Aerco BMK 750 Installation And Startup Manual

Benchmark platinum series

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Page 1 • BMK 1000P • BMK 3000P • BMK 1500P • BMK 2000P Applies to Serial Numbers: G-17-0001 and above. Latest Update: 03/15/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 1 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 2: Table Of Contents
2.5.2 BMK 1500 – 2000 Lifting Provisions ....................20 2.6 SUPPLY AND RETURN PIPING ..................21 2.6.1 BMK 750 – 1000 Supply and Return Piping ..................21 2.6.2 BMK 1500 – 3000 Supply and Return Piping .................. 21 2.6.3 Dual Inlet Return Piping ......................... 22 2.7 PRESSURE RELIEF VALVE INSTALLATION ..............23...
Page 3 3.3 START/STOP LEVELS .......................51 3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT .............52 3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input ............. 52 3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input ..............53 3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input ..............54 3.4.4 BMK 2500 (Nat.
Page 4 7.1.2 Confirming the Ethernet Connection ................... 117 7.1.3 Confirm Ethernet DHCP Configuration ..................117 SECTION 8: TROUBLESHOOTING ..............119 APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ......121 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 5: Foreword
NO emission standards outlined in: South Coast Air Quality Management District (SCAQMD), Rule 1146.2. In addition, the BMK 750 & 1000 comply with the Bay Area Air Quality Management District regulation 9, Rule 7. Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting flexibility with minimum installation space requirements.
Page 6 BTUs per Hour (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 7 Primary Micro-Controller (PMC) board, contained in the C-More Part Number Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 7 of 128 Ph.: 800-526-0288 GF-200...
Page 8 W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 9: Section 1: Safety Precautions
• Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK 2500/3000) may be used in this equipment. Therefore the cover on the unit’s power box (located behind the front panel door) must be installed at all times, except during maintenance and servicing.
Page 10: Emergency Shutdown
Section 5, 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 11: Important - For Massachusetts Installations
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". (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 11 of 128 Ph.: 800-526-0288...
Page 12 ……………….[End of Extracted Information From 248 CMR 5.08 (2)]………………… AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 13: Section 2: Installation
FRONT ONLY. NOTE: AERCO is not responsible for lost or damaged freight. Each unit has a Tip-N-Tell indicator on the outside of the crate. This indicates if the unit has been turned on its side during shipment. If the Tip-N-Tell indicator is tripped, do not sign for the shipment. Note the information on the carrier’s paperwork and request a freight claim and inspection by a claims adjuster before...
Page 14: Site Preparation
750/1000, 1500/2000, and 2500/3000. The unit must be installed with the prescribed clearances for service as shown in Figure 2-1a, 2-1b and 2-1c. The minimum clearance dimensions, required by AERCO, are listed below for all models. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements. The minimum acceptable clearances required are as follows: •...
Page 15 Figure 2-1a: BMK 750/1000 Clearances NOTE: Ensure that condensate assembly is not located over the housekeeping Figure 2-1b: BMK 1500/2000 Clearances AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 15 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 16 For Massachusetts installations, the unit must be installed by a plumber or gas-fitter licensed within the Commonwealth of Massachusetts. In addition, the installation must comply with all requirements specified in Section 1.4, above. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 17: Setting The Unit
2.4.2 Setting the Unit BMK 750/1000 units must be installed on a 4 to 6 inch (10.2 to 15.2 cm) while BMK 1500 – 3000 units must be installed on a 4 to 8 inch (10.2 to 20.3 cm) housekeeping pad to ensure proper condensate drainage.
Page 18 ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME ALL DIMENSIONS SHOWN ARE IN INCHES [MILLIMETERS] Figure 2-2c: BMK 2500/3000 Anchor Bolt Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 19: Lifting Provisions
BAR IN SHIPPING POSITION VIEW A - SHIPPING POSITION VIEW B - LIFTING POSITION Figure 2-3a: BMK 750/1000 Boiler Lifting Provisions AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 19 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 20: Bmk 1500 - 2000 Lifting Provisions
LIFTING LUGS (3 POSITIONS) YELLOW ARROWS 2” NATURAL GAS OR 1” PROPANE GAS INLET Figure 2-3: Boiler Lifting Provisions – BMK 1500/2000 Shown AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 21: Supply And Return Piping
When connecting the hot water outlet and cold water inlet to building piping, first make sure the mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
Page 22: Dual Inlet Return Piping
When configured with a lower return temperature zone or AERCO SmartPlate, thermal efficiency can improve by up to 6% (Based on an 80 °F (26.7 °C) minimum return water temperature at full fire.
Page 23: Pressure Relief Valve Installation
RELIEF VALVE TRIDICATOR GAUGE HERE (P/N 123675-TAB) 4” HOT BOILER WATER OUTLET Figure 2-5b: BMK 1500/2000/2500/3000 P&T Relief Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 23 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 24: Condensate Drain And Piping
The base of the condensate trap must be supported to ensure that it is level (horizontal). • The trap must be removable for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port.
Page 25 EXHAUST EXTEND UNDER THICK FLOOR MANIFOLD THE CONDENSATE DRAIN ASSEMBLY DRAIN PORT Figure 2-6b: BMK 1500/2000/2500/3000 Sample Condensate Trap Installation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 25 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 26: Gas Supply Piping
The gas piping used must meet all applicable codes. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 27: Gas Supply Specifications
2.9.2 Manual Gas Shutoff Valve A manual shut-off valve must be installed in the gas supply line upstream of the boiler as shown in Figure 1-1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 27 of 128 Ph.: 800-526-0288...
Page 28: 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 your AERCO sales representative for more information.
Page 29 SECTION 2 – INSTALLATION 1” MANUAL SHUTOFF VALVE GAS INLET DIRT TRAP GAS PRESSURE REGULATOR Figure 2-7a: BMK 750/1000 Manual Gas Shut-Off Valve and Gas Regulator GAS PRESSURE REGULATOR NATURAL GAS INLET GAS INLET MANUAL SHUT-OFF VALVE Figure 2-7b: BMK 1500-3000 Manual Gas Shut-Off Valve and Gas Regulator AERCO International, Inc.
Page 30: Ac Electrical Power Wiring
Figure 2-7c: BMK 1500-3000DF Dual Fuel Manual Gas Shut-Off Valve & Gas Regulator 2.10 AC ELECTRICAL POWER WIRING AERCO’s Benchmark Electrical Power Guide, TAG-0048 (GF-2060), must be consulted prior to connecting any AC power wiring to the unit. 2.10.1 Electrical Power Requirements The BMK models covered by this manual are available in the following voltage configurations: •...
Page 31 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE SECTION 2 – INSTALLATION Figure 2-8a: Power Box Cover Label – BMK 750 – 2000 BMK 2500/3000 - 460VAC BMK 2500/3000 - 208VAC Figure 2-8b: Power Box Cover Labels – BMK 2500/3000 Each unit must be connected to a dedicated electrical circuit.
Page 32: Power Box Locations
Figure 2-9a: BMK 750/1000 Power Box with Closed Cover POWER BOX FRONT COVER Figure 2-9b: BMK 1500/2000/2500/3000 Power Box with Closed Cover AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 32 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 33: Electrical Power Box Internal Components
12V POWER SUPPLY FLAME ROD SIGNAL AMPLIFIER FUSE BLOCKS (2) TERMINAL BLOCKS Figure 2-10b: BMK 1500/2000 Power Box Internal Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 33 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 34 All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers, inhibit service/maintenance, or prevent access between the unit and walls or another unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 35: Field Control Wiring
WARNING! DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 35 of 128 Ph.: 800-526-0288...
Page 36: Outdoor Air & Air Sensor Common
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. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 37: Air Temp Sensor
Maintenance Guide, OMM-0116 (GF-201). 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 38: Shield (Shld & Shld)
2.11.9 RS485 Comm (+, GND, & -) The three RS-485 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. 2.11.10 RS232 Comm (TxD & RxD) As of Firmware version 4.0 and above, these terminals are used only by factory-trained...
Page 39: Interlocks
• In conjunction with the optional external sequencing valve (see section 2.15: Sequencing Isolation Valve Installation and Section 6: BST), a component of AERCO’s on-board Boiler Sequencing Technology (BST) solution. A cable of the boiler’s wiring harness is connected to these terminals on all units; if BST is implemented, the other end of that cable is connected to the sequencing valve.
Page 40: Flue Gas Vent Installation
Figure 2-12 to locate the AUXILIARY RELAY terminals for wiring connections. 2.12 FLUE GAS VENT INSTALLATION AERCO’s Benchmark Venting and Combustion Air Guide, TAG-0022 (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 41: Combustion Air
6 inch (15.2 cm) diameter connection BMK 1000 BMK 1500 BMK 2000 8 inch (20.3 cm) diameter connection BMK 2500 BMK 3000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 41 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 42: Benchmark Pump Relay
Figure 2-13a: BMK 750/1000 Pump Relay Location POWER BOX PUMP RELAY Figure 2-13b: BMK 1500/2000/2500-3000 Pump Relay Location (BMK 25000/3000 Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017...
Page 43: Sequencing Isolation Valve Installation
(P/N 92084-TAB). 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 “Manager” to manage the other boilers at the site, designed as “Clients”...
Page 44 JUMPER Figure 2-17: Sequencing Isolation Valve Molex Connector and Jumper Wire 4. Plug the Molex connector into the sequencing isolation valve’s connector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 45: Section 3: Start Sequence
CAUTIONS must be observed at all times. WARNING! • Electrical voltages in this system include 120 VAC (BMK 750 – 20000) or 208 or 460 VAC (BMK 2500/3000) and 24 volts AC. It must be serviced only by factory certified service technicians.
Page 46 PRESSURE SWITCH AIR/FUEL VALVE MANUAL SHUT-OFF VALVE LOW GAS PRESSURE SSOV SWITCH Figure 3-1b: BMK 1500 & 2000 SSOV Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 47 The dial on the Air/Fuel Valve (Figure 3-2a and 3-2b) will read 100 to indicate that it is full-open (100%). c. The VALVE POSITION bargraph will show 100%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 47 of 128 Ph.: 800-526-0288...
Page 48 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE SECTION 3 - START SEQUENCE START SEQUENCE: STEPPER MOTOR AIR INLET BLOWER Figure 3-2a: BMK 750 & 1000 Air/Fuel Valve in Purge Position TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN Figure 3-2b: BMK 1500 –...
Page 49 The Dial on the Air/Fuel Valve (Figure 3-4) will read between 25 and 35 to indicate that the valve is in the low fire position. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 49 of 128 Ph.: 800-526-0288...
Page 50 10. 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. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 51: Start/Stop Levels
Normally, these settings do not require adjustment. Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 51 of 128 Ph.: 800-526-0288...
Page 52: Start/Stop Levels - Air/Fuel & Energy Input
The Tables below show the relationship between the energy input and Air/Fuel Valve position for the BMK models covered in this document. 3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input TABLE 3-2a: BMK 750/1000 Air/Fuel Valve Position – NATURAL GAS BOILER ENERGY ENERGY INPUT...
Page 53: Bmk 1500 Air/Fuel Valve Position And Energy Input
5.0% 93,700 6.2% 254,000 16.9% 505,000 33.7% 680,000 45.3% 807,000 53.8% 947,000 63.1% 1,157,000 77.1% 1,379,000 91.9% 100% 1,503,000 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 53 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 54: Bmk 2000 Air/Fuel Valve Position And Energy Input
5.0% 126,600 6.3% 363,000 18.2% 677,000 33.9% 898,000 44.9% 1,070,000 53.5% 1,242,000 62.1% 1,523,000 76.2% 1,845,000 92.3% 100% 2,000,000 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 55: Bmk 2500 (Nat. Gas) Air/Fuel Valve Position And Energy Input
(BTU/HR) (% OF FULL CAPACITY) 18% (Stop Level) 155,000 6.2% 400,000 808,000 1,055,000 1,330,000 1,671,000 1,998,000 2,280,000 100% 2,500,000 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 55 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 56: Bmk 3000 Air/Fuel Valve Position And Energy Input
(BTU/HR) (% OF FULL CAPACITY) 18% (Stop Level) 200,000 6.7% 520,000 920,000 1,270,000 1,570,000 1,960,000 2,330,000 2,700,000 100% 3,000,000 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 57: Section 4: Initial Start-Up
Section 5: Safety Device Testing, below, 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 58: Installing Gas Supply Manometer
1/4” NTP PLUG (Install manometer here for combustion calibration) LEAK DETECTION BALL VALVE Figure 4-1a: BMK 750 & 1000 1/4 Inch Gas Plug Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 59 AIR/FUEL BALL VALVE VALVE LOW GAS PRESSURE MANUAL SWITCH SHUT-OFF VALVE Figure 4-1c: BMK 2500 1/4 Inch Gas Plug Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 59 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 60: Accessing The Analyzer Probe Port
2. If necessary, adjust the stop on the combustion analyzer probe so it will extend mid-way into the flue gas flow. DO NOT install the probe at this time. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 61: Fuel Types And Combustion Calibration
SECTION 4 – INITIAL START-UP ANALYZER PROBE PORT ACCESS Instructions PRIMARY HOT WATER INLET ANALYZER PROBE EXHAUST MANIFOLD PORT CONDENSATE DRAIN Figure 4-2a: BMK 750 & 1000 Analyzer Probe Port Location DRAIN VALVE PRIMARY HOT WATER INLET EXHAUST MANIFOLD ANALYZER PROBE PORT CONDENSATE DRAIN Figure 4-2b: BMK 1500 –...
Page 62: Combustion Calibration
The Benchmark boiler is combustion calibrated with either standard combustion or Ultra-Low (on the BMK 750/1000 only) at the factory, whichever was ordered, prior to shipping. This gas pressure must be within the ranges shown in Table 4-1 for each model of boiler at full fire.
Page 63: Natural Gas Combustion Calibration
Press the Up ▲ arrow key until SET Stdby V Out (Standby Voltage) setting appears. Verify that it is set to 2.0 V (the default). AERCO recommends it be kept at 2.0 volts to prevent flue gas recirculation. Individually vented units in positive pressure boiler rooms may set SET Stdby V Out to 0 volts.
Page 64 4-3). Slowly rotate the gas pressure adjustment in 1/4-turn increments) Clockwise to reduce O level or counterclockwise to increase it. Allow the combustion analyzer to stabilize following each adjustment. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 65 1% higher than the listed calibration range. Record the increased O value on the Combustion Calibration sheet. Repeat steps 21 through 25 for valve positions shown in Table 4-3a (BMK 750 & 1000) and Table 4-3b (BMK 1500-3000). The O , NO and CO should stay within the ranges shown Table 4-3a and Table 4-3b.
Page 66 60% down to the lowest valve position after making a change to the idle screw (TAC valve). This completes the NATURAL GAS combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 67: Propane Gas Combustion Calibration
Press the Up ▲ arrow key until SET Stdby V Out (Standby Voltage) setting appears. Verify that it is set to 2.0 V (the default). AERCO recommends it be kept at 2.0 volts to prevent flue gas recirculation. Individually vented units in positive pressure boiler rooms may set SET Stdby V Out to 0 volts.
Page 68 Once the oxygen level is within the specified range at 100%, record the O , NO and CO readings on the Combustion Calibration Data Sheets provided with the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 69 6.0% ± 0.3% <100 PPM <100 PPM 6.4% ± 0.3% <100 PPM <100 PPM 6.4% ± 0.3% <100 PPM <100 PPM AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 69 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 70 60% down to the lowest valve position after making a change to the idle screw (TAC valve). This completes the PROPANE gas combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 71: Reassembly
BMK 1500 – 3000 units is shown in Figure 4-5, below; for the location of this panel on BMK 750 and 1000 units see Figure 4-6a in Section 4.7. Instructions for switching from one fuel to the other are in Sections 4.6.1 and 4.6.2.
Page 72: Switchover From Natural Gas To Propane
18. Press the ENTER key to store the Propane Fuel type. 19. Replace the front door panel previously removed from the boiler. This completes the switchover from NATURAL GAS to PROPANE. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 73: Switchover From Propane To Natural Gas
19. Replace the front door panel previously removed from the boiler. This completes the steps necessary to switch from PROPANE Gas to NATURAL GAS. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 73 of 128 Ph.: 800-526-0288...
Page 74: Over-Temperature Limit Switches
LIMIT SWITCH DIGITAL OVER- ADJUSTABLE TEMPERATURE TEMPERATURE LIMIT CONTROLLER LIMIT SWITCH (AUTO-REST) Figure 4-6a: BMK 750 & 1000 Over-Temperature Limit Switch Location DIGITAL OVER-TEMPERATURE LIMIT CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH (AUTO-REST) RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 4-6b: BMK 1500 –...
Page 75: Digital Alarm Switch Checks And Adjustments
To calibrate the offset (P1), press and hold the SET button on the Over-Temperature Alarm switch for 8 seconds. 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 76 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE SECTION 4 – INITIAL START-UP (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 77: Section 5: Safety Device Testing
WARNING! Electrical voltages in this system include 120 VAC (BMK 750 – 20000) or 208 or 460 VAC (BMK 2500/3000) and 24 volts AC. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock.
Page 78: Low Gas Pressure Test
SECTION 5 – SAFETY DEVICE TESTING 5.2 LOW GAS PRESSURE TEST Complete the instructions in Section 5.2.1 for BMK 750 – 2500 units, or in Section 5.2.2 for BMK 3000 units, which have different Low and High Gas Pressure switches.
Page 79 LOW GAS BALL VALVE 1/4” NPT PLUG Install manometer here for LOW gas pressure fault test. Figure 5-1b: BMK 1500/2000 LOW Gas Pressure Test Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 79 of 128 Ph.: 800-526-0288...
Page 80: Low Gas Pressure Test: Bmk 3000 Only
5. Remove the cover from the Low Gas Pressure switch and set the dial indicator to 2 (the minimum). 6. Open the external gas supply ball valve (not shown) upstream of the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 81 HIGH GAS PRESSURE Alternative SWITCH LOW Gas Pressure Port Figure 5-2: BMK 3000 LOW and HIGH Gas Pressure Test Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 81 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 82: High Gas Pressure Test
SECTION 5 – SAFETY DEVICE TESTING 5.3 HIGH GAS PRESSURE TEST Complete the instructions in Section 5.3.1 for BMK 750 – 2500 units, or in Section 5.3.2 for BMK 3000 units, which have different High Gas Pressure switches. 5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500...
Page 83 (Install manometer here for HIGH gas pressure HIGH GAS BALL VALVE fault test) Figure 5-3b: BMK 1500/2000: HIGH Gas Pressure Fault Test AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 83 of 128 Ph.: 800-526-0288 GF-200...
Page 84: High Gas Pressure Test: Bmk 3000 Only
6817 and then press the ENTER key. 7. Start the unit in MANUAL mode and adjust the Air/Fuel Valve position to bring the unit up to 100%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 85 Pressure test HIGH GAS BALL VALVE Alternative HIGH Gas Pressure Port Figure 5-4: BMK 3000 HIGH Gas Pressure Test Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 85 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 86: Low Water Level Fault Test
11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message. 12. Set the ON/OFF switch to the ON position. The unit is now ready for operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 87: Water Temperature Fault Test
TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON MANUAL TEMPERATURE LIMIT SWITCH Figure 5-5a: Temperature Limit Switch Location – BMK 1500-3000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 87 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 88 Limit Controller Limit Switch Temperature Limit Switch Adjustable Temperature Limit switch (auto-rest) Figure 5-5b: Temperature Limit Switch Location – BMK 750-1000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 89: Interlock Tests
5. Reconnect the wire or jumper removed in step 3 to restore the interlock. 6. Press the CLEAR button to reset the fault The unit should start. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 89 of 128 Ph.: 800-526-0288...
Page 90: Flame Fault Test
11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message. Set the ON/OFF switch to the ON position. The unit is now ready for operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 91: Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches
VALVE SSOV BLOCKED INLET SWITCH FILTER TRAIN Figure 5-6a: Bare Boiler – Partial View – BMK 1500 – 3000 Shown AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 91 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 92 SWITCH INLET SWITCH AIR/FUEL VALVE Figure 5-6b: Bare Boiler – Partial View – BMK 750/13000 Shown BLOWER PROOF SWITCH TEST Instructions 1. Disable the blower output drive voltage as follows: a) Press the MENU key until CONFIGURATION MENU is displayed.
Page 93: Blocked Inlet Switch Test
9. Remove the jumper wires installed in step 3 and replace the black connector boot on the Flame Detector. 10. Press the CLEAR button. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 93 of 128 Ph.: 800-526-0288...
Page 94: Ssov Proof Of Closure Switch Check
4. Remove one of the two wires (#171 or #172) from the Purge switch (Figure 5-10a and 5- 10b). 5. Initiate a unit start sequence. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 95 Figure 5-9a: Air/Fuel Valve Cover Location – BMK 1500 – 3000 AIR/FUEL VALVE COVER (Rotate counter-clockwise to remove) Figure 5-9b: Air/Fuel Valve Cover Location – BMK 750/1000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 95 of 128 Ph.: 800-526-0288 GF-200...
Page 96 Figure 5-10a: Air/Fuel Purge and Ignition Locations– BMK 1500 – 3000 Ignition Position Switch Purge Position Switch TO BLOWER AIR IN Figure 5-10b: Air/Fuel Purge and Ignition Locations– BMK 750/1000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 97: Ignition Switch Open During Ignition
5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 97 of 128 Ph.: 800-526-0288...
Page 98 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE SECTION 5 – SAFETY DEVICE TESTING (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 99: Section 6: Boiler Sequencing Technology
(default = 2 minutes) before closing. When the system load is satisfied, the panel will open the isolation valves for all of the boilers. The BST controls the valves via a 0-20 mA signal (see section 2.11.8) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 99 of 128 Ph.: 800-526-0288...
Page 100: Installation Notes
Option 7 – 4-20ma Drive AND Modbus Header Complete section 6.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 6.3.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 101: Bst Implementation Instruction
When ALL C-More units have been configured: 7. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 101 of 128 Ph.: 800-526-0288...
Page 102: Option 2 - Constant Setpoint With Modbus Wired Header Sensor
When ALL C-More units have been configured: 9. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 103: 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 P/N 61047 I/O BOX AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 103 of 128 Ph.: 800-526-0288...
Page 104 When ALL C-More units have been configured: 9. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 105: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter. 3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter. (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 105 of 128 Ph.: 800-526-0288...
Page 106 When ALL C-More units have been configured: 13. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 107: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive
The ground for the shield is at the driver signal source. TEMP SENSOR P/N 61040 HEADER TEMP SENSOR I/O BOX (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 107 of 128 Ph.: 800-526-0288 GF-200...
Page 108 When ALL C-More units have been configured: 8. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 109: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter. 3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter. (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 109 of 128 Ph.: 800-526-0288...
Page 110 When ALL C-More units have been configured: 13. Go to the Boiler Sequencing Menu item of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 111: 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 (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 111 of 128 Ph.: 800-526-0288 GF-200 03/15/2017...
Page 112 When ALL C-More units have been configured: 10. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 113: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive
Step 2: Remote Setpoint with Network 1. Configure and Connect the SSD Device (ProtoNode) per the ProtoNode User Manual, OMM-0080 (GF-129). (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 113 of 128 Ph.: 800-526-0288...
Page 114 When ALL C-More units have been configured: 10. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST MANAGER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 115: Section 7: Onaer Setup
Wirelessly via Wi-Fi. This solution requires the purchase and installation of the optional AERCO Wi-Fi module (P/N 24526-2 for BMK 750 & 1000, and 24526-1 for BMK 1500 – 6000). This module is then connected directly to the boiler’s I/O board, eliminating the need for an Ethernet cable.
Page 116 I/O enclosure grommet here. Ethernet cable plugs into Ethernet PCB here. Figure 7-1: I/O Box Interior Showing Ethernet Cable & OnAER PCB AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017...
Page 117: Confirming The Ethernet Connection
NOTE Static addresses are not required or recommended by AERCO. Reserved addresses are a simpler solution. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 117 of 128 Ph.: 800-526-0288...
Page 118 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE SECTION 7 – ONAER SETUP (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 119: Section 8: Troubleshooting
Refer to SECTION 6: TROUBLESHOOTING GUIDE in the Benchmark 750-3000 Platinum OPERATION and MAINTENANCE GUIDE OMM-0116 (GF-201) for detailed troubleshooting information and instructions. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 119 of 128 Ph.: 800-526-0288...
Page 120 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE SECTION 7 – TROUBLE SHOOTING (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...
Page 121: Appendix A: Dimensional And Clearance Drawings
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix A: DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Dimension Drawing AP-A-891 rev J AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 121 of 128 Ph.: 800-526-0288...
Page 122 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Single Unit Clearance Drawing SD-A-871 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 123 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Zero Side Clearance Drawing SD-A-872 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 123 of 128 Ph.: 800-526-0288...
Page 124 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Dimension Drawing Number: AP-A-1036 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 125 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Clearance Drawing Number: SD-A-995 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 125 of 128 Ph.: 800-526-0288...
Page 126 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Dimension Drawing Number: AP-A-915 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 128 OMM-115_0A Ph.: 800-526-0288...
Page 127 BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Clearance Drawing Number: SD-A-898 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0115_0A Page 127 of 128 Ph.: 800-526-0288...
Page 128 CHANGE LOG: DATE DESCRIPTION CHANGED BY Curtis Harvey, 03/15/2017 Rev A: Initial release Chris Blair © AERCO International, Inc., 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 128 OMM-115_0A Ph.: 800-526-0288 03/15/2017 GF-200...

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Aerco BMK 750 Installation And Startup Manual

Foreword

Section 1: Safety Precautions

Section 2: Installation

Section 3: Start Sequence

Section 4: Initial Start-Up

Section 5: Safety Device Testing

Section 6: Boiler Sequencing Technology

Section 7: Onaer Setup

Section 8: Troubleshooting

Appendix A: Dimensional and Clearance Drawings