms, replace the
switch.
7. Loose temperature to AUX connection 7. Check the actual inlet air temperature and measure voltage at AUX
in I/O Box input in the I/O Box. Verify that the voltage conforms to the values
shown in the tabular listing provided in Appendix C.
8. Defective temperature sensor 8. Refer to CORRECTIVE ACTION 7 and verify that the voltage
conforms to the values shown in Appendix C.
9. Loose wire connection between the 9. Check wire connection from I/O Box 0-10V signal to the Blower
0-10V signal from I/O box to the Motor.
Blower Motor input
10. Defective I/O box 10. Measure voltage at the I/O box 0-10V output. A voltage of 8.2V
equates to a 100% open air/fuel valve position.
11. Wrong 0-10V output selection on the 11. Check the Analog Out option on the C-More Configuration Menu.
control box Valve Position 0-10V should be selected.
12. Defective Air-Fuel Valve 12. Check Air/Fuel Valve position at 0%, 50% and 100% open
potentiometer positions. The position on the VALVE POSITION bar graph should
match the reading on the Air/Fuel Valve dial.
8-2
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued

AIRFLOW FAULT 1. Blower not running or running too slow 1. Start the unit. If the blower does not run check the blower solid
DURING PURGE state relay for input and output voltage. If the relay is okay, check
the blower.
2. Defective Air Flow Switch 2. Start the unit. If the blower runs, check the airflow switch for
continuity. Replace the switch if there is no continuity.
3. Blocked Air flow Switch 3. Remove the air flow switch and inspect for signs of blockage,
4. Blocked Blower inlet or inlet ductwork. 4. Inspect the inlet to the combustion blower including any ductwork
5. No voltage to switch from control box. 5. Measure for 24 VAC during start sequence from each side of the
switch to ground. If 24VAC is not present refer to qualified
service personnel.
6. PROBABLE CAUSES from 3 to 12 6. See CORRECTIVE ACTION from 3 to 12 for AIRFLOW
for AIRFLOW FAULT DURING FAULT DURING IGNITION
IGNITION also apply for this fault
AIRFLOW FAULT 1. Blower stopped running due to thermal 1. Check combustion blower for signs of excessive heat or high
DURING RUN or current overload current draw that may trip thermal or current overload devices.
2. Blocked Blower inlet or inlet ductwork 2. Inspect the inlet to the combustion blower including any ductwork
3. Blocked airflow switch 3. Remove the airflow switch and inspect for signs of blockage,
4. Defective airflow switch 4. Measure the airflow switch for continuity with the combustion
blower running. If there is an erratic resistance reading or the
resistance reading is greater than zero ohms, replace the switch.
5. Combustion oscillations 5. Run unit to full fire. If the unit rumbles or runs rough, perform
combustion calibration.
6. PROBABLE CAUSES from 3 to 12 6. PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT
for AIRFLOW FAULT DURING DURING IGNITION applies for this fault
IGNITION applies for this fault
8-3
TROUBLESHOOTING

DELAYED 1. Delayed Interlock Jumper not 1. Check for a jumper properly installed across the delayed
INTERLOCK OPEN installed or removed. interlock terminals in the I/O box.
2. Device proving switch hooked to 2. If there are 2 external wires on these terminals, check to see if
interlocks is not closed an end switch for a device such as a pump, louver, etc. is tied
these interlocks. Ensure that the device and or its end switch
are functional. (jumper may be temporarily installed to test
interlock)
DIRECT DRIVE 1. Direct drive signal is not present: 1. Check I/O Box to ensure signal is hooked up.
SIGNAL FAULT Not yet installed. Hook up if not installed.
Wrong polarity. If installed, check polarity.
Signal defective at source. Measure signal level.
Broken or loose wiring. Check continuity of wiring between source and boiler.
2. Signal is not isolated (floating). 2. Check signal at source to ensure it is isolated.
3. Control Box signal type selection 3. Check DIP switch on PMC board to ensure it is set correctly for
switches not set for correct signal the type of signal being sent. Check control signal type set in
type (voltage or current). Configuration Menu.
FLAME LOSS 1. Burner Ground Screw not installed 1. Inspect and install/retighten Burner Ground Screw.
DURING IGN or loose.
2. Worn flame detector 2. Remove and inspect the flame detector for signs of wear.
Replace if necessary.
3. No spark from Spark Plug 3. Close the internal gas valve in the boiler. Install and arc a spark
igniter outside the unit.
4. Defective Ignition Transformer 4. If there is no spark, check for 120VAC at the primary side of the
ignition transformer during the ignition cycle.
5. Defective Ignition/Stepper (IGST) 5. If 120VAC is not present, the IGST Board in the Control Box
Board may be defective. Refer fault to qualified service personnel.
6. Defective SSOV 6. While externally arcing the spark igniter, observe the
open/close indicator in the Safety Shut-Off Valve to ensure it is
opening. If the valve does not open, check for 120VAC at the
valve’s input terminals. If 120VAC is not present, the IGST
board in the Control Box may be defective. Refer fault to
qualified service personnel.
8-4
TROUBLESHOOTING

(continued) 7. Carbon or other debris on Burner 7. Remove the burner and inspect for any carbon or debris. Clean
and reinstall.
8. Staged ignition ball valve closed. 8. Open 1/4” ball valve downstream of the SSOV (see Figure 8-1).
9. Staged ignition solenoid valve 9. When boiler goes to ignition, listen to the solenoid valve for a
doesn’t open. clicking sound to ensure it is opening.
10. Clogged staged ignition piece. 10. Remove and inspect staged ignition piece for blockage.
FLAME LOSS 1. Worn Flame Detector or cracked 1. Remove and inspect the Flame Detector for signs of wear or
DURING RUN ceramic. cracked ceramic. Replace if necessary.
2. Defective SSOV Regulator. 2. Check gas pressure readings using a gauge or manometer into
and out of the Air/Fuel Valve to ensure that the gas pressures
into and out of the valve are correct.
3. Poor combustion calibration. 3. Check combustion calibration. Adjust as necessary.
4. Debris on burner. 4. Remove the burner and inspect for any carbon or debris. Clean
and reinstall.
5. Blocked condensate drain. 5. Remove blockage in condensate drain.
HEAT DEMAND 1. The Heat Demand Relays on the 1. Press CLEAR button and restart the unit. If the fault persists,
FAILURE Ignition/Stepper board failed to replace Ignition/Stepper (IGST) Board.
activate when commanded
2. Relay is activated when not in 2. Defective relay. Replace IGST Board.

Demand
HIGH EXHAUST 1. Defective exhaust sensor. 1. Measure the actual exhaust temperature and continuity of the
o
TEMPERATURE exhaust sensor. If the exhaust temperature is less than 475 F
and the exhaust sensor shows continuity replace the sensor.
o
2. Carboned heat exchanger due to 2. If exhaust temperature is greater than 500 F, check
incorrect combustion calibration combustion calibration. Calibrate or repair as necessary.
8-5
TROUBLESHOOTING

HIGH GAS 1. Incorrect supply gas pressure. 1. Check to ensure gas pressure at inlet of SSOV is 2 psig
PRESSURE maximum.
2. Defective SSOV Actuator gas 2. If gas supply pressure downstream of the SSOV cannot be
pressure adjustment regulator. lowered, to 1.8” W.C. (see para. 4.3, step 10), the SSOV
Actuator gas pressure adjustment regulator may be defective.
3. Defective High Gas Pressure Switch 3. Remove the leads from the high gas pressure switch and
measure continuity across the common and normally closed
terminals with the unit not firing. Replace the switch if it does not
show continuity.
4. Gas pressure snubber not installed. 4. See Figure 8-1. Ensure that the gas pressure snubber is installed
at the high gas pressure switch.
HIGH WATER TEMP 1. Faulty Water temperature switch. 1. Test the temperature switch to insure it trips at its actual water
SWITCH OPEN temperature setting.
2. Incorrect PID settings. 2. Check PID settings against Menu Default settings in the
Appendix. If the settings have been changed, record the current
readings then reset them to the default values.
3. Faulty shell temperature sensor. 3. Using the resistance charts in the Appendix C, Measure the
resistance of Shell sensor and BTU sensor at a known water
temperature.
4. Unit in Manual mode 4. If unit is in Manual Mode switch to Auto Mode.
5. Unit setpoint is greater than Over 5. Check setpoint of unit and setpoint of Temperature Switch;
Temperature Switch setpoint. Ensure that the temperature switch is set higher than the unit’s
setpoint.
6. Boiler Management System PID or 6. Check the BMS for changes to PID default values, correct as
other settings not correctly setup. necessary.
7. No interlock to boiler or BMS to 7. If system pump is controlled by Energy Management System
disable boiler(s) in event that system other than BMS or pumps are individually controlled by boiler,
pumps have failed. check to see if there are flow switches interlocked to the BMS or
boiler.
8. System flow rate changes are 8. If the system is a variable flow system, monitor system flow
occurring faster than boilers can changes to ensure that the rate of flow change is not faster than
respond. what the boilers can respond to.
8-6
TROUBLESHOOTING

HIGH WATER 1. See HIGH WATER TEMPERATURE 1. See HIGH WATER TEMPERATURE SWITCH OPEN.
TEMPERATURE SWITCH OPEN.
2. Temp HI Limit setting is too low. 2. Check Temp HI Limit setting.
IGN BOARD 1. Communication fault has occurred 1. Press CLEAR button and restart unit. If fault persists, contact
COMM FAULT between the PMC board and qualified Service Personnel.
Ignition/Stepper (IGST) board
IGN SWTCH CLOSED 1. Air/Fuel Valve not rotating 1. Start the unit. The Air/Fuel Valve should rotate to the purge
DURING PURGE (open) position. If the valve does not rotate at all or does not
rotate fully open, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air-Fuel Valve or
the Control Box. Refer to qualified service personnel
2. Defective or shorted switch 2. . If the Air/Fuel Valve does rotate to purge, check the ignition
switch for continuity between the N.O. and COM terminals. If the
switch shows continuity when not in contact with the cam replace
the switch.
3. Switch wired incorrectly 3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals). If the switch is wired
correctly, replace the switch
4. Defective Power Supply Board or 4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
fuse steady ON, replace Power Supply Board.
5. Defective IGST Board 5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board
IGN SWTCH OPEN 1. Air/Fuel Valve not rotating to ignition 1. Start the unit. The Air/Fuel Valve should rotate to the purge
DURING IGNITION position. (open) position, then back to ignition position (towards closed)
during the ignition cycle. If the valve does not rotate back to the
ignition position, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air/Fuel Valve or
the Control Box. Refer fault to qualified service personnel.
2. Defective ignition switch 2. If the Air/Fuel Valve does rotate to the ignition position, check the
ignition position switch for continuity between the N.O. and COM
terminals when in contact with the cam.
every second. If not, replace IGST Board.
8-7
TROUBLESHOOTING

INTERLOCK 1. Interlock jumper not installed or 1. Check for a jumper properly installed across the interlock
OPEN removed terminals in the I/O box
2. Energy Management System does 2. If there are two external wires on these terminals check any
not have boiler enabled. Energy Management system to see if they have the units
disabled (a jumper may be temporarily installed to see if the
interlock circuit is functioning).
3. Device proving switch hooked to 3. Check that proving switch for any device hooked to the interlock
interlocks is not closed. circuit is closing and that the device is operational.
LINE VOLTAGE 1. Line and Neutral switched in AC 1. Check Line (hot) and Neutral in AC Power Box to ensure they
OUT OF PHASE Power Box. are not reversed
2. Incorrect power supply transformer 2. Check transformer wiring, in AC Power Box, against the power
wiring. box transformer wiring diagram to ensure it is wired correctly
LOW GAS 1. Incorrect supply gas pressure. 1. Measure gas pressure upstream of the supply gas regulator with
PRESSURE the unit firing. Ensure it is at least 3.5” W.C. for FM gas train, or
4.0” W.C. for IRI gas train. Max. allowable pressure is 2 psig
(see para. 2.7.1).
2. Defective Low Pressure Gas Switch 2. Measure gas pressure at the low gas pressure switch. If it is
greater than 2.6” W.C., measure continuity across the switch and
replace if necessary.
LOW WATER 1. Insufficient water level in system 1. Check system for sufficient water level.
LEVEL 2. Defective water level circuitry. 2. 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.
3. Defective water level probe. 3. Check continuity of probe end to the shell, change probe if there
is no continuity.
MODBUS COMM 1. Boiler not seeing information from 1. Check network connections. If fault persists, contact qualified
FAULT Modbus network Service Personnel.
PRG SWTCH CLOSED 1. A/F Valve rotated open to purge and 1. Start the unit. The Air/Fuel Valve should rotate to the purge
DURING IGNITION did not rotate to ignition position (open) position, then back to ignition position (towards closed)
during the ignition cycle. If the valve does not rotate back to the
ignition position, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air/Fuel Valve or
the Control Box. Refer fault to qualified service personnel.
8-8
TROUBLESHOOTING

(continued) 2. Defective or shorted switch. 2. If the Air/Fuel Valve does rotate to the ignition position, check the
purge switch for continuity between the N.O. and COM terminals.
If the switch shows continuity when not in contact with the cam,
check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
3. Switch wired incorrectly. 3. If the switch is wired correctly, replace the switch.
PRG SWTCH OPEN 1. Defective purge switch. 1. If the air-fuel valve does rotate, check the purge switch for
DURING PURGE continuity when closing. Replace switch if continuity does not
exist.
2. No voltage present at switch. 2. Measure for 24 VAC from each side of the switch to ground. If
24VAC is not present, refer fault to qualified service personnel.
3. Switch wired incorrectly. 3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
OUTDOOR TEMP 1. Loose or broken wiring. 1. Inspect Outdoor Temperature sensor for loose or broken wiring.
SENSOR FAULT 2. Defective Sensor. 2. Check resistance of sensor to determine if it is within
specification.
3. Incorrect Sensor. 3. Ensure that the correct sensor is installed.
REMOTE SETPT 1. Remote setpoint signal not present: 1. Check I/O Box to ensure signal is hooked up.
SIGNAL FAULT Not yet installed. Hook up if not installed.
Wrong polarity. If installed, check polarity.
Signal defective at source. Measure signal level.
Broken or loose wiring. Check continuity of wiring between source and boiler.
2. Signal is not isolated (floating) if 4 to 2. Check signal at source to ensure it is isolated.
20 mA.
3. Control Box signal type selection 3. Check DIP switch on PMC board to ensure it is set correctly for
switches not set for correct signal the type of signal being sent. Check control signal type set in
type (voltage or current). Configuration Menu.
8-9
TROUBLESHOOTING

RESIDUAL 1. SSOV not fully closed. 1. Check open/close indicator window of Safety Shut-Off Valve
FLAME (SSOV) and ensure that the SSOV is fully closed. If not fully
closed, replace the valve and or actuator.
Close gas shut-off valve downstream of SSOV. Install a

manometer or gauge in a gas test port between the SSOV and
the gas shut off valve. If a gas pressure reading is observed
replace the SSOV valve and or actuator.
2. Defective Flame Detector 2. Replace Flame Detector.
SSOV FAULT See SSOV SWITCH OPEN
DURING PURGE
SSOV FAULT 1. SSOV switch closed for 15 seconds 1. Replace or adjust microswitch in SSOV actuator. If fault
DURING RUN during run. persists, replace actuator.
SSOV RELAY 1. SSOV relay failed on board. 1. Press CLEAR button and restart unit. If fault persists, replace
FAILURE Ignition/Stepper (IGST) Board.
2. Floating Neutral. 2. The Neutral and Earth Ground are not connected at the source
and therefore there is a voltage measured between the two.
Normally this measurement should be near zero or no more than
a few millivolts.
3. Hot and Neutral reversed at SSOV. 3. Check SSOV power wiring.
SSOV 1. Actuator not allowing for full closure 1. Observe operation of the Safety Shut-Off Valve (SSOV) through
SWITCH OPEN of gas valve indicator on the Valve actuator and ensure that the valve is fully
and not partially closing.
2. SSOV powered when it should not be 2. If the SSOV never closes, it may be powered continuously. Close
the gas supply and remove power from the unit. Refer fault to
3. Defective Switch or Actuator qualified service personnel.
3. Remove the electrical cover from the SSOV and check switch
continuity. If the switch does not show continuity with the gas
4. Incorrectly wired switch. valve closed, either adjust or replace the switch or actuator.
4. Ensure that the SSOV Proof of Closure switch is correctly wired.
STEPPER MOTOR 1. Air/Fuel Valve out of calibration. 1. Refer to GF-112 and perform Stepper Test (para. 6.3.5) to
FAILURE ensure stepper motor rotates properly between the 0% (fully
closed) and 100% (fully open) positions. Verify that the VALVE
POSITION bargraph and the dial on the Air/Fuel Valve track
each other to indicate proper operation. If operation is not
correct, perform the Stepper Feedback Calibration (GF-112,
para. 6.2.1).
8-10
TROUBLESHOOTING

(continued) 2. Air/Fuel Valve unplugged. 2. Check that the Air/Fuel Valve is connected to the Control Box.
3. Loose wiring connection to the 3. Inspect for loose connections between the Air/Fuel Valve motor
stepper motor. and the wiring harness.
4. Defective Air/Fuel Valve stepper 4. Replace stepper motor.
motor.
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES

Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed.
TABLE 8-2. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED
OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION

Hard Light-Off 1. Staged Ignition Ball Valve closed. 1. Open the 1/4” Ball Valve downstream of the SSOV (Fig. 8-1).
2. Clogged/damaged Ignitor- Injector 2. Remove and inspect gas injector to ensure it is not clogged or
(Figure 8-2). damaged.
3. Defective Staged Ignition Solenoid 3. Close the 2” and the 1/4” Ball Valve downstream of the SSOV
(Figure 8-2) (Fig. 8-1). Start the unit and listen for a “clicking” sound that the
Staged Ignition Solenoid makes during Ignition Trial. If “clicking”
sound is not heard after 2 or 3 attempts, replace the Staged
Ignition Solenoid.
Fluctuating Gas Pressure 1. Gas pressure going into unit is 1. Stabilize gas pressure going into unit. If necessary, troubleshoot
fluctuating. Building Supply Regulator.
2. Damping Orifice not installed. 2. Check to ensure that the Damping Orifice is installed in the
SSOV Actuator (Figure 8-3). For IRI Gas Trains, the Damping
Orifice is installed in the downstream SSOV Actuator.
Air/Fuel Valve “hunting” at 80% 1. IGST and Power Supply Boards in 1. Check to ensure that the IGST and Power Supply Boards are
valve position Control Box are outdated. Rev. E or higher.
8-11
TROUBLESHOOTING
Figure 8-2
Staged Ignition Solenoid Location
Figure 8-1
High Pressure Gas Switch & Snubber Locations
Figure 8-3
Damping Orifice Location
8-12
RS232 COMMUNICATION
CHAPTER 9 RS232 COMMUNICATION
9.1 INTRODUCTION M = Display next Menu

The RS232 port on the front panel of the C-More D = Display menu items
Control Box (Figure 3-1) can be interfaced to a N = Display next menu items
laptop computer or other suitable terminal using Cxx = Change item xx
a RS232 adapter cable. RS232 communication F = Fault log display
can be accomplished using any “Dumb S = Sensor log display
Terminal” emulation, such as “Hyper Terminal” T = Time line display
which is included with Microsoft Windows. The L = Log off
RS232 communication feature permits viewing
or changing of Control Panel menu options and NOTE:
also provides access to data logs showing Event The Level 1 password (159) must be
Time Line, Fault and Sensor log displays. entered to change options in the Setup,
Configuration and Tuning Menus. The
9.2 RS232 COMMUNICATION SETUP Level 2 password (6817) must be entered
to view or change options in the
Regardless of the terminal emulation utilized, Calibration and Diagnostics Menus.
the following guidelines must be adhered to
when setting up the RS232 communication link: With the exception of the password entry,
all other keyboard entries can be made
1. Baud Rate – The baud rates which can be using either upper or lower case.
used with the C-More Control Panel are:
5. To view the available menus in the top-down
2400 sequence shown in Figure 3-2, enter M
4800 <Rtn>. The Menu title and first 10 options
will be displayed.
9600 (Default)
19.2K 6. When viewing menus containing more than
10 options, enter N <Rtn> to display the
2. Data Format – The program must be set for: remaining options.
8 data bits, 1 stop bit, no parity and either
Xon/Xoff or No flow control. 7. Shortcut keys are also available to go directly
to a specific menu. These shortcut keys are:
9.3 MENU PROCESSING UTILIZING m0 Default (Operating) Menu
RS232 COMMUNICATION m1 Setup Menu
m2 Configuration Menu
Viewing data logs and viewing or changing
m3 Tuning Menu
Control Panel menu options using RS232
m4 Calibration Menu
communication is accomplished as follows:
m5 Diagnostic Menu
1. Start the emulator software program and 8. To change a value or setting for a displayed
ensure that the specified baud rate and data menu option, proceed as follows:
formats have been entered.
(a) Enter C, followed by the number to the
2. Press the Enter key on the laptop. An
right of the displayed option to be
asterisk (*) prompt should appear. changed, and then press <Rtn>.
3. At the prompt, enter the valid RS232
(b) Enter the desired value or setting for the
password (jaguar) in lower case letters and option and press <Rtn>. Refer to
press Enter.
Chapter 3, Tables 3-2 through 3-5 for
4. “Welcome to Aerco” will appear in the laptop allowable entry ranges and settings for
or “dumb terminal” display with a listing of the Operating, Setup, Configuration and
the following available entry choices: Tuning Menus. (The Calibration and
Diagnostic Menus should only be used
by Factory-Trained service personnel).
9-1
RS232 COMMUNICATION
(c) Menu changes will be stored in non- 9.4.2 Operation Time Log
volatile memory.
The Operation Time Log consists of a string of
9. To redisplay the menu and view the option ASCII records stored in non-volatile memory
which was just changed in step 5, enter D within the C-More Control Panel. Events such
and press <Rtn>. as power-up, ignition and turn-off are time
10. To display the Fault (F) Log, Sensor (S) Log stamped. Data logged while the unit is running
or Time (T) Line Log, press F, S or T are run-length encoded. Data is logged or the
followed by <Rtn>. Refer to paragraph 9.4 for run-length incremented every 30 seconds. For a
descriptions and samples of these data logs. new run record to be logged, the fire rate or
flame strength must change by more than 5%,
11. To log off and terminate the RS232 com- or the run mode must change. At steady-state,
munication link, press L followed by <Rtn>. the run-length is allowed to reach a maximum of
30 minutes before the record is logged. This
9.4 DATA LOGGING means that no more than 30 minutes of data can
be lost if the unit loses power. Table 9-2 shows
During operation, the C-More Control Panel a sample Operation Time Log for a boiler:
continuously monitors and logs data associated
with operational events, faults and sensor The Operation Time Log can only be accessed
readings associated with the boiler or water through the RS232 interface using a laptop or
heater system. Descriptions of these data logs other terminal device. Ten operation time
are provided in the following paragraphs. The records are displayed for each T command
basic procedure for accessing each data log is entry. The operation time log can be cleared
described in paragraph 9.3, step 7. ONLY by factory authorized personnel using the
Clear Log option in the Factory menu.
9.4.1 Fault Log
The C-More Control Panel logs the last 10 faults NOTE:
(0 – 9) starting with the most recent (#0). They The Sensor (S) Log can store up to 1200
can be viewed in the front panel display or via records. Therefore, to view the most
the RS232 port. The Fault Log cannot be recently logged record, enter “S” followed
cleared. If the Fault Log already contains 10 by 0 (zero) and then press Enter (i.e. S0
faults, the earliest fault is overwritten when a <Enter>). To view earlier records in
new fault occurs. A sample Fault Log display is reverse chronological order, enter S and
shown in Table 9-1. press Enter. To go back 200 or 700
records, enter S200 or S700, etc. and
NOTE: press Enter.
The Operation Time (T) Log can store
thousands of records. Therefore, to view 9.4.3 Sensor Log
the most recently logged record, enter “T”
The sensor values can be logged at a different
followed by 0 (zero) and press Enter
rate if needed by setting the Sensor Log Interval
(i.e. T0 <Enter>). To view earlier records
in the Diagnostics Menu. The log interval can
in reverse chronological order, enter T
vary from once every minute to once every day.
and press Enter. To go back 200 or 1000
Table 9-3 shows a sample Sensor Log every 5
records, enter T200 or T1000, etc. and
minutes for a boiler running in Constant Setpoint
press Enter.
mode.
9-2
RS232 COMMUNICATION
Table 9-1. Sample Fault Log Display
No. Fault Message Cycle Date Time

0 Direct Drive Signal Fault 609 1/10/02 8:42am
1 Low Gas Pressure 366 7/04/01 5:29pm
2 Loss of Power 0 1/01/01 11:50am
Table 9-2. Sample Operation Time Log Display
Status Fire Rate Flame Run Length Date Time

Off, Direct Drive 0 0 8 1/15/02 2:35pm
Run, Direct Drive 38 100 34 1/15/02 2:27pm
Run, Direct Drive 31 100 30 1/15/02 1:53am
Ignition 0 0 0 1/15/02 1:20pm
Off, Switch 0 0 35 1/15/02 12:30pm
Run, Manual 40 100 0 1/15/02 11:55am
Ignition 0 0 0 1/15/02 11:55am
Power-up 0 0 0 1/15/02 11:50am
Table 9-3. Sample Sensor Log Display
Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time
130 181 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:51pm
9-3
APPENDIX A
APPENDIX A - BOILER MENU ITEM DESCRIPTIONS
MENU LEVEL & OPTION DESCRIPTION

OPERATING MENU
Active Setpoint This is the setpoint temperature to which the
control is set when operating in the Constant
Setpoint, Remote Setpoint or Outdoor Reset
Mode. When in the Constant Setpoint Mode, this
value is equal to the Internal Setpoint setting in the
Configuration Menu. When in the Remote
Setpoint Mode, this value is the setpoint equivalent
to the remote analog signal supplied to the unit.
When in the Outdoor Reset Mode, this is the
derived value from the charts in Appendix D.
Air Temp Air Temp is the air temperature at the input to the
Air/Fuel Valve. This reading is one of the
parameters used to control the Blower Motor
speed.
Outdoor Temp Displayed only if outdoor sensor is installed and
enabled.
Valve Position In Desired input valve position. This would normally
be the same as the fire rate shown on the bar-
graph (valve position out) when the boiler is
operating.
Flame Strength Displays flame strength from 0% to 100%.
Run Cycles Displays the total number of run cycles from 0 to
999,999.
Run Hours Displays total run time of unit in hours from 0 to
9,999,999.
Fault Log Displays information on the last 20 faults.
A-1
APPENDIX A
APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED

SETUP MENU
Password Allows password to be entered.
Once the valid password (159) is entered, options in
the Setup, Configuration and Tuning Menus can be
modified.
Language Permits selection of English, Spanish or French for
displayed messages. Default is English.
Time Displays time from 12:00 am to 11:59 pm.
Date Displays dates from 01/01/00 to 12/31/99
Unit of Temp Permits selection of temperature displays in degrees
Fahrenheit (°F) or degrees Celsius (°C). Default is
°F.
Comm Address For RS-485 communications (0 to 127). Default
address is 0. RS-232 should have its own
(programmable) password.
Baud Rate Allows communications Baud Rate to be set (2400
to 19.2K). Default is 9600.
Software Version Identifies the current software version of the control
box (Ver 0.0 to Ver 9.9).
CONFIGURATION MENU
Internal Setpoint Allows internal setpoint to be set . Default is 130°F.
Unit Type Allows selection of KC Boiler, KC Boiler LN, BMK
Boiler, BMK Boiler LN, BMK Boiler Dual, KC Water
Heater, KC Water Heater LN, Water Heater 2010
Unit Size Sets unit size from 0.5 to 6.0 MBTUs. Default is 1.0
MBTU.
Fuel Type Allows selection of Natural Gas or Propane
Boiler Mode It allows selection of: Constant Setpoint, Remote
Setpoint, Direct Drive, Combination, or Outdoor
Reset Mode. Default is Constant Setpoint Mode.
Remote Signal Used to set the type of external signal which will be
used when operating in the Remote Setpoint, Direct
Drive or Combination Mode. The factory default is
4-20 mA/1-5V.
Bldg Ref Temp Allows the building reference temperature to be set
when operating a boiler in the Outdoor Reset Mode.
Default is 70°F.
A-2
APPENDIX A
APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued

CONFIGURATION MENU (Cont.)
Reset Ratio Permits setting of Reset Ratio when operating boiler
in the Outdoor Reset Mode. Reset Ratio is
adjustable from 0.1 to 9.9. Default is 1.2.
Outdoor Sensor Allows outdoor sensor function to be enabled or
disabled. Default is disabled.
System Start Tmp If outdoor sensor is enabled, this menu item allows
the system start temperature to be set from 30 to
100°F. Default is 60°F.
Setpoint Lo Limit Used to set the minimum allowable setpoint (40°F to
Setpoint Hi Limit). Default is 60°F
Setpoint Hi Limit Used to set the maximum allowable setpoint
(Setpoint Lo Limit to 240°F). Default is 200°F.
Temp Hi Limit This is the maximum allowable outlet temperature
(40 to 240°F). Any temperature above this setting
will turn off the unit. The temperature must then drop
5° below this setting to allow the unit to run. Default
Hi Limit is 210°F.
Max Valve Position Sets the maximum allowable valve position for the
unit (40% to 100%). Default is 100%.
Pump Delay Timer Specifies the amount of time (0 to 30 min.) to keep
the pump running after the unit turns off. Default is
zero.
Aux Start On Dly Specifies the amount of time to wait (0 to 120 sec.)
between activating the Aux Relay (due to a demand)
and checking the pre-purge string to start the boiler.
Default is 0 sec.
Failsafe Mode Allows the Failsafe mode to be set to either
Constant Setpoint or Shutdown. Default is
Shutdown.
Analog Output Must be set to Valve Position 0-10V for Benchmark
3.0LN.
Lo Fire Timer Specifies how long (2 to 600 sec.) to remain in the
low fire position after ignition, before going to the
desired output. Default is 2 sec.
Network Timeout Specifies the timeout value (seconds) before a
Modbus fault is declared. Available settings range
from 5 to 999 seconds.
A-3
APPENDIX A
APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued

CONFIGURATION MENU (Cont.)
HI DB Setpt EN Operating at a Valve Position below this value will
inhibit the DEADBAND feature. When operating at a
Valve Position below this value, the effective
Setpoint is equal to Active Setpoint + DEADBAND
HIGH.
Setting range is from 0 to 100. (Default is 30)
Demand Offset This entry will reduce excessive ON/OFF cycling in
AUTO mode. When this entry is a non-zero value,
the unit will not turn on again until Valve Position In
reaches the Start Level value AND the Outlet
Temperature goes below the Active Setpoint –
Demand Offset. In addition, the boiler will fire at the
29% Valve Position or below for a period of one
minute.
When this entry is set to zero, the unit will turn on
again as soon as the Valve Position In reaches the
Start Level value. There will not be a one minute
delay when firing at the 29% Fire Rate level.
Setting range is 0 to 25. (Default is 10)
Deadband High Deadband High and Deadband Low settings create
an “Outlet Temperature” Zone. In which no Valve
Deadband Low
Position corrections will be attempted.
The Deadband ZONE is defined as operating with
an Outlet Temperature between Active Setpoint +
Deadband High and Active Setpoint – Deadband
Low.
When the Outlet Temperature reaches Active
Setpoint and remains there for a period of 15
seconds, the unit will go into a DEADBAND MODE
at which point no Fire Rate corrections will be
attempted while the Outlet Temperature remains
anywhere within the Deadband ZONE. When the
unit is in the DEADBAND MODE, the °F or °C LED
will flash on and off. When the Outlet Temperature
drifts out of the Deadband ZONE, the DEADBAND
MODE will be terminated and the PID LOOP will
again attempt Valve Position corrections.
Setting range is 0 to 25. (Default is 2 for both
Deadband High and Deadband Low)
A-4
APPENDIX A

TUNING MENU
Prop Band Generates a fire rate based on the error that exists
between the setpoint temperature and the actual
outlet temperature. If the actual error is less than
the proportional band setting (1 to 120°F), the fire
rate will be less than 100%. If the error is equal to
or greater than the proportional band setting, the fire
rate will be 100%.
Integral Gain This sets the fraction of the output, due to setpoint
error, to add or subtract from the output each minute
to move towards the setpoint. Gain is adjustable
from 0.00 to 1.00 (Default is 0.10).
Derivative Time This value (0.0 to 20.0 min.) responds to the rate of
change of the setpoint error. This is the time that
this action advances the output.
Reset Defaults? Allows Tuning Menu options to be reset to their
Factory Default values.
A-5
APPENDIX B
APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES
TABLE B-1. STARTUP AND STATUS MESSAGES
MESSAGE DESCRIPTION
DEMAND DELAY Displayed if Demand Delay is active.
XX sec
DISABLED Displayed if ON/OFF switch is set to OFF. The display also
HH:MM pm, pm shows the time (am or pm) and date that the unit was
MM/DD/YY disabled.
FLAME PROVEN Displayed after flame has been detected for a period of 2
seconds. Initially, the flame strength is shown in %. After 5
seconds has elapsed, the time and date are shown in place
of flame strength.
IGNITION TRIAL Displayed during ignition trial of startup sequence. The
XX sec duration of cycle counts up in seconds.
PURGING Displayed during the purge cycle during startup. The
XX sec duration of the purge cycle counts up in seconds.
STANDBY Displayed when ON/OFF switch is in the ON position, but
there is no demand for heat. The time and date are also
displayed.
WAIT Prompts the operator to wait.
WARMUP Displayed for 2 minutes during the initial warm-up only.
XX sec
B-1
APPENDIX B
TABLE B-2. FAULT MESSAGES
FAULT MESSAGE FAULT DESCRIPTION

AIRFLOW FAULT The Blower Proof Switch opened during purge,
DURING PURGE or air inlet is blocked.
AIRFLOW FAULT The Blower Proof Switch opened during ignition.
DURING IGN
AIRFLOW FAULT The Blower Proof Switch opened during run.
DURING RUN
DELAYED The Delayed Interlock is open.
INTERLOCK OPEN
DIRECT DRIVE The direct drive signal is not present or is out of range.
SIGNAL FAULT
FFWD TEMP The temperature measured by the Feed Forward (FFWD)
SENSOR FAULT Sensor is out of range.
FLAME LOSS The Flame signal was not seen during ignition or lost within 5
DURING IGN seconds after ignition.
FLAME LOSS The Flame signal was lost during run.
DURING RUN
HEAT DEMAND The Heat Demand Relays on the Ignition board failed to
FAILURE activate when commanded.
HIGH EXHAUST The High Exhaust Temperature Limit Switch is closed.
TEMPERATURE
HIGH GAS The High Gas Pressure Limit Switch is open.
PRESSURE
HIGH WATER The temperature measured by the Outlet Sensor exceeded
TEMPERATURE the Temp Hi Limit setting.
HIGH WATER TEMP The High Water Temperature Limit Switch is open.
SWITCH OPEN
IGN BOARD A communication fault has occurred between the PMC board
COMM FAULT and Ignition board.
IGN SWTCH CLOSED The Ignition Position Limit switch on the Air/Fuel Valve closed
DURING PURGE during purge.
IGN SWTCH OPEN The Ignition Position Limit switch on the Air/Fuel Valve
DURING IGNITION opened during ignition.
INTERLOCK The Remote Interlock is open.
OPEN
LINE VOLTAGE The Line (Hot) and Neutral wires are reversed.
OUT OF PHASE
LOW GAS The Low Gas Pressure Limit Switch is open.
PRESSURE
LOW WATER The Low Water Cutoff board is indicating low water level.
LEVEL
NETWORK COMM The RS-485 network information is not present or is
FAULT corrupted.
B-2
APPENDIX B
TABLE B-2. FAULT MESSAGES - Continued
FAULT MESSAGE FAULT DESCRIPTION

OUTDOOR TEMP The temperature measured by the Outdoor Air Sensor is out
SENSOR FAULT of range.
OUTLET TEMP The temperature measured by the Outlet Sensor is out of
SENSOR FAULT range:
• OUTLET TEMPERATURE display = SHt Indicates sensor
is shorted
• OUTLET TEMPERATURE display = OPn indicates sensor
is open-circuited
PRG SWTCH CLOSED The Purge Position Limit Switch on the Air/Fuel Valve closed
DURING IGNITION during ignition.
PRG SWTCH OPEN The Purge Position Limit Switch on the Air/Fuel Valve
DURING PURGE opened during purge.
REMOTE SETPT The Remote Setpoint signal is not present or is out of range.
SIGNAL FAULT
RESIDUAL The Flame signal was seen for more than 60 seconds during
FLAME standby.
SSOV The SSOV switch opened during standby.
SWITCH OPEN
SSOV FAULT The SSOV switch opened during purge.
DURING PURGE
SSOV FAULT The SSOV switch closed or failed to open during ignition.
DURING IGN
SSOV FAULT The SSOV switch closed for more than 15 seconds during
DURING RUN run.
SSOV RELAY A failure has been detected in one of the relays that control
FAILURE the SSOV.
STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to the
FAILURE desired position.
B-3
APPENDIX C
TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART

(BALCO)
TEMP (°F) RES (OHMS) VOLTS*

-40 779.0 1.93
-30 797.5 1.96
-20 816.3 1.99
-10 835.4 2.02
0 854.8 2.05
10 874.6 2.07
20 894.7 2.10
30 915.1 2.12
40 935.9 2.15
50 956.9 2.17
60 978.3 2.20
70 1000.0 2.23
80 1022.0 2.25
90 1044.4 2.27
100 1067.0 2.30
110 1090.0 2.32
120 1113.3 2.34
130 1137.0 2.36
140 1160.9 2.39
150 1185.2 2.41
160 1209.5 2.43
170 1234.7 2.45
180 1260.0 2.47
190 1285.6 2.50
200 1311.4 2.52
210 1337.7 2.54
220 1364.2 2.56
230 1391.0 2.58
240 1418.2
250 1445.7
*Voltage at AUX & Common terminals in the I/O Box
C-1
APPENDIX D
APPENDIX D. - INDOOR/OUTDOOR RESET RATIO CHARTS
Table D-1. Header Temperature for a Building Reference Temperature of 50F
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
50F 50 50 50 50 50 50 50 50 50 50
45F 53 54 55 56 57 58 59 60 60 62
40F 56 58 60 62 64 66 68 70 72 74
35F 59 62 65 68 71 74 77 80 83 86
30F 62 66 70 74 78 82 86 90 94 98
25F 65 70 75 80 85 90 95 100 105 110
20F 68 74 80 86 92 98 104 110 116 122
15F 71 78 85 92 99 106 113 120 127 134
10F 74 82 90 98 106 114 122 130 138 146
5F 77 86 95 104 113 122 131 140 149 158
0F 80 90 100 110 120 130 140 150 160 170
-5F 83 94 105 116 127 138 149 160 171 182
-10F 86 98 110 122 134 146 158 170 182 194
-15F 89 102 115 128 141 154 167 180 193 206
-20F 92 106 120 134 148 162 176 190 204 218
Table D-2. Header Temperature for a Building Reference Temperatrure of 60F
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
60F 60 60 60 60 60 60 60 60 60 60
55F 63 64 65 66 67 68 69 70 71 72
50F 66 68 70 72 74 76 78 80 82 84
45F 69 72 75 78 81 84 87 90 93 96
40F 72 76 80 84 88 92 96 100 104 108
35F 75 80 85 90 95 100 105 110 115 120
30F 78 84 90 96 102 108 114 120 126 132
25F 81 88 95 102 109 116 123 130 137 144
20F 84 92 100 108 116 124 132 140 148 156
15F 87 96 105 114 123 132 141 150 159 168
10F 90 100 110 120 130 140 150 160 170 180
5F 93 104 115 126 137 148 159 170 181 192
0F 96 108 120 132 144 156 168 180 192 204
-5F 99 112 125 138 151 164 177 190 203 216
-10F 102 116 130 144 158 172 186 200 214
-15F 105 120 135 150 165 180 195 210
-20F 108 124 140 156 172 188 204
D-1
APPENDIX D
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
65 65 65 65 65 65 65 65 65 65 65
60 68 69 70 71 72 73 74 75 76 77
55 71 73 75 77 79 81 83 85 87 89
50 74 77 80 83 86 89 92 95 98 101
45 77 81 85 89 93 97 101 105 109 113
40 80 85 90 95 100 105 110 115 120 125
35 83 89 95 101 107 113 119 125 131 137
30 86 93 100 107 114 121 128 135 142 149
25 89 97 105 113 121 129 137 145 153 161
20 92 101 110 119 128 137 146 155 164 173
15 95 105 115 125 135 145 155 165 175 185
10 98 109 120 131 142 153 164 175 186 197
5 101 113 125 137 149 161 173 185 197 209
0 104 117 130 143 156 169 182 195 208
-5 107 121 135 149 163 177 191 205 219
-10 110 125 140 155 170 185 200 215
-15 113 129 145 161 177 193 209
-20 116 133 150 167 201 218
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
70F 70 70 70 70 70 70 70 70 70 70
65F 73 74 75 76 77 78 79 80 81 82
60F 76 78 80 82 84 86 88 90 92 94
55F 79 82 85 88 91 94 97 100 103 106
50F 82 86 90 94 98 102 106 110 114 118
45F 85 90 95 100 105 110 115 120 125 130
40F 88 94 100 106 112 118 124 130 136 142
35F 91 98 105 112 119 126 133 140 147 154
30F 94 102 110 118 126 134 142 150 158 166
25F 97 106 115 124 133 142 151 160 169 178
20F 100 110 120 130 140 150 160 170 180 190
15F 103 114 125 136 147 158 169 180 191 202
10F 106 118 130 142 154 166 178 190 202 214
5F 109 122 135 148 161 174 187 200 213
0F 112 126 140 154 168 182 196 210
-5F 115 130 145 160 175 190 205
-10F 118 134 150 166 182 198 214
-15F 121 138 155 172 189 206
-20F 124 142 160 178 196 214
D-2
APPENDIX D
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
75F 75 75 75 75 75 75 75 75 75 75
70F 78 79 80 81 82 83 84 85 86 87
65F 81 83 85 87 89 91 93 95 97 99
60F 84 87 90 93 96 99 102 105 108 111
55F 87 91 95 99 103 107 111 115 119 123
50F 90 95 100 105 110 115 120 125 130 135
45F 93 99 105 111 117 123 129 135 141 17
40F 96 103 110 117 124 131 138 145 152 159
35F 99 107 115 123 131 139 147 155 163 171
30F 102 111 120 129 138 147 156 165 174 183
25F 105 115 125 135 145 155 165 175 185 195
20F 108 119 130 141 152 163 174 185 196 207
15F 111 123 135 147 159 171 183 195 207 219
10F 114 127 140 153 166 179 192 205 218
5F 117 131 145 159 173 187 201 215
0F 120 135 150 165 180 195 210
-5F 123 139 155 171 187 203 219
-10F 126 143 160 177 194 211
-15F 129 147 165 183 201 219
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
80F 80 80 80 80 80 80 80 80 80 80
75F 83 84 85 86 87 88 89 90 91 92
70F 86 88 90 92 94 96 98 100 102 104
65F 89 92 95 98 101 104 107 110 113 116
60F 92 96 100 104 108 112 116 120 124 128
55F 95 100 105 110 115 120 125 130 135 140
50F 98 104 110 116 122 128 134 140 146 152
45F 101 108 115 122 129 136 143 150 157 164
40F 104 112 120 128 136 144 152 160 168 176
35F 107 116 125 134 143 152 161 170 179 188
30F 110 120 130 140 150 160 170 180 190 200
25F 113 124 135 146 157 168 174 190 201 212
20F 116 128 140 152 164 176 188 200 212
15F 119 132 145 158 171 184 197 210
10F 122 136 150 164 178 192 206
5F 125 140 155 170 185 200 215
0F 128 144 160 176 192 208
-5F 131 148 165 182 199 216
-10F 134 152 170 188 206
D-3
APPENDIX D
RESET RATIO
Air 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
Temp
90F 90 90 90 90 90 90 90 90 90 90
85F 93 94 95 96 97 98 99 100 101 102
80F 96 98 100 102 104 106 108 110 112 114
75F 99 102 105 108 111 114 117 120 123 126
70F 102 106 110 114 118 122 126 130 134 138
65F 105 110 115 120 125 130 135 140 145 150
60F 108 114 120 126 132 138 144 150 156 162
55F 111 118 125 132 139 146 153 160 167 174
50F 114 122 130 138 146 154 162 170 178 186
45F 117 126 135 144 153 162 171 180 189 198
40F 120 130 140 150 160 170 180 190 200 210
35F 123 134 145 156 167 178 189 200
30F 126 138 150 162 174 186 198 210
25F 129 142 155 168 181 194 207
20F 132 146 160 174 188 202 216
15F 135 150 165 180 195 210
10F 138 154 170 186 202 218
5F 141 158 175 192 209
0F 144 162 180 198 216
D-4
APPENDIX E
BOILER DEFAULT SETTINGS
MENU & OPTION FACTORY DEFAULT

Setup Menu
Password 0
Language English
Unit of Temp Fahrenheit
Comm Address 0
Baud Rate 9600
Configuration Menu
Internal Setpt 130°F
Unit Type Boiler
Unit Size 1.5 MBTU
Boiler Mode Constant Setpoint
Remote Signal 4 – 20 mA / 1-5V
(If Mode = Remote Setpoint, Direct Drive or
Combination)
Bldg Ref Temp 70°F
(If Boiler Mode = Outdoor Reset)
Reset Ratio 1.2
(If Boiler Mode = Outdoor Reset)
Outdoor Sensor Disabled
System Start Tmp 60°F
(If Outdoor Sensor = Enabled)
Setpt Lo Limit 60°F
Setpt Hi Limit 200°F
Temp Hi Limit 215°F
Max Fire Rate 100%
Pump Delay Timer 0 min
Aux Start On Dly 0 sec
Failsafe Mode Shutdown
Analog Output Fire Rate Out 0-10V
CAUTION: DO NOT Change
Lo Fire Timer 2 sec
Setpt Limit Band (If Setpt Limiting = Enabled) 5°F
E-1
APPENDIX E
BOILER DEFAULT SETTINGS - Continued
MENU & OPTION FACTORY DEFAULT

Configuration Menu --Continued
Network Timeout 30 seconds
Hi DB Setpt En 30
Demand Offset 10
Deadband High 2
Deadband Low 2
Tuning Menu
Prop Band 70°F
Integral Gain 1.00
Derivative Time 0.0 min
E-2
HEAT EXCHANGERS & COMBUSTION CHAMBER DESIGN STANDARDS LIFTING LUGS
MAX. WORKING MAXIMUM TEST PRESS. HT'G SURFACE MIN. RELIEF VA. 7 15/16 3/4" ELECTRICAL
PRESS. (PSIG) TEMP. (°F) (PSIG) SQ.FT. CAPACITY MBH (20.1) CONDUIT CONNECTION
160 210 240 178 3000
14 5/16
ASME B & PV CODE: SECTION IV STAMP H (PRIMARY H.X.)
(36.4)
SECTION VIII STAMP U (SECONDARY H.X.) 28
8" EXHAUST (71.1)
OUTLET 15
7 7/16 (38.0)
(18.9)
33
8" AIR INLET 6 7/8 (84.7)
(17.4) 64 (162.6) 23
(58.4)
DOOR SWING
78 (198.1)
38
(96.7)
THIS AREA TO BE
ACCESSIBLE FOR 18
PRESS. RELIEF VALVE MAINTENANCE. (45.7)
4"-150# FLG'D 2 5/8
HOT WATER OUTLET CONN. (SEE NOTE 3) (6.6)
PRESS./TEMP. GAUGE CONTROL
PANEL
DISPLAY
69 5/8
54 5/16
(176.9)
(137.0) 4"-150# FLG'D
BMK3.0 LN DIM. DIM. DIM. COLD WATER
MODEL "A" "B" "C" INLET CONN.
CONDENSATE PORT
25 5/16
(64.3) 79
NAT. GAS 28 15/16 (201.4)
N/A FOR IRI 2" NPT NATURAL GAS 5 7/8
ONLY (73.5)
GAS TRAIN INLET CONN. (14.9)
OPTION 42 1/8
DUAL-FUEL (107.0) 1" NPT GAS
25 7/16 15 7/16 VENT CONN.
WITH FM N/A 36 11/16
GAS TRAIN
(64.6) (39.2) FOR "IRI" GAS
(93.2)
TRAIN OPTION" ONLY
DUAL-FUEL
25 7/16 16 3/16 12 1/16 "A" "C" "B"
WITH IRI 13.5
GAS TRAIN
(64.6) (41.1) (30.6)
(34.3)
5 1/4
(13.3) 12 3/4 2" NPT PROPANE GAS
INLET CONN. CONDENSATE PORT NORTHVALE, NJ 07647
(32.4) 1-1/2" NPT
AERCO
FOR DUAL-FUEL
23 3/16 (58.8) DRAIN CONN. OPTION ONLY
4" CONCRETE PAD - SET BENCHMARK 3 MIL. LOW NOx BTU
23 5/8 (60.0)
UNIT FLUSH AT REAR GAS FIRED BOILER
NOTES:
DIMENSIONAL DRAWINGS
1) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS).
2) RELIEF VALVE, TRIDICATOR & CONDENSATE TRAP ARE INCLUDED SEPARATELY IN SHIPMENT. DWN.BY CZ DATE072606 REV.
SCALE SIZE A
3) FIELD PIPING TO THE BOILER MUST ENSURE THAT THE HOT WATER OUTLET CONNECTION FLEXIBLE PIPING AP-A-811 E
CHKD. APPD.
(LOCATED INSIDE THE BOILER) IS LEVEL OR SLOPING UP AS IT EXITS THE BOILER. REV.DATE
F-1
APPENDIX F
F-2
ANCHOR HOLE 4 X Ø.75 (Ø1.91) THRU HOLES
4 PL
APPENDIX F
23
26
FRONT (66.0) (58.4) 28 REAR
(71.1)
1 1/2
9 36 7/8
(3.8)
(22.9) (93.7)
62
(157.5)
64
(162.6)
INTERNATIONAL, INC.
AERCO NORTHVALE, NJ 07647
BENCHMARK 3 MIL. LOW NOx BTU

NOTES: GAS FIRED BOILER
1) DOTTED LINES REPRESENT BENCHMARK SHEET METAL
ANCHOR BOLT LOCATIONS
2) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME
DWN.BY GS DATE 061506 REV.
3) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS)
SCALE
APPD. MC DATE 061506
SD-A-680 A
SIDE VIEW TOP VIEW
24"
78" 18"
56"
101"
79"
43" 24"
(SEE NOTE)
24"
REAR FRONT
4" HIGH PAD

INSTALLATION CLEARANCES
1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING
2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS:
LEFT AND RIGHT SIDES: 24''

FRONT: 24"
REAR: 43" (SEE NOTE)
CEILING HEIGHT: 101"
3) THE INNER SIDE PANELS MUST BE REMOVED FROM BOTH UNITS
FOR ZERO SIDE CLEARANCE INSTALLATIONS
4) THE ZERO SIDE CLEARANCE OPTION CAN ONLY BE EMPLOYED IN
TWO UNIT SETS INTERNATIONAL, INC.
NOTE:
REAR CLEARANCE MAY BE REDUCED TO 24" DEPENDENT UPON PIPING AND VENTING BENCHMARK 3 MIL. BTU LOW NOx
COMPONENT SELECTION, ARRANGEMENT, AND LOCAL CODE REQUIREMENTS. HOWEVER, GAS FIRED BOILER
ZERO SIDE CLEARANCE INSTALLATION
WHEN USING A REAR CLEARANCE OF LESS THAN 43", A 57" FRONT CLEARANCE
WILL BE NEEDED TO ALLOW THE REMOVAL OF EXHAUST CONNECTING MANIFOLD. DWN.BY GS DATE 061506 REV.
SCALE
APPD. MC DATE
SD-A-683 C
F-3
APPENDIX F
F-4
SIDE VIEW TOP VIEW
APPENDIX F
78" 18"
24"
43" 24"
101" 28"
(SEE NOTE)
79"
24"
REAR FRONT
4" HIGH PAD
INSTALLATION CLEARANCES
1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING
2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS:
LEFT AND RIGHT SIDES: 24''

FRONT: 24"
REAR: 43" (SEE NOTE)
CEILING HEIGHT: 101"
INTERNATIONAL, INC.
NOTE:
REAR CLEARANCE MAY BE REDUCED TO 24" DEPENDENT UPON PIPING AND VENTING BENCHMARK 3 MIL. BTU LOW NOx
COMPONENT SELECTION, ARRANGEMENT, AND LOCAL CODE REQUIREMENTS. HOWEVER, GAS FIRED BOILER
WHEN USING A REAR CLEARANCE OF LESS THAN 43", A 57" FRONT CLEARANCE INSTALLATION CLEARANCES
WILL BE NEEDED TO ALLOW THE REMOVAL OF EXHAUST CONNECTING MANIFOLD. GS
DWN.BY DATE 061506 REV.
SCALE
APPD. MC DATE
SD-A-686 B
1/8" NPT PLUG
(INSTALL MANOMETER HERE)
HIGH GAS PRESS SWITCH
P/N: 61002-3
TEST COCK
PRESSURE SNUBBER
P/N: 99017 TO AIR/FUEL VALVE
ASSEMBLY
FULL PORT BALL VALVE

2" NPT P/N: 123540
LOW GAS PRESS
SWITCH
P/N: 61002-1
2" SAFETY SHUT-OFF

VALVE BODY
P/N: 124136 SAFETY SHUT-OFF VALVE
ACTUATOR P/N: 64048
(INCLUDES RESISTOR)
INTERNATIONAL, INC.
2" SCH. 40 PIPE

BENCHMARK 3.0 LOW NOx
FM GAS TRAIN ASSY. FM GAS TRAIN
P/N: 22026-1
DRWN BY:SJD REV
DATE:3/09/09 AP - A - 844 B
*NOT TO SCALE*
F-5
APPENDIX F
F-6
HIGH GAS PRESS. 1/8" NPT PLUG
SWITCH (INSTALL
BOILER BOUNDARY P/N: 61002-3 MANOMETER HERE)
TO AIR-FUEL VALVE ASS'Y TEST

COCK
APPENDIX F
SAFETY SHUT-OFF
VALVE ACTUATOR w/ GAS
PRESSURE ADJUSTMENT
FULL PORT P/N 64048
BALL VALVE
2" NPT
P/N: 123540
2" DOUBLE BODY

CONNECTING FLANGE
P/N: 124156
SAFETY SHUT-OFF
VALVE ACTUATOR
P/N 69038
LOW GAS PRESS.

2" SAFETY SHUT-OFF SWITCH
DOUBLE-BODY P/N: 61002-1
GAS VALVE
P/N 124142
2"-SCH.40 PIPE
1" NORMALLY OPEN

VENT VALVE
P/N 123769
1"-SCH.40 PIPE
ENTIRE ASSEMBLY PART NUMBER INTERNATIONAL, INC.

VENT TO ATMOSPHERE 22026-2
PER ANSI Z223.1 (NFPA54)
BENCHMARK3.0 LOW NOx
IRI GAS TRAIN
DWN.BY CZ DATE 072806 REV.
SCALE NTS SIZE AP-A-803
CHKD. APPD.
E
15
4
5
11
13
19 1 44084 PLUG, GAS INJECTOR

18 1 81129 GASKET, PLUG
7
17 1 58023 IGNITOR-INJECTOR
1 12
16 4 123886 WASHER, FLAT #10
17
16 15 1 123534 PLUG, HEX 1/8 NPT
19 14 1 9-25 PLUG, 1/2" NPT
7 18 13 1 81048 GASKET, FLAME ROD LOW NOX

12 2 54016 SCREW, MACH #10-32 X .50 LG
14 11 1 54015 SCREW, MACH #8-32 X 3/8 LG
10 6 55027 BOLT, HEX HD SERRATED 1/4-20 X 1.75 LG
9 1 81019 GASKET, BURNER HOUSING
8 1 122377 SCREW, MACH #10-32 X 3/8 LG
10
7 2 9-75 PLUG, 1" NPT
6 1 59104 OBSERVATION PORT
5 1 24227 STAGED IGNITION ASSY, BMK LOW NOX
9
4 1 66006 FLAME ROD
3 1 46013 BURNER, BMK 3.0 LOW NOX
6
2 2 81030 GASKET, BURNER 9.65 DIA LOW NOX
2 1 1 43016 HOUSING, BURNER LOW NOX

ITEM QTY PART NUMBER DESCRIPTION
NO.
3 INTERNATIONAL, INC.
2
BURNER ACCESSORIES
DWN.BY CZ DATE 072606 REV.
SCALE SIZE
CHKD. APPD. PL-A-151 D
REV. DATE
F-7
APPENDIX F
APPENDIX F
EXHAUST MANIFOLD HOSES,GASKETS, & INSULATION

ITEM PART NO. QTY DESCRIPTION ITEM PART NO. QTY DESCRIPTION
39033 1 EXHAUST MANIFOLD 27 88003 1 O-RING #2-339

1
2 49102 3 EXHAUST MANIFOLD SEAL 28 59041 1 HOSE ASSEMBLY, 4"
3 39036 1 CONNECTING MANIFOLD 29 80024-8 1 INSULATION 4" FLEX PIPE 8 LONG
EXHAUST MANIFOLD
4 81098 1 30 80024-12 1 INSULATION 4" FLEX PIPE 12" LONG
ORIFICE GASKET
31 80021-12 1 INSULATION 4" PIPE 12" LONG
GAS TRAIN ASSEMBLY 32 80022 1 CONNECTING INSULATION
ITEM PART NO. QTY DESCRIPTION
33 80023 2 TOP MANIFOLD INSULATION
22026-1 STD FM GAS TRAIN
ASSEMBLY 34 4-58 3 4" FLANGE GASKET
22026-2 IRI GAS TRAIN ASSEMBLY 35 62005 1 CORD GRIP
(3) 5 1
22040-1 DUAL FUEL FM GAS TRAIN 36 59030 1 HOSE ASSY, 4" (FLEXIBLE)
22040-2 DUAL FUEL IRI GAS TRAIN
BURNER & AIR/FUEL VALVE

6 46013 1 BURNER
24010 A/F VALVE ASSEMBLY

7 1
24010-1 DUEL FUEL A/F VALVE ASSY.
BMK3.0LN STAGED
8 24227 1
IGNITION ASSY.
9 81030 2 BURNER GASKET
10 81019 1 BURNER HOUSING GASKET
HEAT EXCHANGER
PRIMARY HEAT EXCH.
11 80018 1
UPPER INSULATION
PRIMARY HEAT EXCH.
12 80019 1
LOWER INSULATION
13 80020 1 SECONDARY HEAT EXCH.
INSULATION
14 28030 1 PRIMARY HEAT EXCH.
15 28029 1 SECONDARY HEAT EXCH.
BLOWER
16 24045 1 BLOWER ASSEMBLY
17 123815 1 IRIS AIR DAMPER
18 123681 1 8"x6" REDUCING COUPLING
19 33028 1 BLOWER BRACKET
20 124245 4 5/16 DAMPENER
21 81057 1 BLOWER GASKET
22 96006 1 6" 90 DEG ELBOW
23 96009 1 6" DIAM. x 4" LG DUCT W/PORT
24 96008 1 6" DIAM. x 4" LG DUCT
25 123990 1 REDUCER OFFSET COVER AERCO INTERNATIONAL,
NORTHVALE, NJ
INC.
07647
26 123583 1 CLAMP HOSE SAE #96 BENCHMARK 3.0 LOW NOx
BOILER PARTS LIST
DRAWN BY SJD PL - A - 150
DATE 2/18/09 (SHEET 1 OF 7)
H
F-8
APPENDIX F
CONTROLS OTHER DUAL FUEL COMPONENTS

ITEM PART NO. QTY DESCRIPTION ITEM PART NO. QTY DESCRIPTION
37 65091 1 DRIVE REACTOR
(1)(5) 73 72031 1 "PROPANE" LABEL
38 123966 1 OVER TEMP SWITCH AUTO
39 123552 1 OVER TEMP SWITCH MANUAL (1)(5) 74 72032 1 "NAT. GAS" LABEL
DOUBLE GAS TRAIN WIRING
40 60011-1 1 BLOWER PROOF SWITCH (5)(6) 75 63032 1
HARNESS
41 61002-5 1 BLOCKED INLET SWITCH (5) 76 65024 1 FUEL SELECTOR SWITCH
42 161560 1 I /O WIRING BOX 77 33036 1 FUEL SELECTOR SWITCH
(5) MOUNTINGBRACKET
43 181197 1 C-MORE CONTROL BOX
78 72030 1 FUEL SELECTOR SWITCH LABEL
(5)
44 GP-122464 1 IGNITION TRANSFORMER
45 33030 1 VFD MOUNTING BRACKET (5) 79 63034 1 DUAL FUEL WIRING HARNESS
46 1
64068 VFD
47 93230 1 ORIFICE SNUBBER
(4) 48 124310 1 460V TRANSFORMER SHEET METAL / PANEL ASSEMBLY
(4) 49 124380 1 500 VAC, 4 AMP FUSE ITEM PART NO QTY DESCRIPTION
(4) 50 58009 1 460V Terminal Cover Kit 80 37004 1 LEFT REAR PANEL
DRIVE REACTOR TO VFD 81 37003 1 RIGHT REAR PANEL
(1) 51 63060 1
WIRING HARNESS
82 49028 2 TOP RAIL
(4) 52 79002 1 460V TRANSFORMER LABEL
83 201233 1 MOUNTING PANEL
53 61024 1 AIR TEMP SENSOR
FRONT PANEL
84 201113 1
ENCLOSURE
55 GP- 122569 1 IGNITION CABLE ASSY. 85 201120 1 FRONT DOOR ASSY.
56 63016 1 BMK3.0LN SHELL HARNESS 86 GP-122620 4 HANDLE
57 124320 1 BLOWER HARNESS 87 30022 2 TOP PANEL
88 37002 4 SIDE PANEL
89 74004 1 BMK3.0LN LOGO
58
OTHER PARTS
64016 208V POWER WIRING BOX ITEM PART NO QTY DESCRIPTION

59 1
64017 460V POWER WIRING BOX GAS PRESSURE SNUBBER -
90 99017 1
BMK3.0LN GAS TRAIN WIRING PART OF GAS TRAIN
(1) (6) 60 63015 1 CONDENSATE TRAP
HARNESS (1) 91 93283 1
ADAPTER ASSY
61 122843 1 LOW WATER CUT-OFF TOP MANIFOLD
92 80066 1
62 123449 1 SHELL TEMP. SENSOR INSULATION(WITH FLAP)
63 161521 1 THERMOWELL, DUAL AQUASTAT BULB
(7) 64 61002-1 1 LOW GAS PRESSURE SWITCH

61002-3 HIGH GAS PRESSURE SWITCH
(NON DUAL FUEL) NOTES:
(6) (8) 65 61002-15 1 DUAL FUEL HGPS - NAT. GAS
(1) NOT SHOWN IN DRAWING
61002-16 DUAL FUEL HGPS - PROPANE (2) -5 (30 AND 50 PSI RELIEF VALVE SETTING)
-6 (60,75,100 & 125 PSI RELIEF VALVE SETTING)
-7 (150 PSI RELIEF VALVE SETTING)
(3) FOR PICTORAL PURPOSES ONLY,
OTHER ACCESORIES / PARTS FM GAS TRAIN (NON DUAL FUEL) IS SHOWN
ITEM PART NO. QTY DESCRIPTION (4) FOR 460 V OPTION ONLY
(5) ONLY NEEDED ON DUAL FUEL
(1)(2) 66 69087 - 1 PRESS./TEMP. GAUGE
(6) PART OF GAS TRAIN ASSY.
67 SEE SD-A-700 1 PRESSURE RELIEF VALVE
(7) TWO (2) REQUIRED FOR DUAL FUEL BMK3.0 LN
(1)(7) 68 123540 1 EXT. MANUAL SHUT-OFF VALVE (8) SEE DRAWING AP-A-826 FOR DUAL FUEL DETAILS
(1) 69 91030 1 1" DRAIN HOSE, 60" LG
70 12820-11 1 1-1/2" NPT BALL VALVE
71 59043 1 CONDENSATE FLOAT
AERCO INTERNATIONAL,
NORTHVALE, NJ
INC.
07647
(1) 72 24060 1 COND. TRAP ASSEMBLY BENCHMARK 3.0 LOW NOx

BOILER PARTS LIST
H
F-9
APPENDIX F
1
2
11
13
15 14
12
3 53 2 6 8
25 61 92
18
24
17 9
10
55
39
23 40 BLOWER PROOF SWITCH
41
38
44
22
26
47
16
DETAIL A
SCALE 1 : 10
NORTHVALE, NJ
INC.
07647
5
BOILER PARTS LIST
H
F-10
APPENDIX F
31 67 34 30 28
20
19
B
71
4
B SECTION B-B
SCALE 1 : 18
36
70
34 32 29 33 34
21 27 7
35 62
63 AERCO INTERNATIONAL,
NORTHVALE, NJ
INC.
07647
BOILER PARTS LIST
H
F-11
APPENDIX F
59
37 46
DETAIL B:
43 TERMINAL COVER
ARE HIDEN
B
45
42 48
C
52 50
SEE 49
DETAIL C DETAIL C:
FUEL SELECTOR SWITCH
(DUAL FUEL ONLY)
78
76 77 79
65
90
IRI GAS TRAIN

(NON DUAL FUEL)
56
64
57
NORTHVALE, NJ
INC.
07647
BOILER PARTS LIST
H
F-12
APPENDIX F
82
83
80 81
NORTHVALE, NJ
INC.
07647
BOILER PARTS LIST
84 H
F-13
APPENDIX F
F-14
LEGEND
AUTOMATIC Y STRAINER
CHECK SYSTEM AIR VENT
HEATING VALVE RELIEF ISOLATION VALVE
PUMP
SYSTEM (TYP.) VALVE (TYP.) UNION
SUPPLY BALANCING VALVE
P&T
PRESSURE &
AIR TEMPERATURE GAUGE
WATER SEPARATOR AT MAXIMUM BTU/HR INPUT,
SUPPLY MAINTAIN MINIMUM NATURAL GAS PRESSURE AT
3.5" W.C. (FM GAS TRAIN)/4.0" W.C. (IRI GAS TRAIN)
MAX GAS PRESSURE = 2.0 PSIG.
(SEE NOTE 6)
PRESSURE
REDUCING
FILL VALVE P&T
Diagram 1
(SEE NOTE 8)
MAINTAIN A REGULATED
3.5" W.C. (NAT. GAS, FM/
LINE 4.0" W.C. (NAT. GAS, IRI/GAS
SIZE PRESSURE AT MAX BTU/HR INPUT
BYPASS
(TO BOILER)
BACKFLOW PREVENTER GAS SUPPLY
DIAPHRAGM TYPE
EXPANSION TANK
* 2" MANUAL
HEATING SHUTOFF
1-1/2" NPT SYSTEM VALVE
DRAIN CONN. RETURN DRIP TRAP
GAS SUPPLY
* CONDENSATE DRAIN TRAP * 2" MANUAL
SHUTOFF DRIP TRAP
VALVE
(SEE NOTE 7)
NOTES:
1) FOR ACTUAL SIZES AND LOCATIONS OF PIPING AND OTHER CONNECTIONS TO THE BOILER, SEE DIMENSIONAL DRAWING (AP-A-802).
2) SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN
FREELY, BY GRAVITY, TO A CONVENIENT FLOOR DRAIN. RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A
HEIGHT 18'' ABOVE FLOOR.
3) ALL (*) ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT FROM FACTORY.
4) LOCATE WATER INLET AND OUTLET FITTINGS (i.e. UNIONS, ELBOWS, ETC.) A MINIMUM OF 6'' FROM BOILER
FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PANELS AND COVERS. ALL PIPING AND
ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE
BE 6'' AWAY FROM SIDE PANELS. INTERNATIONAL, INC.
5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED.
6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.0 PSIG, A LOCK-UP STYLE REGULATOR MUST BE INSTALLED BENCHMARK 3 MIL. BTU LOW NOx
DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG. GAS FIRED BOILER
SINGLE UNIT INSTALLATION
7) EACH CONDENSATE PORT CAN BE PIPED INDIVIDUALLY TO MAIN DRAIN.
8) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE, DWN.BY SD DATE 061506 REV.
SCALE
SEE DIAGRAM 1 APPD. MC DATE
SD-A-681 C
G-1
APPENDIX G
HEATING CHECK RELIEF
G-2
SYSTEM VALVE VALVE (TYP.)
AUTOMATIC
SUPPLY (TYP.) SYSTEM AIR VENT AT MAXIMUM BTU/HR INPUT, LEGEND
PUMP MAINTAIN MINIMUM NATURAL GAS
AIR PRESSURE AT 3.5" W.C. (FM GAS Y STRAINER
WATER SEPARATOR TRAIN)/4.0" W.C. (IRI GAS TRAIN) ISOLATION VALVE
SUPPLY MAX GAS PRESSURE = 2.0 PSIG. UNION
(SEE NOTE 6) BALANCING VALVE
P&T
PRESSURE &
APPENDIX G
TEMPERATURE GAUGE
PRESSURE
REDUCING
FILL VALVE P&T
LINE
SIZE
BYPASS
BACKFLOW PREVENTER
P&T
Diagram 1
(SEE NOTE 8)
DIAPHRAGM TYPE
MAINTAIN A REGULATED EXPANSION TANK
4" W.C. GAS PRESSURE
AT MAX BTU/HR INPUT
1-1/2" NPT
DRAIN CONN.
(TO BOILER) * 2" MANUAL
SHUTOFF
GAS SUPPLY
VALVE
(SEE NOTE 7) HEATING

DRIP TRAP SYSTEM
* 2" MANUAL
SHUTOFF
RETURN
VALVE
GAS SUPPLY
* CONDENSATE DRAIN TRAP
DRIP TRAP
NOTES:
ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE
BE 6'' AWAY FROM SIDE PANELS. INTERNATIONAL, INC.
5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED.
6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.0 PSIG, A LOCK-UP STYLE REGULATOR MUST BE INSTALLED BENCHMARK 3 MIL. BTU LOW NOx
DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG. GAS FIRED BOILER
7) EACH CONDENSATE PORT CAN BE PIPED INDIVIDUALLY TO MAIN DRAIN. MULTIPLE UNIT INSTALLATION
8) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. DWN.BY SD DATE 061506 REV.
SCALE
SEE DIAGRAM 1 APPD. MC DATE
SD-A-682 C
APPENDIX G
G-3
G-4
HEATING CHECK LEGEND
SYSTEM VALVE Y STRAINER
AUTOMATIC
SUPPLY (TYP.) SYSTEM AIR VENT ISOLATION VALVE
PUMP
RELIEF UNION
AIR
VALVE (TYP.) BALANCING VALVE
WATER SEPARATOR
SUPPLY P&T
PRESSURE &
TEMPERATURE GAUGE
APPENDIX G
PRESSURE
REDUCING AT MAXIMUM BTU/HR INPUT,
FILL VALVE MAINTAIN MINIMUM NATURAL GAS PRESSURE AT
P&T 3.5" W.C. (FM GAS TRAIN)/4.0" W.C. (IRI GAS TRAIN)
MAX GAS PRESSURE = 2.0 PSIG.
(SEE NOTE 6)
P&T
LINE
SIZE
BYPASS
BACKFLOW PREVENTER
DIAPHRAGM TYPE
EXPANSION TANK
P&T
Diagram 1
(SEE NOTE 8)
P&T
MAINTAIN A REGULATED
4" W.C. GAS PRESSURE
AT MAX BTU/HR INPUT 1-1/2" NPT
DRAIN CONN.
* CONDENSATE DRAIN TRAP
(TO BOILER) * 2" MANUAL
SHUTOFF
GAS SUPPLY
(SEE NOTE 7) VALVE
DRIP TRAP
* 2" MANUAL
SHUTOFF
VALVE HEATING
SYSTEM
DRIP TRAP RETURN
GAS SUPPLY
NOTES:
ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE INTERNATIONAL, INC.
BE 6'' AWAY FROM SIDE PANELS. AERCO NORTHVALE, NJ 07647
5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED. BENCHMARK 3 MIL. BTU LOW NOx
6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.0 PSIG, A LOCK-UP STYLE REGULATOR MUST BE INSTALLED GAS FIRED BOILER MULT. INSTALLATION
DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG. WITH ZERO SIDE CLEARANCE
7) EACH CONDENSATE PORT CAN BE PIPED INDIVIDUALLY TO MAIN DRAIN. SD
DWN.BY DATE 072606 REV.
8) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SCALE
APPD. DATE
SD-A-691 C
SEE DIAGRAM 1
APPENDIX G
G-5
APPENDIX H
CONTROL BOX CONNECTORS

19-PIN CONNECTOR 16-PIN CONNECTOR 9-PIN CONNECTOR
7-PIN CONNECTOR
19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
7 6 5 4 3 2 1
141 193 136 135 138 190 172 170 168 166 164 162 152 150 148 146
173 171 169 167 165 163 161 133 134
191 194 137 155 154 192 140 195 153 151 149 147 145
IGNITION
TRANSFORMER
141
BLOWER PROOF SW.

AIR
TEMP.
SENSOR
WATER LEVEL PROBE

GND
FLAME ROD
1 149 148
352
CLOSURE SWITCH
SHUTOFF VALVE
153 151
351
321
SHELL
WHT
GRN
LOW GAS PRESS. SW.

YEL
RED
HIGH GAS PRESS. SW.

BLU
BLK
BLOCKED AIR INLET SW.
2 10K TEMP.
IGNITOR
PROOF OF
SENSOR
SAFETY
NC C
1K
3
POSITION
POSITION
STEPPING G
IGNITION
A H N
SWITCH
SWITCH
MOTOR
PURGE
142
5K B
147
154 146
53
AIR/FUEL VALVE C 152 150 145
137 209 136
FUSE
MANUAL RESET AUTO RESET 200
201 364
OVER TEMPERATURE SWITCHES TO I/O BOX
FUSE
AIR TEMP
SENSOR
363
207 24 VAC 202
209 XFMR
208 204
TO I/O BOX
0-10V
6 PIN CONNECTOR AGND
201 GND 260
FUSE BLOCK
190 202 NEU 203
204 20 AMP
191 203 263 333
T1 T2 T3 T4 T5 T6
BLOWER
L3 263 333 333 303
208 VAC L3 L1 U MOTOR
192 206 20 AMP
3O L2 262 262 332 332 332 302
193 209 60 HZ L2 L2 V
200 20 AMP
194 208 L1 261 261 331 331 331 301
L3 W
195 260 142
L1
GND BLOCK A1 A2 B1 B2 C1 C2 PE PE
206 330 375 300
321 330 GND
TO CONTROL BOX
ENCLOSURE { 320 366 DRIVE
POWER BOX VFD
REACTOR
SOLENOID 350 375
WIRING SCHEMATIC, BMK 3.0 LN
208 VAC, 3 PHASE
REF: 68007 REV. I (SHT. 1 OF 2)
H-1
1
OUTDOOR AIR SENSOR IN
FROM AIR 2
SENSOR COMMON IN
TEMP SENSOR 3
AUX SENSOR IN
4
+
CO SENSOR IN 5
-
6
+
FLOW SENSOR IN 7
-
8
+
OXYGEN SENSOR IN 9
-
10
SENSOR EXCIT. (12 VDC)
11
+
ANALOG IN 12
-
13
+
BMS (PWM) IN 14
-
15
SHIELD 16
1
+
ANALOG OUT 2
-
1
+
2
RS-485 IN GND
3
-
1
A
IN 2
B
3
0-10V
TO VFD 4
AGND
NOT USED 7
6
N.O.
AUX 5
C
RELAY N.C. 4
N.O. 3
FAULT 2
C
RELAY N.C. 1
7
NOT USED 6
IN
DELAYED INTLK 5
OUT
4
IN
EXHAUST TEMP 3
OUT
2
IN
1
REMOTE INTLK OUT
H-2
APPENDIX H
APPENDIX H

16-PIN CONNECTOR 9-PIN CONNECTOR 7-PIN CONNECTOR
19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
141 193 136 135 138 190 172 170 168 166 164 162 152 150 148 146 133 134
191 194 137 155 154 192 140 195 173 171 169 167 165 163 161 153 151 149 147 145
IGNITION
BLOWER PROOF SW.

TRANSFORMER
141
AIR
TEMP.
SENSOR
WATER LEVEL PROBE
GND
1 149 148
FLAME ROD
SHELL
352
351
153 151
321
SHUTOFF VALVE
BLOCKED AIR INLET SW.
TEMP.
YEL
CLOSURE SWITCH
HIGH GAS PRESS. SW.
2 10K SENSOR
IGNITOR
WHT
GRN
RED
BLU
SAFETY
BLK
PROOF OF
NC C
LOW GAS PRESS. SW.

1K
3
STEPPING H N G
A
POSITION
MOTOR
142
POSITION
IGNITION
SWITCH
SWITCH
PURGE
5K B
147
146
154 53
C 152 150 145
AIR/FUEL VALVE
SHIELD
363 TO I/O BOX
AIR TEMP
364 SENSOR
137 209 136
FUSE 120 VAC

MANUAL RESET AUTO RESET CONTROL TRANSFORMER
201 200
OVER TEMPERATURE SWITCHES
200
FUSE 315 315
203
207 202 314 314 FUSE
24 VAC
209 XFMR 4 AMPS
319 X2 XF
208 204 X1
460VAC TO I/O BOX

AGND
H1 H2 H3 H4 0-10V
316
6 PIN CONNECTOR 317
201 GND 260
FUSE BLOCK VFD
190 202
204 316 15 AMP T1 T2 T3 T4 T5 T6
191 203 263 BLOWER
L3 263 333 333 303
L3 L1 U
192 206 317 15 AMP MOTOR
60 HZ L2 262
262 332 332 302
193 209 3O L2 L2 V
460VAC 15 AMP
194 208 L1 261 261 331 331 301
142 L3 W
195 260 L1
206 GND BLOCK A1 A2 B1B2 C1 C2 PE
319 330 375 PE 300
321 330 GND
TO CONTROL BOX
ENCLOSURE
{ 320 366 DRIVE
POWER BOX REACTOR VFD
375 375
SOLENOID 350

460 VAC, 3 PHASE
REF: 68006 REV. I (SHT. 1 OF 2)
H-3
1
FROM AIR 2
SENSOR COMMON IN
TEMP SENSOR 3
AUX SENSOR IN
4
+
CO SENSOR IN 5
-
6
+
FLOW SENSOR IN 7
-
8
+
OXYGEN SENSOR IN 9
-
10
11
+
ANALOG IN 12
-
13
+
BMS (PWM) IN 14
-
15
SHIELD 16
1
+
ANALOG OUT 2
-
1
+
2
RS-485 IN GND
3
-
1
A
IN 2
B
3
0-10V
TO VFD 4
AGND
NOT USED 7
6
N.O.
AUX 5
C
RELAY N.C. 4
N.O. 3
FAULT 2
C
RELAY N.C. 1
7
NOT USED 6
IN
DELAYED INTLK 5
OUT
4
IN
EXHAUST TEMP 3
OUT
2
IN
1
REMOTE INTLK OUT
H-4
APPENDIX H
APPENDIX H
H-5
APPENDIX H
24-PIN CONNECTOR 16-PIN CONNECTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
232 234 236 238 240 242 244 246 250 252 254 220 215 213 211
231 233 235 237 239 241 243 245 247 251 253 226 221 219 216 214 212
J3 J2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12
J1
LS4
LS3
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
1
2
1
2
3
1
2
3
4
LS2 LS1
AGND
A
B
SENSOR COMMON IN
0-10V
AUX SENSOR IN
7
6
5
4
3
2
1
7
6
5
4
3
2
1
RS-485 IN GND
+
+
-
-
SHIELD
ANALOG OUT
ANALOG IN
OUT
BMS (PWM) IN
IN
FLOW SENSOR IN
CO SENSOR IN
OXYGEN SENSOR IN
OUT
OUT
N.O.
N.O.
N.C.
N.C.
C
IN
IN
IN
NOT USED
DELAYED INTLK
REMOTE INTLK
EXHAUST TEMP
NOT USED
RELAY
FAULT
RELAY
AUX
TO VFD
AUX SENSOR IN
FROM AIR
SENSOR
TEMP
INPUT/OUTPUT BOX

208 VAC 3 PHASE IRI
REF: 68025 REV. D (SHT. 2 OF 2)
H-6
APPENDIX H
H-7
1
FROM AIR 2
SENSOR COMMON IN
TEMP SENSOR 3
AUX SENSOR IN
4
+
CO SENSOR IN 5
-
6
+
FLOW SENSOR IN 7
-
8
+
OXYGEN SENSOR IN 9
-
10
11
+
ANALOG IN 12
-
13
+
BMS (PWM) IN 14
-
15
SHIELD 16
1
+
ANALOG OUT 2
-
1
+
2
RS-485 IN GND
3
-
1
A
IN 2
B
3
0-10V
TO VFD 4
AGND
NOT USED 7
6
N.O.
AUX 5
C
RELAY N.C. 4
N.O. 3
FAULT 2
C
RELAY N.C. 1
7
NOT USED 6
IN
DELAYED INTLK 5
OUT
4
IN
EXHAUST TEMP 3
OUT
2
IN
1
REMOTE INTLK OUT
H-8
APPENDIX H
APPENDIX I
RECOMMENDED PERIODIC TESTING CHECK LIST
WARNING
NOTE: Periodic testing of all boiler controls and safety devices is required to determine that they are operating as
designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property
damage. The owner or user of an automatic boiler system should set up a formal system of periodic preventive
maintenance and testing. Tests should be conducted on a regular basis and the results recorded in a log-book.
Accomplished
Item Frequency By Remarks
Refer to indicated paragraphs of this manual for detailed procedures
Gauges, monitors and Visual inspection and record readings in operator
Daily Operator
indicators log
Instrument and Visual check against factory recommended
Daily Operator
equipment settings specifications
Weekly Operator Verify factory settings
Semi- Service
Firing Rate Control Verify factory settings
Annually Technician
Service Check with combustion calibration test
Annually
Technician equipment. See paragraph 7.4 and Chapter 4.
Flue, vent, stack or Visually inspection condition and check for
Monthly Operator
intake air duct obstructions
Igniter Weekly Operator See paragraph 7.2
Air/Fuel Valve position Weekly Operator Check position indicator dial (paragraph 3.8)
Service Check for leakage in accordance with the SSOV
SSOV Leakage test Annually
Technician manufacturer’s (Siemens) recommendations.
Close manual gas shutoff valve and check safety
Flame failure Weekly Operator
shutdown. See paragraph 6.7
Check flame strength using the Control Panel
Flame signal strength Weekly Operator
Operating Menu. See paragraph 3.4.
Low water level cut off
Weekly Operator See paragraph 6.4
and alarm
Perform a slow drain test in accordance with
Semi-
Slow drain test Operator ASME Boiler and Pressure Vessel Code,
Annually
Section IV.
High water temperature Service
Annually See paragraph 6.4
safety control test Technician
Operating controls Annually Operator See paragraph 3.2
Low air flow Monthly Operator See paragraph 6.6
High and low gas
Monthly Operator See paragraphs 6.2 and 6.3
pressure interlocks
Air/Fuel Valve purge Service
position switch Technician
Air/Fuel Valve ignition Service
position switch Technician
Check per A.S.M.E. Boiler and Pressure Vessel
Safety valves As required Operator
Code, Section IV
Inspect burner Semi- Service See paragraph 7.6
components Annually Technician
I-1
APPENDIX J
BENCHMARK CONTROL PANEL EXPLODED VIEW
J-1
APPENDIX J
P6
P5
P4
P3
P2
P1
BENCHMARK CONTROL PANEL REAR VIEW
J-2
APPENDIX K
RECOMMENDED SPARE PARTS LISTS
NOTE
Refer to the Parts List Illustrations in Appendix F for the
locations of the recommended and optional spare parts
listed in the following Tables.
Table K-1. Recommended Emergency Spare Parts

DESCRIPTION PART NUMBER
3-Phase Blower 24045
SSOV Actuator/Regulator Combo - Used on: 64048
• ALL FM gas train models
• Downstream SSOV of IRI gas train models
SSOV Actuator Without Proof of Closure Switch - Used on: 69038
• Upstream SSOV of IRI gas train models
Temperature Switch - Manual Reset (SEE NOTE 1) 123552
Table K-2. Spare Parts Recommended for Maintenance

Annual Maintenance Kit 58025-01
24-month Waterside/Fireside Inspection Kit 58025-04
Table K-3. Optional Spare Parts

C-More Control Box 181197
Burner 46013
Temperature Switch - Auto Reset (SEE NOTE 1) 123966
NOTE:
1. If boiler is installed in the State of Kentucky, contact your local AERCO Sales
Representative for Temperature Switch rated for 200°F max.
K-1
Standard Warranty:
Benchmark Gas-Fired Hydronic Boiler
International, Inc.
PRESSURE VESSEL/HEAT EXCHANGER: 10 YEARS FROM SHIPMENT
The pressure vessel/heat exchanger shall carry a 10-year prorated, limited warranty from shipment
against any failure due to condensate corrosion, thermal stress, mechanical defects or workmanship.
Operation of the boiler using contaminated air will void the warranty. The pressure vessel/heat
exchanger shall not be warranted from failure due to scaling, liming, corrosion, or erosion due to water
or installation conditions. AERCO will repair, rebuild or exchange, at its option the heat
exchanger/combustion chamber according to the following schedule:
Year Discount From Then Prevailing List Price

1 through 7 100%
8 70%
9 40%
10 25%
“C-MORE” CONTROL PANEL: 2 YEARS FROM SHIPMENT
AERCO labeled control panels are conditionally warranted against failure for (2) two years from
shipment.
OTHER COMPONENTS: 18 MONTHS FROM SHIPMENT

All other components, with the exception of the ignitor and flame detector, are conditionally
guaranteed against any failure for 18 months from shipment.
AERCO shall accept no responsibility if such item has been improperly installed, operated, or
maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to
the item.
The warranty as set forth on the back page of the Operations & Maintenance Manual is in lieu of and
not in addition to any other express or implied warranties in any documents, or under any law. No
salesman or other representative of AERCO has any authority to expand warranties beyond the face of
the said warranty and purchaser shall not rely on any oral statement except as stated in the said
warranty. An Officer of AERCO must do any modifications to this warranty in writing. AERCO
MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES. AERCO disclaims all
responsibility for any special, incidental or consequential damages. Any claim relating to the product
must be filed with AERCO not later than 14 days after the event-giving rise to such claim. Any claims
relating to this product shall be limited to the sale price of the product at the time of sale. The sale of
the product is specifically conditioned upon acceptance of these terms.
Rev. 02/04/08 W-1 C103.0

Standard Warranty:
Benchmark Gas-Fired Hydronic Boiler
International, Inc.
CONDITIONS OF WARRANTY
Should an AERCO gas-fired Hydronic boiler fail for any of the above reasons within the specified time
period from the date of original shipment(s), AERCO shall, at its option, modify, repair or exchange
the defective item. AERCO shall have the option of having the item returned, FOB its factory, or to
make field replacements at the point of installation. In no event shall AERCO be held liable for
replacement labor charges or for freight or handling charges.
AERCO shall accept no responsibility if such item has been improperly installed, operated, or
maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to
the item. The use of replacement parts not manufactured or sold by AERCO will void any warranty,
express or limited.
In order to process a warranty claim a formal purchase order number is required prior to shipment of
any warranty item. In addition, the returned item must include a Returned Goods Authorization (RGA)
label, attached to the shipping carton, which identifies the item’s return address, register number and
factory authorized RGA number.
Warranty coverage for all components and equipment mentioned in said warranty are not valid unless
the Hydronic boiler is started up by a factory certified SST (Service, Start-Up and Troubleshooting)
Technician and an AERCO start-up sheet is completed.
This warranty coverage is only applicable within the United States and Canada. All other geographical
areas carry a standard warranty of 18 months from date of shipment or 12 months from startup,
whichever comes first.
Rev. 02/04/08 W-2 C103.1

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Instruction

Applicable for Serial Numbers G-10-1031 and above

Printed in U.S.A. REVISED JUNE 15, 2010

The information contained in this

GF-116 - AERCO BENCHMARK 3.0LN GAS FIRED LOW NOx BOILER

Chapter 1 – SAFETY PRECAUTIONS 1-1

Para. Subject Page Para. Subject Page

Chapter 2 – INSTALLATION 2-1

Para. Subject Page Para. Subject Page

Chapter 3 – CONTROL PANEL OPERATING PROCEDURES 3-1

Para. Subject Page Para. Subject Page

Chapter 4 – INITIAL START-UP 4-1

Para. Subject Page Para. Subject Page

Chapter 5 – MODE OF OPERATION 5-1

Para. Subject Page Para. Subject Page

Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1

Para. Subject Page Para. Subject Page

Chapter 7 – MAINTENANCE REQUIREMENTS 7-1

Para. Subject Page Para. Subject Page

Chapter 8 – TROUBLESHOOTING GUIDE 8-1

Para. Subject Page Para. Subject Page

Chapter 9 - RS232 COMMUNICATION 9-1

Para. Subject Page Para. Subject Page

App Subject Page App Subject Page

• South Coast Air Quality Management District (SCAQMD), Rule 1146.1

INSTALLATION DATE: _____________________________________________

CHAPTER 1 SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS WARNING!

1.2 EMERGENCY SHUTDOWN

IMPORTANT MANUAL GAS SHUTOFF VALVE

IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the

Extracted Information From 248 CMR 5.08 (2) – Continued

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

2.1 INTRODUCTION • Pressure/Temperature Gauge

NOTE • Access to AC Input Power corresponding to

Figure 2-1 Benchmark 3.0 Boiler Clearances

FOR MASSACHUSETTS ONLY

2.4.3 Removal of Support Rod This can be easily accomplished by removing

1. Apply Teflon tape to the threads of the 3/4” x

VIEW “A - A” VIEW “B - B” 6. Connect a length of 1” I.D. polypropylene hose

A suitable piping compound, approved for use

UPPER RIGHT CORNER OF FRONT PANEL

208 VAC, 3 PHASE 460 VAC, 3 PHASE

208 VAC, 3 Phase 460 VAC, 3 Phase

LOWER RIGHT CORNER

SHIELD NOT USED

Figure 2-11. I/O Box Terminal Strip

22 AWG, such as Belden 9841 (see 2.10.9 EXHAUST SWITCH IN

2.10.6 mA OUT 2.10.10.2 DELAYED INTERLOCK IN

2.10.11 FAULT RELAY For Massachusetts boiler installations, the

CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES

ELECTRICAL VOLTAGES IN THIS

3.2 CONTROL PANEL DESCRIPTION

Table 3-1 Operating Controls, Indicators and Displays

Table 3-1 Operating Controls, Indicators and Displays – Continued

Once the valid level 1 password (159) is

3.3.1 Menu Processing Procedure