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Installation and Startup Guide- INTERNATIONAL OMM-0129 (GF-207-I) Applies to Serial Numbers: N-17-0850 and above China Patent No. ZL 201280040168.4 Latest Update: 1/30/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0130_0A Page 1 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
4.2 PILOT BURNER ............................ 40 4.3 MAIN FLAME DETECTOR ........................42 4.4 O SENSOR ............................42 4.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT ..........45 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 2 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
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APPENDIX J: LONG TERM STORAGE ............... 125 APPENDIX J-I: LONG TERM BOILER STORAGE .................. 125 APPENDIX J-2: LONG TERM BLOWER STORAGE ................125 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 128 Ph.: 800-526-0288 GF-208-I...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL CONTENTS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
FORWARD FOREWORD The AERCO Benchmark (BMK) 5000 MBH (1465 kW) and 6000 MBH (1758 kW) 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. Designed for application in any closed loop hydronic system, their modulating capability relates energy input directly to fluctuating system loads.
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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 and Innovation product lines. Cubic Feet per Hour (1 CFH = 0.028 m...
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Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) Point-to-Point (usually over RS232 networks) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 7 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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.
Section 5: Safety Device Testing of the Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I) be performed to verify that all system-operating parameters are correct. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 128 OMM-0130_0A Ph.: 800-526-0288...
All of the installation procedures in Section 2 of the Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I) must have been completed before attempting to start the unit. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 11 of 128 Ph.: 800-526-0288 GF-208-I...
Table 2-1. Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section. Figure 2-1: C-More Controller Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 128 OMM-0130_0A Ph.: 800-526-0288...
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• Pressing RESET resets the water level monitor circuit. switches • Pressing the CLEAR key (item 6) resets the display. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 13 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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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 14 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 15 of 128 Ph.: 800-526-0288 GF-208-I...
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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 16 of 128 OMM-0130_0A Ph.: 800-526-0288...
10.00 SSOV Time to OPN 0.00 10.00 Air Pump Voltage 0.20 V 1.2 V Run Cycles 999,999,999 Run Hours 999,999,999 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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 18 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
Outdoor Sensor Enabled or Disabled Disabled * Bldg Ref Temp 40°F 230°F 70°F (If Mode = Outdoor (4.4° (110° (21.1° Reset) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Demand Offset ° ° 10°F (5.5°C) 0°F (0 25°F (13.75 Deadband High ° ° 5°F (2.75°C) 0°F (0 25°F (13.75 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Sensor menu item is set to Enabled. CAUTION! DO NOT change the Analog Output menu item from its default setting (Valve Position 0- 10V). OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 21 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
Warmup Int Gain 0.00 2.00 0.50 Warmup PID timer 0 sec. 240 sec. 20 sec. Reset Defaults? Yes, No, Are You Sure? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 23 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
BST Valve State 0 (CLOSED) 1 (OPEN) 1 BST Comm Errors 1 BST Units 8 0 – 8 (see * NOTE below) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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130°F (54.4°C) Setback Start 12:00am 11:59pm 12.00am Setback End 12:00am 11:59pm 12.00am Rate Threshold 1°F (0.55°C) 30°F (16.5°C) 15°F (8.25°C) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 25 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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120 Sec 30 Sec BST FR Up Rate BST Bldg Ref Tmp 40°F (4.4°C) 230°F (110°C) 70°F (21.1°C) BST Reset Ratio AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Unit 2 is Off Unit 4 is Not Available Unit 5 is Lead On Unit 6 is Lag Off 1 BST Units 8 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
VP Down Rate 60.0 Depends on unit type/size Purge Blwr Offst -1.0 Depends on unit type/size 4-20mA Purge Pct 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Cal Temp Sensors Off or Start FFWD Temp Offset Exhst Tmp Offset Outdr Air Offset Inlet Air Offset Inlet Wtr Offset OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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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 30 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
I/O Box. Refer to Section 2.10: AC Electrical Power Wiring of the Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207- I) for additional information on wiring.. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 31 of 128 Ph.: 800-526-0288 GF-208-I...
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 32 of 128 OMM-0130_0A Ph.: 800-526-0288...
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. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 33 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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;...
REMOTE LED will again light and the MANUAL LED will go off. This will happen automatically after 1 hour after the password has expired. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 35 of 128 Ph.: 800-526-0288...
Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF- 207-I)). 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.
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...
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 descriptions of temperature-related functions, see Appendix A; their factory defaults are included in Sections 2.4 –...
Replace 15 mins. * Only performed after initial 6 month period after initial startup. The following maintenance kits are available through your local AERCO Sales Representative: NOTE: The 24-Month Waterside/Fireside Inspection Kits includes the items contained in the Annual Maintenance Kit (P/N 58025-11). Therefore, when performing the waterside/fireside inspections, only the 24-Month kit is required.
Pilot Burner from the unit after it has cooled to room temperature. PILOT BURNER PILOT BURNER ROD ROD TIP (P/N 66100) Figure 4-1b: Pilot Burner & Pilot Ignition Rod – Cross-Section AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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12. Reconnect the ignition cable. 13. Close the right side door and front panel. Replace the top panel if the unit was serviced from above. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 128 Ph.: 800-526-0288 GF-208-I...
Sensor Cover and holding it in place with a length of cord or wire. 3. Disconnect the O sensor lead wire by pushing in on the release tab and pulling apart the connector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 128 OMM-0130_0A Ph.: 800-526-0288...
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GAS LINE TO EXHAUST AIR EDUCTOR MANIFOLD ASSY. For AERtrim (P/N 24508-TAB) Figure 4-2: O Sensor Mounting Location – Back Panel Semi-Transparent OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 43 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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AIR FILTER COVER BRACKET (Hangs on opening in back panel) Figure 4-3: Air Eductor Assembly – Shown Removed from Unit AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
12. If the Pilot Regulator is NOT within specifications, proceed to Section 4.5.2 and perform the Pilot Regulator Pressure Calibration procedure. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 45 of 128 Ph.: 800-526-0288 GF-208-I...
8. Start the boiler in the MANUAL mode. Observe the manometer pressure when the Pilot solenoid “clicks” open after purge. The manometer should now provide a reading between 4.6” W.C. and 5.0” W.C. (1.15 kPa and 1.25 kPa). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 128 OMM-0130_0A Ph.: 800-526-0288...
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. 10. If the manometer reading is below 4.6” W.C. (1.15 kPa), increase the regulator setting by rotating the adjustment screw clockwise (CW).
18. Loosen and remove the eight (8) 3/8” hex nuts and washers from the Blower Flange where it is attached to the Burner’s Front Plate (see Figure 4-5a). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 128 OMM-0130_0A Ph.: 800-526-0288...
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BLOWER FLANGE MAIN FLAME DETECTOR PILOT FLAME DETECTORS PILOT BLOWER BURNER Figure 4-5a: Burner Assembly Mounting Details – Right-Front View OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
7. Disconnect the wires from the thermal switch on the rear plate. 8. Remove all of the nuts from the rear plate, EXCEPT for the one at the top of the plate. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 51 of 128 Ph.: 800-526-0288...
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A borescope can be used to inspect the front tubesheet as well as under the expansion joints. 16. Following inspection, reinstall the components in the reverse order in which they were removed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 128 OMM-0130_0A Ph.: 800-526-0288...
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Figure 4-8: Partial Rear View Showing Rear Burner Plate METAL TABS (4 EACH) REFRACTORY REFLECTOR Figure 4-9: Partial Rear View – Rear Plate and Refractory Removed OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 53 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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.
7. Replace the front panel on the unit and return boiler to service use. AIR FILTER CLAMPS AIR FILTERS Figure 4-11: Air Filter Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 128 OMM-0130_0A Ph.: 800-526-0288...
6. Open the drain valve and drain all water from the unit. 7. Refer to Appendix J for maintenance of blower during shut down. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 128 Ph.: 800-526-0288...
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 60 of 128 OMM-0130_0A Ph.: 800-526-0288...
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 Figure 4-16: Wiring Diagram After Replacing Actuator OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 61 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL SECTION 4 – MAINTENANCE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 63 of 128 Ph.: 800-526-0288...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL SECTION 5 – TROUBLESHOOTING GUIDE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Air/Fuel Valve dial. Hard light. Check igniter-injector for soot or erosion of electrode. Check injector solenoid valve to insure proper open/close operation. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 65 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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See Corrective Actions for AIRFLOW FAULT DURING IGNITION Probable causes from 3 to 16 for AIRFLOW items 3 to 12. FAULT DURING IGNITION applies for this fault. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
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(voltage type of signal being sent. Check control signal type set in or current). Configuration menu. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 67 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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When unit goes to ignition, listen for a clicking sound at the Pilot ignition solenoid valve to ensure it is opening. Clogged Pilot ignition piece Remove and inspect the ignition piece for blockage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 128 OMM-0130_0A Ph.: 800-526-0288...
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(C) and normally closed (NC) terminals with the unit not firing. Replace the switch if continuity does not exist. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 69 of 128 Ph.: 800-526-0288 GF-208-I...
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Press CLEAR button and restart unit. If fault persists, contact IGN BOARD the PMC board and Ignition/Stepper (IGST) qualified Service Personnel. COMM FAULT board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 71 of 128 Ph.: 800-526-0288 GF-208-I...
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Check network connections. If fault persists, contact qualified Unit not seeing information from Modbus MODBUS Service Personnel. network. COMMFAULT AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Check resistance of sensor to determine if it is within specification. FAULT Incorrect Sensor. Ensure that the correct sensor is installed. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 73 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. RECIRC PUMP Internal recirculation pump failed. 1. Replace recirculation pump. FAILURE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Check SSOV power wiring. Hot and Neutral reversed at SSOV. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 75 of 128 Ph.: 800-526-0288 GF-208-I...
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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 Page 76 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
Check to ensure that the IGST and Power Supply Boards are Rev. E Air/Fuel Valve “hunting” at C-More Controller are outdated. or higher. the 70% Valve Position OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 77 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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- BMK 5000 – 11.0” W.C., 2.7 - BMK 5000 – 8.0” W.C., 2.0 kPa Figure 5-1: Gas Train Component and Pilot Gas Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 128 OMM-0130_0A Ph.: 800-526-0288...
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BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 5-3: SSOV Actuator With Gas Pressure Adjustment (SKP25) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 79 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL SECTION 5 – 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 Page 80 of 128 OMM-0130_0A Ph.: 800-526-0288...
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SECTION 5 – TROUBLESHOOTING GUIDE Continued from Sheet 1 Figure 5-4b: Pilot Assembly Troubleshooting Flow Chart (Sheet 2 of 2) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 81 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL SECTION 5 – TROUBLESHOOTING GUIDE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
Displays the elapsed time between confirmation of gas valve Ignition Time opening (POC) until a stable flame is detected. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 83 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Run 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 84 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
4-digit serial # on the Code Plate, e.g., G-12- Software Version Identifies the current software version of the C-More Controller. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 85 of 128 Ph.: 800-526-0288 GF-208-I...
Temp Hi Limit unit. The temperature must then drop 5°F (2.75 below this °C) setting to allow the unit to run. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
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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. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 87 of 128 Ph.: 800-526-0288 GF-208-I...
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A component of AERCO’s AERtrim functionality, not included O2 Trim Menu on this model. When set to Enabled, the BST menu options appears. BST Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
Range = 0 - 240 seconds Default = 20 seconds Allows Tuning menu options to be reset to their Factory Reset Defaults? Default values. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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 90 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
Exhst Warn Temp Flue temperature high warning Exhst Tmp VP Adj VP adjust value Exhst Adj Rate VP adjust rate OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Allows the Gas Pressure Reset function to be set to AUTO or Gas Press Reset MANUAL. Min Off Time Allows the minimum Off time to be set from 0 to 10 minutes. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
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Range: -20 to + 20 (either ºF or °C) – Inlet Wtr Offset Range: -20 to + 20 (either ºF or °C) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 93 of 128 Ph.: 800-526-0288 GF-208-I...
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Min Spark Amps spark transformer input. Allows the adjustment of the maximum spark current required at Max Spark Amps the spark transformer input. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018...
The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 95 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
The High Water Temperature Limit switch is open, or the VFD is in “Local” mode or voltage to the unit dropped below threshold or the SWITCH OPEN Surface Temp sensor is open. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 128 OMM-0130_0A Ph.: 800-526-0288...
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DURING PURGE REMOTE SETPT The Remote Setpoint signal is not present or is out of range. SIGNAL FAULT OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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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 Page 98 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
OMM-0129 (GF-207-I). Perform a slow drain test per ASME Boiler and Slow drain test Semi-Annual Operator Pressure Vessel Code, Sect. IV. OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 101 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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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 102 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 1 of 7 28657-CHI (BMK 5000) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 2 of 7 28657-CHI (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 3 of 7 28657-CHI (BMK 5000) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 109 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 4 of 7 28657-CHI (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 5 of 7 28657-CHI (BMK 5000) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 6 of 7 28657-CHI (BMK 5000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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10/12/2017 AERCO International, Inc. Whole Boiler P/N 28500-CHI (BMK 6000) Blauvelt, NY 10913 Sheet 7 of 7 28657-CHI (BMK 5000) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 113 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Benchmark 5000 & 6000 FM Gas Train 10/19/2017 International, Inc. 22222-CHI rev F Blauvelt, NY 10913 Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Benchmark 5000 & 6000 FM Gas Train 10/19/2017 International, Inc. 22222-CHI rev F Blauvelt, NY 10913 Sheet 2 of 2 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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10/09/2017 International, Inc. Blauvelt, NY 10913 BMK 5000: 24495-4 rev C, BMK 6000: 24328-4 rev H Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
APPENDIX G – WIRING DIAGRAMS BMK 5000/6000 WIRING DIAGRAMS Standard BMK 5000/6000 Drawing Number: 22222 rev B Gas Train Wiring Diagram Sheet 1 of 1 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 119 of 128 Ph.: 800-526-0288 GF-208-I...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL APPENDIX G – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
TABLE I-3: Optional Spare Parts DESCRIPTION PART NUMBER C-More Controller 69186‐4 Temperature Sensor, 1‐1/2" 123449 Lean Oxygen Sensor 61026 Over Temp‐Auto Reset Switch 123966 OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 123 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL APPENDIX I – RECOMMENDED SPARE PARTS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
Rotate wheel a minimum of 10 full revolutions to keep the motor bearing grease from separating and drying out. (THIS STEP IS CRITICAL!) (Continued) OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 125 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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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 Page 126 of 128 OMM-0130_0A Ph.: 800-526-0288 1/30/2018 GF-208-I...
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Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL NOTES: OMM-0130_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 127 of 128 Ph.: 800-526-0288 GF-208-I 1/30/2018...
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