Aerco 750 Installation And Startup Manual
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Aerco 750 Installation And Startup Manual

Benchmark series natural gas fired, modulating and condensing mbh boilers
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Benchmark 750-3000 Installation & Startup Guide - KOREA
INSTALLATION and STARTUP GUIDE
Natural Gas Fired, Modulating and Condensing Boilers
750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers
Latest Update: 07/17/2017
OMM-0127_0B
GF-205-K
USER MANUAL
®
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
(1 of 2)
SEE ALSO:
Benchmark 750-3000 Boiler
Operation and Maintenance
Guide OMM-0128 (GF-206-K)
APPLIES TO MODELS:
Natural Gas:
• BMK 750
• BMK 1000
• BMK 1500
• BMK 2000
• BMK 2500
• BMK 3000
This Manual Applies to Serial Number:
G-17-1200 and above.
Patent # 10-1755141
GF-205-K
Page 1 of 116
07/17/2017

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  • Page 1 • BMK 2500 • BMK 3000 This Manual Applies to Serial Number: G-17-1200 and above. Patent # 10-1755141 Latest Update: 07/17/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 1 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 2: Table Of Contents

    2.5.2 BMK 1500 – 2000 Lifting Provisions ....................18 2.6 SUPPLY AND RETURN PIPING ..................19 2.6.1 BMK 750 – 1000 Supply and Return Piping ..................19 2.6.2 BMK 1500 – 3000 Supply and Return Piping .................. 19 2.7 PRESSURE RELIEF VALVE INSTALLATION ..............21 2.8 CONDENSATE DRAIN AND PIPING ..................22...
  • Page 3 4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION ........53 4.2.1 Required Tools & Instrumentation ....................53 4.2.2 Installing Gas Supply Manometer – BMK 750 & 1000 ONLY ............54 4.2.3 Gas Supply Gauge – BMK 1500 – 3000 ONLY ................55 4.2.4 Accessing the Analyzer Probe Port ....................
  • Page 4 7.1.2 Confirming the Ethernet Connection ................... 107 7.1.3 Confirm Ethernet DHCP Configuration ..................107 APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ......109 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 5: Foreword

    These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In addition, the BMK 750 & 1000 models are also approved for PVC and CPVC, 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.
  • 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 PMC Board Controller 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-0127_0B Page 7 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 8 W.C. Water Column, a unit of pressure (1 inch W.C. = 249 Pa) µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017...

  • Page 9: Section 1: Safety Precautions

    • Electrical voltages up to 220 VAC (BMK 750 – 2000) or 220 or 380 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: 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 12: Site Preparation

    All piping must include ample provisions for expansion. NOTE: Benchmark 750 – 3000 units may be installed with zero side clearances in pairs only. The perimeter clearances still apply. See drawings in Appendix A: Dimensions and Clearance Drawings.
  • Page 13 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-0127_0B Page 13 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 14 Figure 2-1c: BMK 2500/3000 Clearances WARNING! Keep the unit area clear and free from all combustible materials and flammable vapors or liquids AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 15: 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 16 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 16 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 17: Lifting Provisions

    BAR IN SHIPPING POSITION VIEW B - LIFTING POSITION VIEW A - SHIPPING POSITION Figure 2-3a: BMK 750/1000 Boiler Lifting Provisions AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 17 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 18: Bmk 1500 - 2000 Lifting Provisions

    LIFTING LUGS (3 POSITIONS) YELLOW ARROWS 2” NATURAL Figure 2-3b: Boiler Lifting Provisions – BMK 1500/2000 Shown AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017...

  • Page 19: Supply And Return Piping

    2.6 SUPPLY AND RETURN PIPING 2.6.1 BMK 750 – 1000 Supply and Return Piping Benchmark 750 and 1000 Boiler utilizes 3” (7.62cm) 150# flanges for the water system supply and return piping connections. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-4a.
  • Page 20 AIR INLET WATER INLET (RETURN) EXHAUST MANIFOLD CONDENSATE DRAIN Figure 2-4b: BMK 1500/2000 and BMK 2500/3000 Supply and Return Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 21: 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-0127_0B Page 21 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 22: 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 23 EXHAUST THICK EXTEND UNDER 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-0127_0B Page 23 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 24: Gas Supply Piping

    All gas piping must be arranged so that it does not interfere with removal of any covers, inhibit service/maintenance, or restrict access between the unit and walls, or another unit. Benchmark 750 and 1000: Features a 1 inch (2.54 cm) NATURAL GAS gas inlet connection on the rear of the unit.

  • Page 25: 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-0127_0B Page 25 of 116 Ph.: 800-526-0288...

  • Page 26: 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 27 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 28: Ac Electrical Power Wiring

    AC power wiring to the unit. BMK 750, BMK 1000 BMK 1500 and BMK 2000 units operate internally on 120 VAC power. All such units shipped to Korea include a pre-wired 220 VAC to 120 VAC transformer (P/N 24468) installed inside the unit, mounted on the base, as shown in Figure 2-8.
  • Page 29 For electrical power wiring diagrams, see the Benchmark Electrical Power Guide, TAG-0048 (GF-2060). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 29 of 116 Ph.: 800-526-0288...

  • Page 30: Power Box Locations

    2.10.3 Electrical Power Box Internal Components WARNING! The power breaker shown in Figure 2-10a, 2-10b and 2-10c does NOT remove power from the terminal blocks. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 30 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 31 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-0127_0B Page 31 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 32 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 32 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 33: 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-0127_0B Page 33 of 116 Ph.: 800-526-0288...

  • Page 34: Outdoor Air & Air Sensor Common

    Section 2.6: CONFIGURATION Menu, item 7, in the Benchmark 750 – 3000 Boiler Operation and Maintenance Guide, OMM-0128 (GF-206-K). The outdoor sensor may be wired up to 200 feet (61m) from the boiler. It is connected to the OUTDOOR AIR and AIR SENSOR COMMON terminals of the I/O board (Figure 2-12).

  • Page 35: Air Temp Sensor

    I/O board. The O concentration is displayed in the Operating menu after a 60 second warm- up period. See Section 2.4: OPERATING Menu, item 13, of the Benchmark 750 – 3000 Boiler Operation and Maintenance Guide, OMM-0128 (GF-206-K). 2.11.4 SPARK SIGNAL (+ & –) The two SPARK SIGNAL terminals (+ &...

  • Page 36: Valve Feedback

    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 37: 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 38: 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 39: 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-0127_0B Page 39 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 40: 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 40 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017...

  • Page 41: 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 42 120 seconds (see Section 2.6: CONFIGURATION Menu, item 16, in the Benchmark 750 – 3000 Boiler Operation and Maintenance Guide, OMM-0128 (GF-206-K)). The Sequencing Isolation Valve control is only available when BST is enabled. Refer to section 2.11.12.2 (wiring) and Section 6: Boiler Sequencing Technology in this guide, and Section 2.6:...

  • Page 43: Section 3: Start Sequence

    CAUTIONS must be observed at all times. WARNING! • ELECTRICAL VOLTAGES UP TO 220 VAC (BMK 750 – 2000) OR 220 OR 380 VAC (BMK 2500/3000) MAY BE USED IN THIS EQUIPMENT. It must be serviced only by factory certified service technicians.
  • Page 44 Shut-Off Valve (SSOV) is closed. See Figure 3-1a through 3-1d for SSOV location. TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE LOW GAS SSOV PRESSURE SWITCH NATURAL GAS INLET Figure 3-1a: BMK 750 & 1000 SSOV Location (P/N 22140-1) NATURAL GAS INLET SSOV MANUAL SHUT-OFF VALVE AIR/FUEL LOW GAS VALVE PRESSURE...
  • Page 45 VALVE MANUAL SHUT-OFF VALVE LOW GAS HIGH GAS PRESSURE PRESSURE SWITCH SWITCH Figure 3-1d: BMK 3000: SSOV Location (P/N 22215) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 45 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 46 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%. STEPPER MOTOR AIR INLET BLOWER Figure 3-2a: BMK 750 & 1000 Air/Fuel Valve in Purge Position TO BLOWER STEPPER MOTOR PURGE VALVE POSITION...
  • Page 47 PROOF SWITCH AIR/FUEL VALVE INLET FROM GAS TRAIN BLOCKED INLET SWITCH Figure 3-3b: BMK 1500 – 3000 Blower Proof Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 47 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 48 If no spark is present 3 seconds into the IGNITION TRIAL, the C-More Controller will abort the Ignition Cycle and shut down the boiler. Refer to Section 5: Troubleshooting Guide in the Benchmark 750 – 3000 Boiler Operation and Maintenance Guide, OMM- 0128 (GF-206-K) for guidance if this occurs.

  • Page 49: 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-0127_0B Page 49 of 116 Ph.: 800-526-0288...

  • Page 50: Start/Stop Levels - Air/Fuel & Energy Input

    3.4 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. TABLE 3-2: BMK 750/1000 Air/Fuel Valve Position – NATURAL GAS BOILER ENERGY ENERGY INPUT...
  • Page 51 1,270,000 (372 kW) 1,680,000 (492 kW) 2,100,000 (615 kW) 2,390,000 (700 kW) 2,650,000 (777 kW) 100% 3,000,000 (879 kW) 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 51 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 52 Benchmark 750-3000 Installation & Startup Guide - KOREA SECTION 3 - START SEQUENCE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 53: Section 4: Initial Start-Up

    The requirements for the initial start-up of the Benchmark boiler consists of the following: • Complete the installation (Section 2: Installation) • Set proper controls and limits (Section 2: Operation of the of the Benchmark 750 – 3000 Boiler Operation and Maintenance Guide, OMM-0128 (GF-206-K) • Perform combustion calibration (Section 4: Initial Start-Up) •...

  • Page 54: Installing Gas Supply Manometer - Bmk 750 & 1000 Only

    Benchmark 1500 – 3000 gas trains have a gas pressure gauge installed on the gas train, close to the High Gas pressure switch. However, Benchmark 750 & 1000 units must have a gas supply manometer (or gauge) installed on the downstream side of the SSOV in order to perform the Combustion Calibration procedure described in Section 4.3: Natural Gas Combustion...

  • Page 55: Gas Supply Gauge - Bmk 1500 - 3000 Only

    SWITCH AIR/FUEL VALVE LOW GAS PRESSURE MANUAL GAUGE SHUT-OFF VALVE Figure 4-1c: BMK 2500 Gas Pressure Gauge Location (P/N 22244) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 55 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 56 PRESSURE SWITCH HIGH GAS PRESSURE LOW GAS GAUGE PRESSURE SWITCH Figure 4-1d: BMK 3000 Gas Pressure Gauge Location (P/N 22215) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 57: Accessing The Analyzer Probe Port

    DO NOT install the probe at this time. AIR INLET EXHAUST MANIFOLD HOT WATER INLET ANALYZER PROBE CONDENSATE DRAIN PORT Figure 4-2a: BMK 750 & 1000 Analyzer Probe Port Location AIR INLET DRAIN VALVE HOT WATER INLET EXHAUST MANIFOLD ANALYZER PROBE PORT CONDENSATE DRAIN Figure 4-2b: BMK 1500 –...

  • Page 58: 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 59 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 60 Once the oxygen level is within the specified range at 100%, press the ENTER key to store the selected blower output voltage for the 100% valve position. Record all readings on the Combustion Calibration Sheets provided. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 61 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 62 60% 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 62 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 63: Reassembly

    1/4” NPT plug in the vent hole. 6. Replace all previously removed sheet metal enclosures on the unit. This concludes reassembly after combustion calibration. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 63 of 116 Ph.: 800-526-0288...

  • Page 64: Over-Temperature Limit Switches

    LIMIT SWITCH DIGITAL OVER- ADJUSTABLE TEMPERATURE TEMPERATURE LIMIT CONTROLLER LIMIT SWITCH (AUTO-REST) Figure 4-5a: 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 4-5b: BMK 1500 –...

  • Page 65: 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 66 Benchmark 750-3000 Installation & Startup Guide - KOREA SECTION 4 – INITIAL START-UP (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 67: Section 5: Safety Device Testing

    It is necessary to remove the front door and side panels from the unit to perform the tests described below. WARNING! ELECTRICAL VOLTAGES UP TO 220 VAC (BMK 750 – 2000) OR 220 OR 380 VAC (BMK 2500/3000) MAY BE USED IN THIS EQUIPMENT.

  • Page 68: 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 69 LEAK DETECTION BALL VALVE LOW GAS PRESSURE SWITCH Figure 5-1b: BMK 1500 – 2500 LOW Gas Pressure Test Components (BMK 2000 shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 69 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 70: Low Gas Pressure Test: Bmk 3000 Only

    C-More Controller. 10. The fault message should clear and the FAULT indicator should go off. The unit should now restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 71 PRESSURE LOW GAS SWITCH PRESSURE BALL VALVE LOW GAS PRESSURE SWITCH Figure 5-2: BMK 3000: LOW Gas Pressure Test Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 71 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 72: 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 73 LOW GAS PRESSURE HIGH GAS GAUGE PRESSURE SWITCH HIGH GAS PRESSURE GAUGE Figure 5-3b: BMK 1500/2000: HIGH Gas Pressure Test Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 73 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 74: High Gas Pressure Test: Bmk 3000 Only

    6817 and then press the ENTER key. 6. Place the unit in MANUAL mode and adjust the Air/Fuel Valve position (% open) to 100%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 75 HIGH GAS PRESSURE BALL VALVE LOW GAS HIGH GAS PRESSURE PRESSURE SWITCH GAUGE Figure 5-4: BMK 3000: HIGH Gas Pressure Test Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 75 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...

  • Page 76: 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 76 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 77: 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-0127_0B Page 77 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 78 Limit Switch Temperature Limit Limit Controller 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 78 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 79: 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-0127_0B Page 79 of 116 Ph.: 800-526-0288...

  • Page 80: Flame Fault Test

    BMK 2500 & 3000 units: the unit will Lockout and FLDR (Flame Loss During Run) will flash in the display. b) BMK 750 – 2000 units: the unit will execute an IGNITION RETRY cycle by performing the following steps: •...

  • Page 81: 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-0127_0B Page 81 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 82 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 83: 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-0127_0B Page 83 of 116 Ph.: 800-526-0288...

  • Page 84: 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 84 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 85 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-0127_0B Page 85 of 116 Ph.: 800-526-0288 GF-205-K...
  • Page 86 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 86 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 87: 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-0127_0B Page 87 of 116 Ph.: 800-526-0288...
  • Page 88 Benchmark 750-3000 Installation & Startup Guide - KOREA SECTION 5 – SAFETY DEVICE TESTING (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 89: 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-0127_0B Page 89 of 116 Ph.: 800-526-0288...

  • Page 90: 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 90 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 91: 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-0127_0B Page 91 of 116 Ph.: 800-526-0288...

  • Page 92: 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 92 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 93: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor93

    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-0127_0B Page 93 of 116 Ph.: 800-526-0288...
  • Page 94 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 94 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 95: 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-0127_0B Page 95 of 116 Ph.: 800-526-0288...
  • Page 96 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 96 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 97: 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-0127_0B Page 97 of 116 Ph.: 800-526-0288 GF-205-K...
  • Page 98 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 98 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 99: 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-0127_0B Page 99 of 116 Ph.: 800-526-0288...
  • Page 100 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 100 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 101: 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-0127_0B Page 101 of 116 Ph.: 800-526-0288 GF-205-K 07/17/2017...
  • Page 102 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 102 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 103: 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-0127_0B Page 103 of 116 Ph.: 800-526-0288...
  • Page 104 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 104 of 116 OMM-127_0B Ph.: 800-526-0288...

  • Page 105: 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 both the Ethernet cable and the WIZnet card.
  • Page 106 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 106 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017...

  • Page 107: 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-0127_0B Page 107 of 116 Ph.: 800-526-0288...
  • Page 108 Benchmark 750-3000 Installation & Startup Guide - KOREA SECTION 7 – ONAER SETUP (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

  • Page 109: Appendix A: Dimensional And Clearance Drawings

    Benchmark 750-3000 Installation & Startup Guide - KOREA APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix A: Dimensional and Clearance Drawings Benchmark 750/1000 Dimension Drawing AP-A-891 rev H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 109 of 116 Ph.: 800-526-0288...
  • Page 110 Benchmark 750-3000 Installation & Startup Guide - KOREA 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 110 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 111 Benchmark 750-3000 Installation & Startup Guide - KOREA 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-0127_0B Page 111 of 116 Ph.: 800-526-0288...
  • Page 112 Benchmark 750-3000 Installation & Startup Guide - KOREA APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Dimension Drawing Number: AP-A-936 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 113 Benchmark 750-3000 Installation & Startup Guide - KOREA APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Clearance Drawing Number: SD-A-995 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 113 of 116 Ph.: 800-526-0288...
  • Page 114 Benchmark 750-3000 Installation & Startup Guide - KOREA APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Dimension Drawing Number: AP-A-900 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 116 OMM-127_0B Ph.: 800-526-0288...
  • Page 115 Benchmark 750-3000 Installation & Startup Guide - KOREA APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Clearance Drawing Number: SD-A-898 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0127_0B Page 115 of 116 Ph.: 800-526-0288...
  • Page 116 PIR 17-033: Corrected text in section 5.7 Flame Fault Test. 07/17/2017 Chris Blair DIR 17-050: Corrected target values in Section 4, Combustion Calibration. © AERCO International, Inc., 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 116 OMM-127_0B Ph.: 800-526-0288 07/17/2017 GF-205-K...

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