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Aerco Benchmark BMK 5000 Installation And Startup 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 INSTALL and STARTUP GUIDE
INSTALLATION and STARTUP GUIDE
Natural Gas, Propane Gas and Dual Fuel Fired Modulating, Condensing Boilers
5000 and 6000 MBH Boilers
Latest Update: 05/30/2017
OMM-0123_0A
GF-207
USER MANUAL
®
Single Fuel
Natural Gas
• BMK 5000
•
BMK 6000
Propane
• BMK 5000 P
•
BMK 6000 P
See also:
Benchmark 5000 – 6000 OPERATION,
SERVICE and MAINTENANCE Guide
OMM-0124 (GF-208)
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-207
(1 of 2)
Dual Fuel
Page 1 of 98
05/30/2017

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  • Page 1 Benchmark 5000 – 6000 OPERATION, SERVICE and MAINTENANCE Guide OMM-0124 (GF-208) Applies to Serial Numbers: N-17-0100 and above Latest Update: 05/30/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 1 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...

  • Page 2: Table Of Contents

    2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) ..............31 2.12 FLUE GAS VENT INSTALLATION ..................32 2.12.1 MASSACHUSETTS INSTALLATIONS ................32 2.13 COMBUSTION AIR ......................33 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 2 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 3 5.8.2 Blocked Inlet Switch Test ....................73 5.9 SSOV PROOF OF CLOSURE SWITCH CHECK ..............74 5.10 PURGE SWITCH OPEN DURING PURGE ...............75 5.11 IGNITION SWITCH OPEN DURING IGNITION..............76 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 3 of 98 Ph.: 800-526-0288...
  • Page 4 7.1.1 Connecting the Ethernet Cable ..................93 7.1.2 Confirming the Ethernet Connection ................95 7.1.3 Confirm Ethernet DHCP Configuration ................95 APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ..... 96 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 5: Foreword

    These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 5 of 98 Ph.: 800-526-0288...
  • 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 Part Number Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) Point-to-Point (usually over RS232 networks) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 7 of 98 Ph.: 800-526-0288 GF-207...
  • 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 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

  • 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

    After prolonged shutdown, it is recommended that the procedures in Section 4: Initial Startup and Section 5: Safety Device Testing of this manual be performed to verify that all system- operating parameters are correct. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 98 OMM-0123_0A 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-0123_0A Page 11 of 98 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 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 13: Section 2: Installation

    NOTE: AERCO is not responsible for lost or damaged freight. Check for indications that the unit has been turned on its side during shipment. If you see any such signs, 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 proceeding.

  • Page 14: Site Preparation

    2.4.1 Installation Clearances The Benchmark 5000 and 6000 boiler dimensions and minimum acceptable clearances are shown in Figure 2-2. 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 15 When using the AERCO Condensate Neutralizer Tank for condensate drainage, the tank must be installed in a pit, OR the boiler and AERCO Condensate Trap must be elevated higher than 4” (10.2 cm) above the floor. See Condensate Neutralizer Tank Instructions TID-0074 for details.

  • Page 16: Setting The Unit

    When using the AERCO Condensate Neutralizer Tank for proper condensate drainage, the Neutralizer Tank must be stored in a pit, OR the boiler and AERCO Condensate Trap must be elevated higher than 4” (10.2 cm) above the floor. Ensure that the condensate assembly is not positioned above the housekeeping pad during installation so as not to interference with condensate piping.

  • Page 17: Lifting Provisions

    In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. All piping must include ample provisions for expansion. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 17 of 98 Ph.: 800-526-0288...

  • Page 18: 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 19: Pressure Relief Valve Installation

    It must be installed so that the sensing bulb is inserted into the hot water outlet flow from the boiler. Refer to Figure 2-7 for sample installations. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 19 of 98 Ph.: 800-526-0288...

  • Page 20: Condensate Drain And Piping

    The following general guidelines must be observed to ensure proper condensate drainage: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 21 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 22: Gas Supply Piping

    BMK 5000-6000 Boiler INSTALL and STARTUP GUIDE SECTION 2 – INSTALLATION 2.9 GAS SUPPLY PIPING AERCO’s Benchmark Gas Components and Supply Design Guide, TAG-0047 (GF-2030) must be consulted prior to designing or installing any gas supply piping. WARNING! NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO...

  • Page 23: Manual Gas Shutoff Valve

    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 24 PROPANE ONLY VALVES (dual fuel shown) PROPANE SUPPLY DRIP LEG GAS PRESSURE REGULATORS Figure 2-10: Manual Gas Shut-Off Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

  • Page 25: Ac Electrical Power Wiring

    SECTION 2 – INSTALLATION 2.10 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 2-11.

  • 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). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 27: 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-0123_0A Page 27 of 98 Ph.: 800-526-0288...

  • Page 28: 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 28 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 29: Air Temp Sensor

    Guide, OMM-0124 (GF-208). 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 Controller. Contact the AERCO factory for information on setting DIP switches. All supplied signals must be floating (ungrounded) signals. Connections between the source and the boiler’s I/O board (Figure 2-15) must be made using twisted shielded pair of 18–22...

  • Page 30: 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 31: Fault Relay (Nc, Com, & No)

    • 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 32: Flue Gas Vent Installation

    SECTION 2 – INSTALLATION 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 33: Combustion Air

    The pump relay is attached to the outside of the power box, as shown below. Boilers equipped with the pump relay have a label on the power box cover adjacent to the relay. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 33 of 98 Ph.: 800-526-0288...
  • Page 34 POWER PUMP(S) FROM INDEPENDENT FUSED CIRCUITS Heating Pump Figure 2-18: Schematic – System Pump Start using a Separate Contact Relay AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

  • Page 35: Sequencing Isolation Valve Installation

    2.15 SEQUENCING ISOLATION VALVE INSTALLATION All Benchmark units are pre-wired with a connection for an optional motorized external sequencing isolation valve (P/N 92084-TAB). This valve is an integral component of AERCO’s on-board Boiler Sequencing Technology (BST) solution. BST allows sites with multiple boilers to have one boiler, acting as a “Manager”...
  • Page 36 JUMPER Figure 2-20: 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 36 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 37: Section 3: Start Sequence

    If any of the Pre-Purge safety device switches are open, the appropriate fault message will be displayed. Also, the appropriate messages will be displayed throughout the start sequence, if the required conditions are not observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 37 of 98 Ph.: 800-526-0288...
  • Page 38 The VALVE POSITION bargraph will show 100%. TO BLOWER STEPPER MOTOR AIR IN Figure 3-2: Air/Fuel Valve In Purge Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...
  • Page 39 Ignition relay 1 (R1) closes allowing the main Burner ignition sequence to start. TO BLOWER STEPPER MOTOR AIR IN Figure 3-4: Air/Fuel Valve in Ignition Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 39 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...
  • Page 40 10. Once the demand for heat has been satisfied, the C-More Controller will turn off the SSOV gas valves, the blower relay will be deactivated, the Air/Fuel Valve will be closed and STANDBY will be displayed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 41 SKP15 Proof of Closure C-NO SKP25 Power through R1 Power through R2 and AUX Proof of Closure C-NC Proof of Closure C-NO AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 41 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...

  • Page 42: Start/Stop Levels

    5,000,000 (1465 kW) 14” (3.49 kPa) 6.8” (1.70 kPa) 5,000,000 (1465 kW) 10” (3.23 kPa) 6.8” (1.70 kPa) 5,000,000 (1465 kW) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

  • Page 43: Benchmark 6000 Air/Fuel Valve Position And Energy Input

    14” (3.49 kPa) 8” (1.99 kPa) 6,000,000 (1758 kW) 5.40 13” (3.23 kPa) 8” (1.99 kPa) 5,860,000 (1717 kW) 5.45 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 43 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...

  • Page 44: Boiler Energy Input Charts

    Figure 3-5: Relationship Between BMK 5000 Air/Fuel Valve Position and Energy Input Boiler Energy Input BMK 6000 Figure 3-6: Relationship Between BMK 6000 Air/Fuel Valve Position and Energy Input AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 45 BMK 5000-6000 Boiler INSTALL and STARTUP GUIDE SECTION 3 - START SEQUENCE Figure 3-7: Burner Ignition Sequence Flow Chart AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 45 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...
  • Page 46 BMK 5000-6000 Boiler INSTALL and STARTUP GUIDE SECTION 3 - START SEQUENCE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

  • Page 47: Section 4: Initial Start-Up

    Section 5: Safety Device Testing, below, before putting the unit into service. 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.

  • Page 48: Tools & Instruments For Combustion Calibration

    Combustion Calibration. - BMK 6000: 10.5” W.C. (2.6 kPa) - BMK 5000: 11.0” W.C. (2.7 kPa) Figure 4-1: Port Location for Combustion Calibration AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 49: Accessing The Analyzer Probe Port

    ANALYZER PROBE PORTS WITH 1/4” PLUGS 1 IN FRONT 2 IN REAR PARTIAL RIGHT SIDE VIEW Figure 4-2: Analyzer Probe Hole Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 49 of 98 Ph.: 800-526-0288 GF-207...

  • Page 50: Pilot Ignition

    Instructions for switching between fuel types in dual fuel models is presented in section 4.7. CAUTION! Ensure the appropriate combustion calibration instructions are used for the fuel being used in the boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 51: Combustion Calibration

    However, 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 52: 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 53 CO readings on the Combustion Calibration Data Sheets provided with the unit. Lower the valve position to 70% using the ▼arrow key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 53 of 98 Ph.: 800-526-0288...
  • Page 54 Recalibration MUST be performed again from 50% down to the lowest valve position after making a change to the TAC screw. This completes the NATURAL GAS combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 55: 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 56 CO readings on the Combustion Calibration Data Sheets provided with the unit. Lower the valve position to 70% using the ▼arrow key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 57 Recalibration MUST be performed again from 50% down to the lowest valve position after making a change to the TAC screw. This completes the PROPANE gas combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 57 of 98 Ph.: 800-526-0288...

  • Page 58: Reassembly

    Instructions for switching from one fuel to the other are in Sections 4.7.1 and 4.7.2. DUAL FUEL CUTOVER SWITCH Figure 4-4: Dual Fuel Switch Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017...

  • Page 59: 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 OMM-0123_0A Page 59 of 98 Ph.: 800-526-0288...

  • Page 60: 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 Page 60 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 61: Over-Temperature Limit Switches

    DIGITAL OVER-TEMPERATURE LIMIT CONTROLLER RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 4-5: Over-Temperature Limit Switch Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 61 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...

  • Page 62: 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 63: Section 5: Safety Device Testing

    Electrical voltages in this system include 120, 208, 460, 575 and 24 volts AC. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 63 of 98 Ph.: 800-526-0288...

  • Page 64: Low Gas Pressure Test

    15. For Dual Fuel units, repeat the previous procedure on the PROPANE gas train, starting with the PROPANE Low Gas Pressure Switch, shown in the bottom-half of Figure 5-1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 65 Dual Fuel gas train showing both Natural Gas and Install manometer here Propane gas trains Figure 5-1: Low Gas Pressure Switch Locations & Test Ports AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 65 of 98 Ph.: 800-526-0288...

  • Page 66: High Gas Pressure Test

    11. Readjust the manifold gas supply pressure to what it was before it was increased in step 8. 12. Press the CLEAR button on the Control Panel to clear the fault. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 67 Install manometer here for High Gas Pressure test Alternative location for manometer if hose barb is Figure 5-3: High Gas Pressure Switch Locations & Test Ports AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 67 of 98 Ph.: 800-526-0288...

  • Page 68: 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 68 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 69: Water Temperature Fault Test

    LIMIT DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON MANUAL TEMPERATURE LIMIT SWITCH Figure 5-4: Temperature Limit Switch Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 69 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...

  • Page 70: 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 Page 70 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 71: Flame Fault Test

    MANUAL SHUT- OFF VALVE HEX SCREWS HOLDING WYE DUCT TO A/F VALVE Figure 5-5: Blower Proof & Blocked Inlet Switch Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 71 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...

  • Page 72: Blower Proof Switch Test

    7. The Blower Proof switch will open and the blower should stop. The unit should shut down and display AIRFLOW FAULT DURING RUN. 8. Go to the Configuration menu, Analog Output item and select VALVE POSITION 0-10v. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 73: 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-0123_0A Page 73 of 98 Ph.: 800-526-0288...

  • Page 74: Ssov Proof Of Closure Switch Check

    10. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. SSOV ACTUATOR COVER ACTUATOR COVER SCREW Figure 5-7: SSOV Actuator Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

  • Page 75: Purge Switch Open During Purge

    Replace the wire on the Purge switch and depress the CLEAR button. The unit should restart. AIR/FUEL VALVE COVER (ROTATE TO REMOVE) Figure 5-8: Air/Fuel Valve Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 75 of 98 Ph.: 800-526-0288 GF-207...

  • Page 76: 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 Page 76 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 77: 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-0123_0A Page 77 of 98 Ph.: 800-526-0288...

  • Page 78: 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 78 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 79: 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-0123_0A Page 79 of 98 Ph.: 800-526-0288...

  • Page 80: 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 80 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 81: 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 (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 81 of 98 Ph.: 800-526-0288 GF-207...
  • Page 82 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 82 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 83: 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-0123_0A Page 83 of 98 Ph.: 800-526-0288...
  • Page 84 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 84 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 85: 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-0123_0A Page 85 of 98 Ph.: 800-526-0288 GF-207...
  • Page 86 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 86 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 87: 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-0123_0A Page 87 of 98 Ph.: 800-526-0288...
  • Page 88 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 88 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 89: 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-0123_0A Page 89 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...
  • Page 90 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 90 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 91: 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-0123_0A Page 91 of 98 Ph.: 800-526-0288...
  • Page 92 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 92 of 98 OMM-0123_0A Ph.: 800-526-0288...

  • Page 93: Section 7: Onaer Setup

    Router are in Technical Instruction document TID-0178, included with the module. If you did not order the Wi-Fi module but are now interested in it, contact your AERCO representative and ask about purchasing the Wi-Fi module (P/N 24526-1) and optional Wi-Fi Router (P/N 69038).
  • Page 94 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 94 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017...

  • Page 95: Confirming The Ethernet Connection

    DHCP addresses, and allows access without the need for a password. 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...

  • Page 96: Appendix A: Dimensional And Clearance Drawings

    BMK 5000-6000 Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix A: Dimensional and Clearance Drawings Drawing Number: AP-A-901 rev L AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 98 OMM-0123_0A Ph.: 800-526-0288...
  • Page 97 BMK 5000-6000 Boiler INSTALL and STARTUP GUIDE APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: SD-A-919 rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0123_0A Page 97 of 98 Ph.: 800-526-0288 GF-207 05/30/2017...
  • Page 98 BMK 5000-6000 Boiler INSTALL and STARTUP GUIDE CHANGE LOG: Date Description Changed By 05/30/2017 Rev A: Initial release © AERCO International, Inc., 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 98 OMM-0123_0A Ph.: 800-526-0288 05/30/2017 GF-207...

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