Aerco BMK 1500 User Manual
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Aerco BMK 1500 User Manual

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Benchmark 1500 - 2000 Boilers
Installation, Operation & Maintenance Manual
USER MANUAL
Installation, Operation and Maintenance
BENCHMARK
Natural Gas Modulating
1500 and 2000
& Condensing Hot Water
Gas-Fired Boilers
Boiler Models:
• BMK 1500
• BMK 2000
Applicable to Serial Numbers:
G-15-2700 and Above
Latest Update: 10/01/2015
OMM-0097_0E
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 182
GF-142
Ph.: 800-526-0288
10/01/2015

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Summary of Contents for Aerco BMK 1500

  • Page 1 Gas-Fired Boilers Boiler Models: • BMK 1500 • BMK 2000 Applicable to Serial Numbers: G-15-2700 and Above Latest Update: 10/01/2015 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 2 The information contained in this 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.

  • Page 3: Table Of Contents

    3.2 CONTROL PANEL DESCRIPTION ...................... 35 3.3 CONTROL PANEL MENUS ........................39 3.3.1 Menu Processing Procedure ........................... 39 3.4 OPERATING MENU ..........................41 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 4 6.5 WATER TEMPERATURE FAULT TEST ....................76 6.6 INTERLOCK TESTS ..........................78 6.6.1 Remote Interlock Test............................. 78 6.6.2 Delayed Interlock Test ............................ 78 Page 4 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 5 TABLE A-4: TUNING MENU ITEM DESCRIPTIONS ................136 TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS ........... 137 APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES ..........139 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 5 of 182 GF-142 Ph.: 800-526-0288...
  • Page 6 APPENDIX I: PIPING DRAWINGS ....................173 APPENDIX J: C-MORE CONTROL PANEL VIEWS ..............179 APPENDIX K: RECOMMENDED SPARES ................... 181 Page 6 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 7: Foreword

    The turn down ratios for these boilers is 20:1. These BMK models provide extremely high efficiency operation and are ideally suited for modern low temperature, as well as, conventional heating systems. The Benchmark Model BMK 1500 and BMK 2000 boilers operate within the following input and output ranges: Benchmark Input Range (BTU/hr.)
  • Page 8 (1 BTU/hr = 0.29 W) Combination Control Panel Combination Control System C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Cubic Feet per Hour (1 CFH = 0.028 m...
  • Page 9 Printed Circuit Board PMC Board Primary Micro-Controller (PMC) board, contained in the C-More Part Number Proof of Closure Parts per Million OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 10 W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 million of an ampere) Page 10 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 11: Chapter 1. Safety Precautions

    In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers.

  • Page 12: Emergency Shutdown

    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.
  • Page 13 248 CMR 5.08(2)(a)1 through 4. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 13 of 182 GF-142 Ph.: 800-526-0288...
  • Page 14 ____________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] Page 14 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 15: Chapter 2. Installation

    2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark Boiler Model BMK 1500 and BMK 2000. 2.2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for these BMK models is approximately 1800 pounds (817 kg).

  • Page 16: Site Preparation

    The Benchmark Model 1500 and 2000 are packaged in an enclosure having identical exterior dimensions. The unit must be installed with the prescribed clearances for service as shown in Figure 2-1a. The minimum clearance dimensions, required by AERCO, are listed below. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements.

  • Page 17: Setting The Unit

    WARNING! When lifting or moving the boiler, DO NOT attempt to manipulate the boiler using the gas train or blower. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 18 Combination Mode Boilers in advance and place them in the proper physical location. Refer to Chapter 5 for information on Combination Mode Boilers. Page 18 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 19: Supply And Return Piping

    AERCO SmartPlates, thermal efficiency can improve by up to 10%. If your unit includes the secondary inlet, pipe the warmer return water to the secondary (upper) inlet and the cooler return water to the primary (lower) inlet. Contact your AERCO representative for additional information.

  • Page 20: Pressure Relief Valve Installation

    PRESSURE RELIEF VALVE INSTALL TRIDICATOR GAUGE HERE 4” HOT BOILER (P/N 123675-TAB) WATER OUTLET Figure 2-4: P&T Relief Valve Location Page 20 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 21: Condensate Drain & Piping

    Connect a length of 1” (2.54 cm) diameter polypropylene hose to the trap outlet and secure with a hose clamp. Route the hose on the trap outlet to a nearby floor drain. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 21 of 182 GF-142 Ph.: 800-526-0288...
  • Page 22 EXHAUST THICK UNDER THE FLOOR MANIFOLD CONDENSATE DRAIN PORT DRAIN ASSEMBLY. Figure 2-6: Sample Condensate Trap Installation (Right Side View) Page 22 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 23: Gas Supply Piping

    Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION 2.8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING! NEVER USE MATCHES, CANDLES, FLAMES OR OTHER...

  • Page 24: External Gas Supply Regulator

    It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above. However, AERCO offers for sale an appropriate regulator, which may be ordered at the time of unit purchase or separately. Contact AERCO for more information. Page 24 of 182 AERCO International, Inc.

  • Page 25: Ac Electrical Power Wiring

    CHAPTER 2 – INSTALLATION 2.9 AC ELECTRICAL POWER WIRING The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to connecting any AC power wiring to the unit. External AC power connections are made to the unit inside the Power Box on the front of the unit. Remove the front panel to access the Power Box, which is mounted in the upper right corner of the unit as shown in Figure 2-8.

  • Page 26: Electrical Power Requirements

    National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code. For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF- 2060). Page 26 of 182 AERCO International, Inc.

  • Page 27: Field Control Wiring

    DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 182 GF-142 Ph.: 800-526-0288...

  • Page 28: Outdoor Air In (Out) & Air Sensor Common (Com)

    The sensor must be shielded from direct sunlight as well as impingement by the elements. If a shield is used, it must allow for free air circulation. Page 28 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 29: Air Temp Sensor Terminals

    Chapter 3. If voltage rather than current is selected as the drive signal, a DIP switch must be set on the PMC Board located inside the C-More Control Box. Contact the AERCO factory for information on setting DIP switches.

  • Page 30: Shield Terminals (Shld & Shld)

    2.10.9 RS485 Comm (+, GND, & -) The RS485 communication terminals are used when the boiler plant is being controlled by an Energy Management System (EMS) or an AERCO Control System (ACS) using Modbus (RS485) communication. 2.10.10 RS232 Comm (TxD & RxD) As of Firmware version 4.0 and above, these terminals are used only by factory-trained...

  • Page 31: Fault Relay (Nc, Com, & No)

    Figure 2-12 to locate the AUXILLIARY RELAY terminals for wiring connections. 2.11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-2050 must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification.

  • Page 32: Combustion Air

    For combustion air supply from ducting, see section 2.13 below and consult the AERCO GF- 2050, Gas Fired Venting and Combustion Air Guide.

  • Page 33: Sequencing Isolation Valve Installation

    (P/N 92084-TAB) included in the shipping container. This valve is an integral component of the AERCO’s on-board Boiler Sequencing Technology (BST) solution. BST allows sites with multiple boilers to have one boiler, acting as a “master” to manage the other boilers at the site in such a way that the efficiency of the entire boiler array is maximized.
  • Page 34 Figure 2-14: Sequencing Isolation Valve Installed Remove the jumper wire from the Molex connector and then plug it into the sequencing isolation valve’s connector. Page 34 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 35: Chapter 3. Operation

    These operating controls, indicators and displays are listed and described in Table 3-1. Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this Chapter. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 35 of 182 GF-142 Ph.: 800-526-0288...
  • Page 36 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Figure 3-1: Control Panel Front View Page 36 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 37 Low Water Level alarm. TEST/RESET switches Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 37 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 38 20 segment red LED bargraph continuously shows the VALVE POSITION Air/Fuel Valve position in 5% increments from 0 to 100% Bargraph Page 38 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 39: Control Panel Menus

    The menu option choices do not wrap around. To select and store a changed menu item, press the ENTER key. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 39 of 182 GF-142 Ph.: 800-526-0288...
  • Page 40 Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. Page 40 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 41: Operating Menu

    Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration menu (Table 3-4). OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 182 GF-142 Ph.: 800-526-0288...

  • Page 42: Setup Menu

    Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. Page 42 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 43 Shutdown or Constant Setpt Shutdown Off, Setpoint, Outlet Temp, Valve Pos Analog Output Valve Pos 0-10v 4-20mA, valve Pos 0-10v OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 43 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 44 Outdoor Sensor menu item is set to Enabled. CAUTION DO NOT change the Analog Output menu item from its default setting (Valve Position 0-10V). Page 44 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 45: Tuning Menu

    SET Valve Position SET Valve Position Blower Output Blower Output Set Stdby Volt Set Stdby Volt Oxygen Level Oxygen Level OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 45 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 46: Bst (Boiler Sequencing Technology) Menu

    Head Temp Source Network FFWD Temp FFWD Temp Header Temp Addr Header Temp Point BST Outdoor Sens Disabled Enabled Disabled Page 46 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 47 100°F (37.8°C) BST Intgral Gain 0.00 2.00 0.50 BST Deriv Time 0.00 Min 2.00 Min 0.10 Min BST Deadband Hi OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 47 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 48: Start Sequence

    Also, the appropriate messages will be displayed throughout the start sequence, if the required conditions are not observed. Page 48 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 49 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%. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 182 GF-142 Ph.: 800-526-0288...
  • Page 50 The Dial on the Air/Fuel Valve (Figure 3-6) will read between 25 and 35 to indicate that the valve is in the low fire position. Page 50 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 51 Once the demand for heat has been satisfied, the Control Box will turn off the SSOV gas valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed. STANDBY will be displayed. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 51 of 182 GF-142 Ph.: 800-526-0288...

  • Page 52: Start/Stop Levels

    1,069,000 (313.2 kW) 1,283,000 (375.9 kW) 1,476,000 (432.5 kW) 1,675,000 (490.1 kW) 1,833,000 (537.1 kW) 100% 2,000,000 (586.0 kW) 100% Page 52 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 53: Chapter 4. Initial Start-Up

    Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start-up requirements. An AERCO Gas Fired Startup Sheet, included with each Benchmark unit, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO via e-mail at: STARTUP@AERCO.COM. WARNING! DO NOT ATTEMPT TO DRY FIRE THE UNIT.

  • Page 54: Required Tools & Instrumentation

    (Install manometer here for LEAK DETECTION BALL VALVE Combustion Calibration) Figure 4-1: 1/4 Inch Gas Plug Location for Combustion Calibration Page 54 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 55: Accessing The Analyzer Probe Port

    WATER INLET DRAIN VALVE EXHAST MANIFOLD ANALYZER PORT CONDENSATE DRAIN Figure 4-2: Analyzer Probe Port Location (Right Side Partial View) OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 55 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 56: Natural Gas Combustion Calibration

    Recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU content, gas supply piping and supply regulators. Combustion Calibration Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
  • Page 57 23. Next, press the down (▼) arrow key until CAL Voltage 70% is displayed. 24. Press the CHANGE key and observe that CAL Voltage 70% is flashing. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 57 of 182 GF-142 Ph.: 800-526-0288...
  • Page 58 Recalibration MUST be performed again from 60% down to 16% after making a change to the idle screw (TAC valve). 30. This completes the BMK 1500 Natural Gas combustion calibration procedures. Page 58 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 59 Adjustment Screw). Figure 4-3: Gas Pressure Adjustment Screw Location TAC VALVE IDLE SCREW Figure 4-4: TAC Valve Adjust (Idle Screw) OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 60: Bmk 2000 Natural Gas Combustion Calibration

    Table 4-5: Combustion Calibration Readings – 100% Valve Position Valve Position Oxygen (O Nitrogen Oxide (NOx) Carbon Monoxide (CO) 100% 5.0% - 6.0% ≤20 ppm <100 ppm Page 60 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 61 Pressing the ▲ arrow key increases the oxygen level and pressing the down ▼ arrow key decreases the oxygen level. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 61 of 182 GF-142 Ph.: 800-526-0288...

  • Page 62: Reassembly

    6. Replace all previously removed sheet metal enclosures on the unit. 7. This concludes reassembly of the unit after combustion calibration. Page 62 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 63: Over-Temperature Limit Switches

    Figure 4-6 and Table 4-8. Alarm Limit Control Figure 4-6: Digital Over-Temperature Alarm Switch Front Panel OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 63 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 64 6. To calibrate the offset (P1), press and hold the SET button for 8 seconds on the Over- Temperature Alarm switch. Access code value 0 should appear in the display. The switch comes from the factory with the code set at 0. AERCO recommends that you do not change this code.

  • Page 65: Chapter 5. Mode Of Operation

    I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is provided on the cover of the I/O Box. Refer to Chapter 2, section 2.9.1 for additional wiring information. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 65 of 182 GF-142 Ph.: 800-526-0288...

  • Page 66: Indoor/Outdoor Startup

    AERCO representative be contacted. For descriptions of temperature-related functions, see Appendix A; their factory defaults are included in Chapter 3, sections 3.4 – 3.8. Page 66 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 67: Setting The Setpoint

    Boiler Mode Remote Setpoint Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network Refer to section 3.3 for detailed instructions on changing menu options. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 67 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 68: Remote Setpoint Field Wiring

    While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions, see Appendix A;...

  • Page 69: Direct Drive Field Wiring

    To change back to the Direct Drive mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 69 of 182 GF-142 Ph.: 800-526-0288...

  • Page 70: Aerco Control System (Acs)

    485 signaling to the boiler. Installations with 1 to 8 boilers can use BST (see Chapter 9). The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible.

  • Page 71: Combination Control System (Ccs)

    Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay...

  • Page 72: Combination Control System Field Wiring

    These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Chapter 3.

  • Page 73: Chapter 6. Safety Device Testing

    Electrical voltages in this system may include 120 and 24 volts AC. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 73 of 182 GF-142 Ph.: 800-526-0288...

  • Page 74: Low Gas Pressure Test

    Upon test completion, close the ball valve and remove the manometer. Replace the 1/4" NPT plug removed in step 2. Page 74 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 75: High Gas Pressure Test

    Reduce the gas pressure back to the value recorded in step 6. This pressure should be within the following ranges: • BMK 1500 = 3.6” ± 0.2” W.C. (897 ± 50 Pa) • BMK 2000 = 3.4” ± 0.2” W.C. (847 ± 50 Pa) Press the CLEAR button on the Control Box to clear the fault.

  • Page 76: Low Water Level Fault Test

    HIGH WATER TEMP SWITCH OPEN fault message should be displayed. It should not be possible to restart the unit. Page 76 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 77 LIMIT DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON MANUAL TEMPERATURE LIMIT SWITCH Figure 6-2: Temperature Limit Switch Location OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 77 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 78: Interlock Tests

    Reconnect the wire or jumper removed in step 3 to restore the interlock. Press the CLEAR button to reset the fault The unit should start. Page 78 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 79: Flame Fault Tests

    The unit should shut down and Lockout, flashing FLDR in the display. Open the valve previously closed in step 8. Press the CLEAR button. The unit should restart and fire. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 79 of 182 GF-142 Ph.: 800-526-0288...
  • Page 80 SWITCH EXCHANGER AIR/FUEL VALVE MANUAL SHUT-OFF VALVE SSOV BLOCKED INLET SWITCH FILTER TRAIN Figure 6-3: Bare Boiler – Partial View Page 80 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 81: Air Flow Fault Tests

    (see Figure 6-5, below). For units that have an air filter in place of a Combustion Air Duct (not shown), remove the air filter. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 81 of 182 GF-142 Ph.: 800-526-0288...
  • Page 82 Remove the jumper wires installed in step 2 and replace the black connector boot on the Flame Detector. Press the CLEAR button. The unit should restart. Page 82 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 83: Ssov Proof Of Closure Switch

    The unit should shut down and display SSOV FAULT DURING PURGE. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 83 of 182 GF-142 Ph.: 800-526-0288...

  • Page 84: Purge Switch Open During Purge

    The unit should begin its start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE. Replace the wire on the Purge switch and depress the CLEAR button. The unit should restart. Page 84 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 85: Ignition Switch Open During Ignition

    BLOWER PROOF SWITCH AIR/FUEL VALVE COVER (Rotate Counter-Clock-Wise to Remove) AIR/FUEL VALVE BLOCKED INLET SWITCH Figure 6-7: Air/Fuel Valve Cover Location OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 85 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 86: Safety Pressure Relief Valve Test

    6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. Page 86 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 87: Chapter 7. Maintenance

    Air Filter ( Clean Replace 15 mins. P/N 59138 * Only performed after initial 6 month period after initial startup. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 87 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 88: Igniter-Injector

    This will disengage the shroud from the four (4) pins in the side panels. Disconnect the cable from the igniter-injector (Figure 7-1). Page 88 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 89 Chapter 4 for combustion calibration procedures. Prior to reinstalling the igniter-injector, a high temperature, conductive, anti-seize com- pound must be applied to the threads. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 182 GF-142 Ph.: 800-526-0288...

  • Page 90: Flame Detector

    Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels. Page 90 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 91: O 2 Sensor

    The results of the tests should be recorded in a log book. See Chapter 6- Safety Device Testing Procedures. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 182 GF-142 Ph.: 800-526-0288...

  • Page 92: Burner Assembly Inspection

    Remove the burner by pulling straight up. Remove and replace the burner gasket(s) (see Figure 7-5). NOTE The burner assembly weighs approximately 65 lbs (29.5 kg). Page 92 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 93 HEX NUTS BURNER (8 each) PLATE 1/2” NUTS & BOLTS (4 each) FILTER GAS TRAIN Figure 7-4a: Burner Assembly Mounting Details OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 93 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 94 81186 – LOWER RELEASE GASKET BARE BURNER INSTALLED IN HEAT EXCHANGER ASSY. Figure 7-5: Bare Burner and Replacement Gaskets Location Page 94 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 95: Condensate Drain Trap

    INLET Float 3/4" NPT Port O-Rings OUTLET CROSS-SECTION EXPLODED VIEW Figure 7-6: External Condensate Trap – Cross-Section & Exploded View OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 95 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 96: Air Filter Cleaning & Replacement

    Replace the top shroud on the unit and return boiler to service use. AIR/FUEL VALVE AIR FILTER MANUAL HOSE CLAMP SHUT-OFF VALVE AIR FILTER TRAIN Figure 7-7: Air Filter Location Page 96 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 97: Water Cutoff (Lwco) Capacitor Integrity Test

    Serious personal injury or death may occur if this warning is not observed. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 182 GF-142 Ph.: 800-526-0288...
  • Page 98 19-Pin Shell Harness Cable Connector LWCO Probe Assembly Connector Figure 7-10: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable Page 98 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 99: Low Water Cutoff (Lwco) - Standard C-More Test

    Close the water supply and return valves to isolate boiler. Close external gas supply valve. Open relief valve to vent water pressure. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 99 of 182 GF-142 Ph.: 800-526-0288...

  • Page 100: Placing The Boiler Back In Service After A Prolonged Shutdown

    I/O board’s Spark Signal terminals, red wire to the positive (+) terminal and black to negative (-). Page 100 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 101: Chapter 8. Troubleshooting Guide

    The front panel of the C-More Control Box contains an RS232 port. This port is used only by factory-trained personnel to monitor OnAER communications via a portable computer. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 101 of 182 GF-142 Ph.: 800-526-0288...
  • Page 102 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE (This page left intentionally blank) Page 102 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 103 Air/Fuel Valve dial. Check igniter-injector for soot or erosion of electrode. Check Hard light. injector solenoid valve to insure proper open/close operation. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 103 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 104 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW AIRFLOW FAULT DURING FAULT DURING IGNITION. IGNITION applies for this fault. Page 104 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 105 If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 105 of 182 GF-142 Ph.: 800-526-0288...
  • Page 106 If exhaust temperature is greater than 200 F (93.3 TEMPERATURE incorrect combustion calibration. check combustion calibration. Calibrate or repair as necessary. Page 106 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 107 Press CLEAR button and restart unit. If fault persists, contact IGN BOARD between the PMC board and qualified Service Personnel. COMM FAULT Ignition/Stepper (IGST) board. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 108 Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF Defective IGST Board. every second. If not, replace IGST Board. Page 108 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 109 Measure NATURAL GAS pressure at the Low Gas Pressure switch. If it is switch. greater than 4.7” W.C. (1171 Pa) for both BMK 1500 and BMK 2000, measure continuity across the switch and replace if necessary. Insufficient water level in system.
  • Page 110 O2 % OUT OF RANGE Blocked inlet air duct or louver. Unblock air inlet and measure open area for combustion air to the room. Page 110 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 111 Hot and Neutral reversed at SSOV. Check SSOV power wiring. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 182 GF-142 Ph.: 800-526-0288...
  • Page 112 Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. Page 112 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 113: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 70% Valve Position in Control Box are outdated. are Rev. E or higher. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 113 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 114 BRASS HEX HEAD (Remove to access the Gas Pressure DAMPING ORIFICE Adjustment Screw). Figure 8-2: SSOV Actuator with Gas Pressure Adjustment Page 114 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 115: Chapter 9. Boiler Sequencing Technology

    A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 9-1 below. Figure 9-1. Simplified BST Block Diagram OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 182 GF-142 Ph.: 800-526-0288...

  • Page 116: Installation Notes

    ProtoNode installed. Set the BST system for desired mode of operation (SETPOINT mode). Test the system completely with the ProtoNode installed. Page 116 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 117: Aerco Bst Quick Start Chart

    Option 7 – 4-20ma Drive AND Modbus Header Complete section 9.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 9.3.8 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 117 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 118: Bst Implementation Instruction

    7. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. Page 118 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 119: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    9. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 119 of 182 GF-142 Ph.: 800-526-0288...

  • Page 120: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    The outdoor sensor may be wired up to 200 feet (61m) from the boiler. Temp Sensor PN 123525 Page 120 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 121 9. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 121 of 182 GF-142 Ph.: 800-526-0288...

  • Page 122: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    The sensor must be shielded from direct sunlight as well as impingement by the elements. The outdoor sensor may be wired up to 200 feet (61m) from the boiler. Page 122 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 123 13. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 123 of 182 GF-142 Ph.: 800-526-0288...

  • Page 124: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be observed. • The ground for the shield is at the driver signal source. I/O Box Page 124 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 125 8. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 125 of 182 GF-142 Ph.: 800-526-0288...

  • Page 126: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Header Temp Sensor I/O Box Step 2: Remote Setpoint with Network 1. Configure and Connect the SSD Device (ProtoNode) per the AERCO Manual (GF129). Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration menu item and set the BST Menu item to Enabled.

  • Page 127: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Unit’s I/O Box. Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be observed. • The ground for the shield is at the driver signal source. I/O Box OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 127 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 128 10. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. Page 128 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 129: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Temp Sensor PN 24410 Modbus Transmitter I/O Box Step 2: Remote Setpoint with Network 1. Configure and Connect the SSD Device (ProtoNode) per the AERCO Manual (GF129). OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 129 of 182 GF-142 Ph.: 800-526-0288...
  • Page 130 10. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. Page 130 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...

  • Page 131: Appendix A: Boiler Menu Item Descriptions

    Gas Valve and confirmation of gas valve opening (POC). Run Hours Displays total run time of unit in hours. Fault Log Displays information on the last 20 faults. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 131 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 132: Table A-2: Setup Menu Item Descriptions

    4-digit serial # on the Code Plate, e.g., G-12-1234. Software Version Identifies the current software version of the control box. Page 132 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288...
  • Page 133 Specifies the amount of time, up to 30 minutes, to keep the Pump Delay Timer pump running after the unit turns off. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 133 of 182 GF-142 Ph.: 800-526-0288...
  • Page 134 Allows the Failsafe mode to be set to either Constant Setpoint Failsafe Mode or Shutdown. Must be set to Valve Pos 0-10V for both BMK 1500 and BMK Analog Output 2000. DO NOT CHANGE from its default value. Specifies how long, from 2 to 600 seconds, to remain in the low Lo Fire Timer fire position after ignition, before going to the desired output.
  • Page 135 Spark Monitor Spark Current Disabled on Benchmark 1500 and 2000. BST Menu When set to Enabled, the BST menu options appears. OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 135 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 136: Tuning Menu

    Range = 0 - 240 seconds Default = 20 seconds Reset Defaults? Allows Tuning menu options to be reset to their Factory Default values. Page 136 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 137 Permits the Standby Voltage to be set from 0 to 4.00 Volts. Permits the combustion oxygen level to be displayed (0% to Oxygen Level 25%) OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 137 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 138 Benchmark 1500 - 2000 Boilers APPENDIX A: BOILER MENU DESCRIPTIONS This Page Is Intentionally Blank Page 138 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 139: Appendix B: Startup, Status & Display Messages

    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 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 139 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 140 INTERLOCK The Remote Interlock is open. OPEN LINE VOLTAGE The Line (Hot) and Neutral wires are reversed. OUT OF PHASE Page 140 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 141 A failure has been detected in one of the relays that control the SSOV. FAILURE STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to the desired position. FAILURE OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 141 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 142 Benchmark 1500 - 2000 Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES This Page Is Intentionally Blank Page 142 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 143: Appendix C: Sensor Resistance/Voltage Chart

    1260.0 2.47 87.8 1285.6 2.50 93.3 1311.4 2.52 98.9 1337.7 2.54 104.4 1364.2 2.56 1391.0 2.58 115.6 1418.2 121.1 1445.7 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 143 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 144 Benchmark 1500 - 2000 Boilers APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART This Page Is Intentionally Blank Page 144 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 145: Appendix D: Recommended Periodic Testing

    See section 7.7 Annually Verify oxygen level is between 3% and 8% during Oxygen (O ) Level Monthly Operator boiler operation OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 145 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 146 Benchmark 1500 - 2000 Boilers APPENDIX D – RECOMMENDED PERIODIC TESTING This Page Is Intentionally Blank Page 146 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 147: Appendix E: Indoor/Outdoor Reset Ratio Charts

    RESET RATIO Air Temp °F °C 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 -26.1 -28.9 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 147 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 148 Air Temp °F °C 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 -26.1 -28.9 Page 148 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 149 Air Temp °F °C 26.7 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 149 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 150 Air Temp °F °C 32.2 29.4 26.7 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 Page 150 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 151: Appendix F: Dimensional And Clearance Drawings

    Benchmark 1500 - 2000 Boilers APPENDIX F – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix F: DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-936 rev A OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 151 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 152 Benchmark 1500 - 2000 Boilers APPENDIX F – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: SD-A-995 rev A Page 152 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 153: Appendix G: Part List Drawings

    AERCO 01/15/2015 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 1 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 153 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 154 AERCO 01/15/2015 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 2 of 7 Whole Boiler 29313-1 – 29337-1 Page 154 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 155 AERCO 01/15/2015 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 3 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 155 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 156 AERCO 01/15/2015 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 4 of 7 Whole Boiler 29313-1 – 29337-1 Page 156 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 157 AERCO 01/15/2015 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 5 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 157 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 158 AERCO 01/15/2015 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 6 of 7 Whole Boiler 29313-1 – 29337-1 Page 158 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 159 AERCO 02/01/2014 Benchmark 1500-2000 Part List International, Inc. Blauvelt, NY 10913 Sheet 7 of 7 Whole Boiler 29313-1 – 29337-1 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 159 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 160 (1171 Pa) AERCO 05/28/2015 Benchmark 1500-2000 Gas Train International, Inc. Blauvelt, NY 10913 Sheet 1 of 1 22188 rev E Page 160 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 161 PIPE PLUG, 1/4" NPT, STEEL AERCO 05/28/2015 Benchmark 1500-2000 DBB Gas Train International, Inc. Blauvelt, NY 10913 Sheet 1 of 1 22199 rev D OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 161 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 162 AERCO 01/15/2015 Benchmark 1500 - 2000 Burner Assembly International, Inc. Blauvelt, NY 10913 Sheet 1 of 1 24378-TAB rev E Page 162 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 163 Benchmark 1500 - 2000 Boilers APPENDIX G – PART LIST DRAWINGS (This page intentionally blank) OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 163 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...

  • Page 165: Appendix H: Wiring Diagrams

    Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS Appendix H: WIRING DIAGRAMS Drawing Number 68050 rev C page 1 of 2 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 165 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 166 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS (This page intentionally blank) Page 166 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 167 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS Drawing Number 68050 rev C page 2 of 2 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 167 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 168 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS (This page intentionally blank) Page 168 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 169 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS Drawing Number 68071 rev C page 1 of 2 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 169 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 170 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS (This page intentionally blank) Page 170 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 171 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS Drawing Number 68071 rev C page 2 of 2 OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 171 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 172 Benchmark 1500 - 2000 Boilers APPENDIX H – WIRING DIAGRAMS (This Page Is Intentionally Blank) Page 172 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 173: Appendix I: Piping Drawings

    Benchmark 1500 - 2000 Boilers APPENDIX I – PIPING DRAWINGS Appendix I: PIPING DRAWINGS Drawing Number: SD-A-989 rev A OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 173 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 174 Benchmark 1500 - 2000 Boilers APPENDIX I – PIPING DRAWINGS Drawing Number: SD-A-990 rev A Page 174 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 175 Benchmark 1500 - 2000 Boilers APPENDIX I – PIPING DRAWINGS Drawing Number: SD-A-991 rev A OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 175 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 176 Benchmark 1500 - 2000 Boilers APPENDIX I – PIPING DRAWINGS Drawing Number: SD-A-992 rev A Page 176 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...
  • Page 177 Benchmark 1500 - 2000 Boilers APPENDIX I – PIPING DRAWINGS Drawing Number: SD-A-993 rev A OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 177 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 178 Benchmark 1500 - 2000 Boilers APPENDIX I – PIPING DRAWINGS Drawing Number: SD-A-994 rev A Page 178 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 179: Appendix J: C-More Control Panel Views

    P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure J-1 – Benchmark Series Control Panel - Exploded View OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 179 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 180 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure J-2: Benchmark Control Panel Rear View Page 180 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E 10/01/2015 Ph.: 800-526-0288 GF-142...

  • Page 181: Appendix K: Recommended Spares

    Table K-3: Optional Spare Parts DESCRIPTION PART NUMBER C-More Control Box 181197 BMK 1500: 46042 Burner BMK 2000: 46044 61026 Lean Oxygen Sensor OMM-0097_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 181 of 182 GF-142 Ph.: 800-526-0288 10/01/2015...
  • Page 182 934-145: Warranty pages removed. Warranty information for all BMK units is now included in a new stand-alone document, All Benchmark Limited Warranty, posted on the AERCO web site. 934-150: Clarified references to & function of spark monitor (p/n 61034) (or AC current transducer) in section 2.10.4, added new section 7.12 Spark Monitor...

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