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Aerco Benchmark BMK 5000 Operation, Service And Maintenance Manual

Benchmark series natural gas, propane gas and dual fuel fired modulating, condensing boilers
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Download this manual See also: User Manual
BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
OPERATION, SERVICE, and MAINTENANCE GUIDE
Natural Gas, Propane Gas and Dual Fuel Fired Modulating, Condensing Boilers
5000 and 6000 MBH Boilers
Latest Update: 05/03/ 2017
OMM-0124_0A
GF-208
USER MANUAL
®
Single Fuel
Natural Gas
• BMK 5000
•
BMK 6000
Propane
• BMK 5000 P
•
BMK 6000 P
See also:
Benchmark 5000 – 6000 INSTALLATION
and STARTUP Guide
OMM-0123 (GF-207)
Applies to Serial Numbers:
N-17-0100 and above
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
This Guide Applies to Models:
Natural Gas & Propane
• BMK 5000 DF
•
BMK 6000 DF
GF-208
(2 of 2)
Dual Fuel
Page 1 of 136
05/03/2017

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Summary of Contents for Aerco Benchmark BMK 5000

  • Page 1 Benchmark 5000 – 6000 INSTALLATION and STARTUP Guide OMM-0123 (GF-207) Applies to Serial Numbers: N-17-0100 and above Latest Update: 05/03/ 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 1 of 136 Ph.: 800-526-0288 GF-208 05/03/2017...

  • Page 2: Table Of Contents

    4.4 O SENSOR ............................40 4.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT ..........42 4.5.1 Pilot Regulator Pressure Testing ........................42 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 2 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 3 APPENDIX I: RECOMMENDED SPARES ............133 APPENDIX J: LONG TERM STORAGE ............... 134 J-I: LONG TERM BOILER STORAGE ...................... 134 J-2: LONG TERM BLOWER STORAGE ....................134 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 3 of 136 GF-208 Ph.: 800-526-0288...
  • Page 4 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE CONTENTS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 5 FORWARD FOREWORD The AERCO Benchmark (BMK) 5000 MBH (1465 kW) and 6000 MBH (1758 kW) natural gas and dual fuel propane/natural gas fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns.
  • Page 6 BTUs per Hour (1 BTU/hr = 0.29 W) Combination Control Panel Combination Control System A control system developed by AERCO and currently used in all C-More Controller 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-0124_0A Page 7 of 136 GF-208 Ph.: 800-526-0288...
  • 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 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 9: Section 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 10: Emergency Shutdown

    Section 5: Safety Device Testing of the Benchmark 5000 – 6000 Installation and Startup Guide OMM-0123 (GF-207) be performed to verify that all system-operating parameters are correct. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • 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-0124_0A Page 11 of 136 GF-208 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 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 13: Section 2: Operation

    All of the installation procedures in Section 2 of the Benchmark 5000 – 6000 Installation and Startup Guide OMM-0123 (GF-207) must have been completed before attempting to start the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 13 of 136 GF-208 Ph.: 800-526-0288...

  • Page 14: Control Panel Description

    Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section. Figure 2-1: Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 15 • Pressing RESET resets the water level monitor circuit. switches • Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 15 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 16 20 segment red LED bargraph continuously shows the Air/Fuel VALVE POSITION Valve position in 5% increments from 0 to 100% Bargraph AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 17: Control Panel Menus

    The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 17 of 136 GF-208 Ph.: 800-526-0288...
  • Page 18 Refer to Appendix A in this guide for detailed descriptions of each menu option. Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 136...

  • Page 19: Operating Menu

    Max = 100) does not appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More Controller’s front face. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 19 of 136 GF-208 Ph.: 800-526-0288...

  • Page 20: Setup Menu

    E, G, H, R, N or A Unit Year Unit Serial # 9999 Current software Software Ver 0.00 Ver 9.99 version AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 21: Configuration Menu

    100°F 60°F (If Outdoor Sensor = (-1.1° (37.8° (15.6° Enabled) Setpt Lo Limit 40°F (4.4° Setpt Hi Limit 60°F (15.6° AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 21 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 22 Sensor menu item is set to Enabled. CAUTION! DO NOT change the Analog Output menu item from its default setting (Valve Position 0- 10V). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 23: Tuning Menu

    Monitor Blower Output Voltage Set Stdby Volt 4.00 V 0/2.00 V 4.00 V 0/2.00 V 10 Oxygen Level Variable Variable AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 23 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 24: Bst (Boiler Sequencing Technology) Menu

    Head Temp Source Network FFWD Temp FFWD Temp Mdbus Temp Units Degrees C or Degrees F Degrees C Header Temp Addr AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 25 100°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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 25 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 26: Calibration Menu

    Enabled or Disabled Valv Pos Out Dsp Enabled Enabled or Disabled Exhaust Tmp Dsp Disabled Enabled or Disabled Exhaust Safety Enabled AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 27 Skip Speed O2 Gain 0.500 1.500 1.024 O2 Offset -24.0 +2.0 O2 Sensor Enabled or Disabled Depends on unit type/size AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 27 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 28 Depends on unit type/size Min Spark Amps 0 Amps 2.5 Amps 0.1 Amps Max Spark Amps 0 Amps 2.5 Amps 0.4 Amps AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 29: Section 3: Modes Of Operation

    I/O Box. Refer to Section 2.10: AC Electrical Power Wiring of the Benchmark 5000 – 6000 Installation and Startup Guide, OMM-0123 (GF-207) for additional information on wiring.. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 29 of 136 GF-208 Ph.: 800-526-0288...

  • Page 30: Indoor/Outdoor Startup

    AERCO representative be contacted. For descriptions of temperature-related functions, see Appendix A; their factory defaults are included in Sections 2.4 – 2.8. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 30 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 31: Setting The Setpoint

    Remote Setpoint Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network Refer to section 2.3 for detailed instructions on changing C-More Controller menu options. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 31 of 136 GF-208 Ph.: 800-526-0288...

  • Page 32: 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 33: Direct Drive Field Wiring

    REMOTE LED will again light and the MANUAL LED will go off. This will happen automatically after 1 hour after the password has expired. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 33 of 136 GF-208 Ph.: 800-526-0288...

  • Page 34: Aerco Control System (Acs)

    Installations with 1 to 8 boilers can use BST (see Section 6). 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 35: 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 36: 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 Section 2.

  • Page 37: Section 4: Maintenance

    Gaskets Air Filter (P/N 59138) Clean Replace 15 mins. * Only performed after initial 6 month period after initial startup. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 37 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 38: Pilot Burner

    The Pilot Burner may be hot, therefore care should be exercised to avoid burns. It is easier to remove the Pilot Burner from the unit after it has cooled to room temperature. To inspect/replace the Pilot Burner, perform the following procedure: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 39 12. Reconnect the ignition cable. Close the right side door and front panel. Replace the top panel if the unit was serviced from above. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 39 of 136 GF-208 Ph.: 800-526-0288...

  • Page 40: Main Flame Detector

    5. Thoroughly inspect the O2 sensor. If corroded, the sensor should be replaced. Ensure that the hole in the refractory is clean and that the gas sample suction tube is not clogged. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 136...
  • Page 41 8. Reinstall the left-rear access panel on the unit. SENSOR GAS SUCTION LINE TO EXHAUST MANIFOLD EXHAUST MANIFOLD Figure 4-2: O Sensor Mounting Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 41 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 42: Combustion Calibration & Pilot Regulator Adjustment

    12. If the Pilot Regulator is NOT within specifications, proceed to section 4.5.2 and perform the Pilot Regulator Pressure Calibration procedure. TEE WITH 1/4" NPT PLUG AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 136 OMM-0124_0A Install manometer 05/03/2017 Ph.: 800-526-0288...
  • Page 43 (Install manometer here for Pilot Regulator test) PROPANE PILOT REGULATOR Figure 4-3b: BMK 5000/6000 Dual Fuel Pilot Regulator Mounting Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 43 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 44: Pilot Regulator Pressure Calibration

    You should see the orange glow of the Pilot flame during the ignition trial period. NOTE: If you do not see the orange glow, contact AERCO technical support to ascertain the problem. If you DO see it, proceed to the next step.

  • Page 45: Safety Device Testing

    The following parts will be required for reassembly after Burner inspection: BMK 750/1000 Burner Inspection Parts PART NO. DESCRIPTION 81159 Burner Gaskets (2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 45 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 46 Burner to one side or the other. 23. Remove and replace the two (2) Burner Gaskets (see Figure 4-5) and clean the gasket surface on the burner front plate. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 47 PILOT BURNER AIR/FUEL VALVE WYE DUCT GAS TRAIN FILTERS Figure 4-4a: Burner Assembly Mounting Details – Right-Front View (Continued) TURNBUCKLE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 47 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 48 BURNER GASKET (P/N 81159) 3/8” HEX NUTS/WASHERS (8 EA.) O-RING AIR/FUEL VALVE BURNER BLOWER FLANGE BLOWER Figure 4-5: Burner Assembly – Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 49: Refractory Removal & Replacement

    8. Loosen (but DO NOT REMOVE) the top nut and slide a thin metal object (such as a hacksaw blade) between the rear plate and the fiber material of the rear refractory to separate the material from the plate. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 49 of 136 GF-208 Ph.: 800-526-0288...
  • Page 50 Torque bolts to approximately 20 ft-lbs. 17. To avoid exhaust leaks, ensure that a uniform seal is established when reconnecting the flue system to the boiler. (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 51 THERMAL SWITCH REAR BURNER PLATE SENSOR GAS SUCTION LINE FROM EXHAUST MANIFOLD Figure 4-7: Partial Rear View Showing Rear Burner Plate AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 51 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 52: Front Refractory Replacement

    As previously mentioned, it is much easier to remove the rear refractory to inspect the combustion chamber of the unit. However if the front refractory must be replaced, order the AERCO Front Refractory Replacement kit, P/N 27103, which includes full instructions in Technical Instruction Document TID-0117.

  • Page 53: Condensate Drain Trap

    FLOAT INLET OUTLET O-Rings EXPLODED CROSS-SECTION VIEW 3/4" NPT Port Figure 4-10: External Condensate Trap – Cross-Section & Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 53 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 54: Air Filter Cleaning And Replacement

    7. Replace the front panel on the unit and return boiler to service use. BLOWER AIR/FUEL VALVE WYE DUCT AIR FILTER CLAMPS GAS TRAIN AIR FILTERS Figure 4-11: Air Filter Location and Removal AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 55: Water Cutoff (Lwco) Capacitor Integrity Test

    LWCO Probe Connector LWCO Probe Terminal (to Shell Harness) Capacitor Assembly (Covered By Shrink Tubing) Figure 4-12: LWCO Probe Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 55 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 56: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    LWCO Probe Assembly Connector 19-Pin Shell Harness Cable Connector Figure 4-14: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 57: Low Water Cutoff (Lwco) - Standard C-More Controller Test

    6. Open the drain valve and drain all water from the unit. 7. Refer to Appendix J for maintenance of blower during shut down. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 57 of 136 GF-208 Ph.: 800-526-0288...

  • Page 58: Placing The Boiler Back In Service After Aprolonged Shutdown

    The blower can be damaged if it is unused for a prolonged period of time. If this occurs, it is critical that you complete the instructions for Long Term Blower Storage in Appendix J. Failure to complete these instructions will void all warranties. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 59: Gas Valve Actuator Replacement

    2. Disconnect Wire 153 (dotted line) from Terminal 3 and connect it to the Low Gas Pressure Switch. WIRE 153 – FROM C-MORE LOW GAS PRESSURE SWITCH (DUNGS) Figure 4-16: Wiring Diagram After Replacing Actuator AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 59 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 60 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE SECTION 6 – MAINTENANCE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 61: Section 5: Troubleshooting Guide

    The front panel of the C-More Controller contains an RS232 port. This port is used only by factory-trained personnel to monitor onAER communications via a portable computer. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 61 of 136 GF-208 Ph.: 800-526-0288...
  • Page 62 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE SECTION 6 – TROUBLESHOOTING GUIDE (This page intentionally blank) Benchmark 5000 – 6000 Installation and Startup Guide, OMM-0123 (GF-207) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 63 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. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 63 of 136 GF-208 Ph.: 800-526-0288...
  • Page 64 Probable causes from 3 to 16 for AIRFLOW See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT FAULT DURING IGNITION applies for this fault. DURING IGNITION. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 65 Check scanner Red LED. It should change from flashing to steady when Pilot Scanner failed this Chapter. pointed at a small flame from a match or lighter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 65 of 136 GF-208 Ph.: 800-526-0288...
  • Page 66 F (93.3 C), check TEMPERATURE Carboned heat exchanger due to incorrect combustion calibration. Calibrate or repair as necessary. combustion calibration. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 67 See HIGH WATER TEMPERATURE SWITCH OPEN. HIGH WATER OPEN. TEMPERATURE Temp HI Limit setting is too low. Check Temp HI Limit setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 67 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 68 ON, replace Power Supply Board. Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 69 Measure the gas pressure between the SSOV and the Air/Fuel Valve. It should be 7.9” W.C. ± 0.2” W.C. (2.0 kPa ± 50 Pa). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 69 of 136 GF-208 Ph.: 800-526-0288...
  • Page 70 (correct wire numbers on the normally open terminals). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 71 Check DIP switch on PMC board to ensure it is set correctly for the type set for correct signal type (voltage or current). of signal being sent. Check control signal type set in Configuration menu. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 71 of 136 GF-208 Ph.: 800-526-0288...
  • Page 72 Incorrectly wired switch. Ensure that the SSOV Proof of Closure switch is correctly wired. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 73 SSOV FAULT Check scanners sensed pilot flame. DURING Check power through ignition relay. IGNITION Scanners close neutral side of relay coil. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 73 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 74: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards are Rev. E or Air/Fuel Valve “hunting” at C-More Controller are outdated. higher. the 70% Valve Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 75 - BMK 6000 – 8.5” W.C., 2.1 kPa - BMK 5000 – 4.5” W.C., 1.1 Figure 5-1: Gas Train Component and Pilot Gas Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 75 of 136 GF-208 Ph.: 800-526-0288...
  • Page 76 BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 5-3: SSOV Actuator With Gas Pressure Adjustment (SKP25) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 77 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE SECTION 7 – TROUBLESHOOTING GUIDE Continued on Sheet 2 Figure 5-4a: Pilot Assembly Troubleshooting Flow Chart (Sheet 1 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 77 of 136 GF-208 Ph.: 800-526-0288...
  • Page 78 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE SECTION 7 – TROUBLESHOOTING GUIDE Continued from Sheet 1 Figure 5-4b: Pilot Assembly Troubleshooting Flow Chart (Sheet 2 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 79: Appendix A: Boiler Menu Item Descriptions

    Displays the elapsed time between 120VAC being applied to SSOV Time to OPN the Gas Valve and confirmation of gas valve opening (POC). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 79 of 136 GF-208 Ph.: 800-526-0288...
  • Page 80 Displays total run time of unit in hours. Fault Log Displays information on the last 20 faults. Manual Valve Pos Selects valve position. Available in Manual mode only! AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 81: Table A-2: Setup Menu Item Descriptions

    4-digit serial # on the Code Plate, e.g., G-12- Software Version Identifies the current software version of the C-More Controller. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 81 of 136 GF-208 Ph.: 800-526-0288...

  • Page 82: Table A-3: Configuration Menu Item Descriptions

    Sets the maximum allowable valve position for the unit. Specifies the amount of time, up to 30 minutes, to keep the Pump Delay Timer pump running after the unit turns off. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 83 Valve Position In reaches the Start Level value (Calibration menu item 37). There will not be a one minute delay when firing at the 29% Valve Position level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 83 of 136 GF-208 Ph.: 800-526-0288...
  • Page 84 When set to Enabled, the AERtrim menu options appears. O2 Trim Menu When set to Enabled, the BST menu options appears. BST Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...

  • Page 85: Table A-4: Tuning Menu Item Descriptions

    Range = 0 - 240 seconds Default = 20 seconds Reset Defaults? Allows Tuning menu options to be reset to their Factory Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 85 of 136 GF-208 Ph.: 800-526-0288...

  • Page 86: Table A-5: Combustion Calibration Menu Item Descriptions

    Permits the Standby Voltage to be set from 0 to 4.00 Set Stby V out Volts. Permits the combustion oxygen level to be displayed Oxygen Level (0% to 25%). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 87: Table A-6: Calibration Menu Item Descriptions

    PWM In Adj -5.0% to +5.0% in 0.1% increments. Analog In Adj Allows adjustment of the analog input from -5.0% to +5.0%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 87 of 136 GF-208 Ph.: 800-526-0288...
  • Page 88 – FFWD Temp Offset Range: -20 to + 20 (either ºF or °C) – Exhst Tmp Ofset Range: -20 to + 20 (either ºF or °C) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 89 Min Spark Amps transformer input. Allows the adjustment of the maximum spark current required at the spark Max Spark Amps transformer input. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 89 of 136 GF-208 Ph.: 800-526-0288...
  • Page 90 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX A: BOILER MENU DESCRIPTIONS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 91: 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 91 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 92: Table B-2: Fault Messages

    The Line (Hot) and Neutral wires are reversed. OUT OF PHASE LOW WATER The Low Water Cutoff board is indicating low water level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 93 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 93 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 94 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX B – STARTUP, STATUS, AND DISPLAY MESSAGES (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 95: 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 95 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 96 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 97: Appendix D: Recommended Periodic Testing

    See section 5.5 of the Benchmark 5000 – 6000 High water temp. Installation and Startup Guide, OMM-0123 (GF- Annually Service Technician safety control test 207) . AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 97 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 98 See section 4.9 of this guide. Verify oxygen level is between 3% and 8% during Oxygen (O ) Level Monthly Operator boiler operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 99: 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 99 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 100 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 101 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 101 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 102 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 103: Appendix F: Part Lists And Drawings

    02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 1 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 103 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 104 02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 2 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 105 02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 3 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 105 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 106 02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 4 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 107 02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 5 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 107 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 108 02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 6 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 109 02/02/2017 AERCO International, Inc. Whole Boiler P/N 28500-TAB (BMK 6000) Blauvelt, NY 10913 Sheet 7 of 7 28657-TAB (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 109 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 110 Benchmark 5000 & 6000 FM Gas Train 01/14/2017 International, Inc. 22222 rev E Blauvelt, NY 10913 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 111 Benchmark 5000 DF & 6000 DF Gas Train AERCO 01/16/2017 International, Inc. Blauvelt, NY 10913 P/N 22187 rev D Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 111 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 112 International, Inc. Blauvelt, NY 10913 22185 rev F ( Component of DF Gas Train P/N 22187) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 113 Inc. Blauvelt, NY 10913 P/N 22186 rev E ( Component of DF Gas Train P/N 22187) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 113 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 114 08/24/2016 International, Inc. Blauvelt, NY 10913 BMK 5000: 24495 rev A, BMK 6000: 24328 rev G Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 115: Appendix G: Wiring Diagrams

    BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Appendix G: WIRING DIAGRAMS Wiring Diagram 68043 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 115 of 136 GF-208 Ph.: 800-526-0288...
  • Page 116 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68043 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 117 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68048 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 117 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 118 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68048 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 119 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68052 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 119 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 120 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68052 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 121 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68053 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 121 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 122 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68053 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 123 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68076 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 123 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 124 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68076 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 125 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68077 rev B Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 125 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 126 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Wiring Diagram 68077 rev B Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 127: Bmk 5000/6000 Standard Fuel Model Wiring Diagrams

    APPENDIX G – WIRING DIAGRAMS BMK 5000/6000 STANDARD FUEL MODEL WIRING DIAGRAMS Standard BMK 5000/6000 Drawing Number: 22222 rev B Gas Train Wiring Diagram Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 127 of 136 GF-208 Ph.: 800-526-0288...
  • Page 128 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Drawing Number: 63035-2 rev B, Duel Fuel Selector Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...
  • Page 129 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS Gas Train Wiring Diagrams: 22185 rev C (Natural Gas) and 22186 rev C (Propane) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 129 of 136 GF-208 Ph.: 800-526-0288...
  • Page 130 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE APPENDIX G – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 131: Appendix H: C-More Controller Views

    PUSH BUTTON P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure H-1 – Benchmark Series Controller - Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 131 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 132 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure H-2: Benchmark Control Panel Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

  • Page 133: Appendix I: Recommended Spares

    TABLE I-3: OPTIONAL SPARE PARTS DESCRIPTION PART NUMBER C-More Controller 69186‐1 Temperature Sensor, 1‐1/2" 123449 Lean Oxygen Sensor 61026 Over Temp‐Auto Reset Switch 123966 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 133 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...

  • Page 134: Appendix J: Long Term Storage

    Rotate wheel a minimum of 10 full revolutions to keep the motor bearing grease from separating and drying out. (THIS STEP IS CRITICAL!) (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288...
  • Page 135 8. MOTOR 9. RISER BLOCKS * 10. RISER BASE * * IF REQUIRED Figure J-1: Benchmark 6000 Blower Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0124_0A Page 135 of 136 GF-208 Ph.: 800-526-0288 05/02/2017...
  • Page 136 BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE CHANGE LOG CHANGE LOG: DATE DESCRIPTION CHANGED BY 05/03/2017 Rev-A: Initial release © AERCO International, Inc., 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 136 OMM-0124_0A 05/03/2017 Ph.: 800-526-0288 GF-208...

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