Aerco BMK 750 User Manual
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Aerco BMK 750 User Manual

Benchmark series gas-fired boilers, natural gas & propane modulating & condensing hot water boiler
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
Natural Gas & Propane
Modulating &
Condensing Hot Water Boiler
Models:
• BMK 750
• BMK 1000
Applicable to Serial Numbers:
• G-14-0752 and above
Latest Update: 05/21/2014
OMM-0082_0J
GF-130
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
USER MANUAL
Installation, Operation and Maintenance
BENCHMARK Series
Gas-Fired Boilers
Page 1 of 192
05/21/2014

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Summary of Contents for Aerco BMK 750

  • Page 1 Gas-Fired Boilers Models: • BMK 750 • BMK 1000 Applicable to Serial Numbers: • G-14-0752 and above Latest Update: 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 1 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    2.10.14 AUX RELAY CONTACTS (NC, COM, & NO) Terminals .............. 31 2.11 FLUE GAS VENT INSTALLATION ....................... 31 2.12 COMBUSTION AIR ..........................32 2.12.1 Combustion From Outside the Building ................... 32 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 3 of 192 Ph.: 800-526-0288...
  • Page 4 5.5 DIRECT DRIVE MODES ........................72 5.5.1 Direct Drive Field Wiring ......................73 5.5.2 Direct Drive Startup ........................73 5.6 AERCO CONTROL SYSTEM (ACS) ......................73 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 5 9.1.2 Logging on to a Remote Machine Using PuTTY ................ 117 9.1.3 Running a Command on a Remote Machine Using PuTTY ............118 9.2 RS-232 COMMUNICATION SETUP ....................119 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 5 of 192 Ph.: 800-526-0288...
  • Page 6 APPENDIX K – C-MORE CONTROL PANEL VIEWS ................ 181 APPENDIX L: RECOMMENDED SPARES ..................183 APPENDIX M – ULTRA-LOW NOx CALIBRATION ................. 185 LIMITED WARRANTY ........................189 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 7: Foreword

    Benchmark's modulating capability relates energy input directly to fluctuating system loads. The maximum turn down ratios for the BMK 1000 and BMK 750 are 20:1 and 15:1, respectively. Both BMK models provide extremely high efficiencies and make them ideally suited for modern low temperature, as well as, conventional heating systems.
  • Page 8 British Thermal Unit. A unit of energy approximately equal to the heat required to raise 1 pound of water 1° F. Combustion Control Panel C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Carbon Monoxide...
  • Page 9 RS-485 Standard RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield SSOV Safety Shut Off Valve TEMP (Temp) Temperature AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 9 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 10 Volts, Direct Current Vacuum Fluorescent Display, or Variable Frequency Drive Watt W.C. Water Column µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 11: Chapter 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 12: Emergency Shutdown

    MANUAL GAS SHUT-OFF VALVE VALVE CLOSED VALVE OPEN Figure 1-1: Manual Gas Shutoff Valve AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...

  • Page 13: Prolonged Shutdown

    Chapter 6 of this manual be performed 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 of the unit. The installer must identify the emergency shut-off device.
  • Page 14 ___________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 15: Chapter 2. Installation

    Each Benchmark Boiler System is shipped as a single crated unit. The shipping weights for the BMK 750 and BMK 1000 Models are approximately 1100 and 1200 pounds, respectively. The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage.

  • Page 16: Site Preparation

    The unit must be installed with the prescribed clearances for service as shown in Figure 2-1a. 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. Minimum acceptable clearances required are as follows: •...

  • Page 17: 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” above the floor. See Condensate Tank instructions in TID-0074 for details.
  • Page 18 LIFTING BAR IN SHIPPING VIEW B - LIFTING POSITION POSITION VIEW A - SHIPPING POSITION Figure 2-2: Boiler Lifting Provisions AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 19: Supply And Return Piping

    In multiple unit installations the discharge lines must not be manifolded together. Each must be individually run to a suitable discharge location. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 19 of 192 Ph.: 800-526-0288...

  • Page 20: Condensate Drain & 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 21: Condensate Trap Installation

    FLOOR NIPPLES PAD MUST NOT 4” MINIMUM DRAIN EXTEND (6” MAXIMUM) UNDER THE CONDENSATE ASSEMBLY. Figure2-6: Sample Condensate Trap Installation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 21 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 22: Gas Supply Piping

    Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER...

  • Page 23: Manual Gas Shutoff Valve

    7” W.C. of pressure. Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 23 of 192 Ph.: 800-526-0288...

  • Page 24: Ac Electrical Power Wiring

    Figure2-7: Manual Gas Shut-Off Valve and Gas Regulator Locations 2.9 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.

  • Page 25: Electrical Power Requirements

    Figure 2-10. In addition, a label showing the required AC power connections is provided on the front cover of the Power Box as shown in Figure 2-8. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 25 of 192 Ph.: 800-526-0288...

  • Page 26: Field Control Wiring

    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). 2.10 FIELD CONTROL WIRING Each unit is fully wired from the factory with an internal operating control system.
  • Page 27 Use Figure 2-12 to determine the functions of the I/O PCB connections. Do not use the silkscreened labels on the PCB itself, as these may not match. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 27 of 192 Ph.: 800-526-0288...

  • Page 28: Outdoor Air In Terminals

    Figure2-12: I/O Box Terminal Strips 2.10.1 OUTDOOR AIR IN Terminals The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO Part No. GM-123525), as required primarily for the Indoor/Outdoor reset mode of operation. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature.

  • Page 29: Combustion Air Terminal

    This input is always enabled and is a “to view only” input that can be seen in the operating menu. The sensor is an AERCO BALCO wire sensor P/N 12449. A resistance chart for this sensor is provided in APPENDIX C. This sensor is an active part of the combustion control system and must be operational for accurate air/fuel mixing control.

  • Page 30: Analog Out Terminals

    2.10.9 RS-485 Comm Terminals The RS-485 communication terminals (+, GND, & -) are used when the boiler plant is being controlled by an Energy Management System (EMS) or AERCO Control System (ACS) using Modbus (RS-485) communication. 2.10.10 RS-232 Comm Terminals The RS-232 communication terminals (TxD and RxD) permit a laptop computer or other suitable terminal to be connected to the boiler.

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

    Figure 2-12 to locate the AUX RELAY terminals for wiring connections. 2.11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, 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 32: Combustion Air

    The more common methods of combustion air supply are outlined in the following sections. For combustion air supply from ducting, consult the AERCO GF-2050, Gas Fired Venting and Combustion Air Guide. 2.12.1 Combustion From Outside the Building Air supplied from outside the building must be provided through two permanent openings.

  • Page 33: Ducted Combustion Air

    CHAPTER 2 – INSTALLATION 2.13 DUCTED COMBUSTION AIR The AERCO Benchmark 750 & 1000 MBH Boilers are UL listed for 100%-ducted combustion. For ducted combustion air installations, the screen inlet air ductwork must then be attached directly to the unit’s air inlet.

  • Page 34: Sequencing Isolation Valve Installation

    (p/n 92084-TAB) included in the shipping container. 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 “master” to manage the other boilers at the site in such a way that the efficiency of the entire boiler array is maximized.
  • Page 35 Install the sequencing isolation valve in the boiler’s hot water outlet pipe. SEQUENCING ISOLATION VALVE HOT WATER OUTLET Figure 2-13: Sequencing Isolation Valve Installed AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 35 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 36 Figure 2-14: Sequencing Isolation Valve Installed Remove the jumper wire from the Molex connector and then plug it into the sequencing isolation valve’s connector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 37: Chapter 3. Operation

    These operating controls, indicators and displays are listed and described in Table 3-1. Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this Chapter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 37 of 192 Ph.: 800-526-0288...
  • Page 38 This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial-to- USB adaptor for use in modern computer USB ports. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 39 Low Water Level alarm. TEST/RESET Switches Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 39 of 192 Ph.: 800-526-0288 GF-130...
  • Page 40 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 40 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...

  • Page 41: Control Panel Menus

    The menu option choices do not wrap around. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 41 of 192 Ph.: 800-526-0288...
  • Page 42 Refer to Appendix A 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 42 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 43: Operating Menu

    RS-232 port. A view-only software version display is also provided to indicate the current Control Box software version. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 43 of 192 Ph.: 800-526-0288...

  • Page 44: Configuration Menu

    The Configuration Menu settings shown in Table 3-4 are Factory- Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 45 160°F *NOTE The Bldg Ref Temp and Reset Ratio Menu Items are only displayed when the Outdoor Sensor is set to “Enabled”. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 45 of 192 Ph.: 800-526-0288...

  • Page 46: Tuning Menu

    0.50 Warmup Int Gain 0 sec. 240 sec. 20 sec. Warmup PID timer Yes, No, Are You Sure? Reset Defaults? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 47: Combustion Cal Menu

    These displayed item groups are displayed in UPPER CASE letters, and are bounded by an asterisk * in order to readily identify them within the item list. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 47 of 192 Ph.: 800-526-0288...
  • Page 48 BST Auto Timer 10 sec 120 sec 30 sec System Remote Intlk Use Boiler Shutdown System Shutdown Shutdown AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 49 BST Bldg Ref Tmp 40°F 230°F 70°F BST Reset Ratio System Start Tmp 30°F 120°F 60°F Disabled Enabled Disabled *BST COMM MENU* AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 49 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 50: Start Sequence

    The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for SSOV location. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 51 (100%). c) The VALVE POSITION bargraph will show 100%. STEPPER MOTOR INLET BLOWER Figure 3-4: Air/Fuel Valve In Purge Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 51 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 52 The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve. STEPPER MOTOR BLOWER INLET Figure 3-6: Air/Fuel Valve In Ignition Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 53: Start/Stop Levels

    5.4% 108,000 140,000 246,000 297,000 369,000 443,000 465,000 564,000 554,000 660,000 637,000 789,000 733,000 933,000 100% 750,000 1,000,000 100% 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 53 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 54 7.1% 128,000 181,000 373,000 400,000 508,000 562,000 565,000 703,000 621,000 791,000 660,000 865,000 723,000 963,000 100% 750,000 1,000,000 100% 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 55: Chapter 4. Initial Start-Up

    Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start-up requirements. An AERCO Gas Fired Startup Sheet, included with each Benchmark, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at: AERCO International, Inc. 100 Oritani Drive...

  • Page 56: Required Tools & Instrumentation

    LEAK DETECTION BALL VALVE Figure 4-1: 1/4 Inch Gas Plug Location Install the 16” W.C. manometer(s) as described in the following steps: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 57: Accessing The Analyzer Probe Port

    DO NOT install the probe at this time. Condensate Drain ANALYZER PROBE EXHAUST Figure 4-2: Analyzer Probe Port Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 57 of 192 Ph.: 800-526-0288 GF-130...

  • Page 58: Natural Gas Combustion Calibration

    However, recalibration is necessary as part of initial start-up 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 59 , NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit. Lower the valve position to 80% using the ▼arrow key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 59 of 192 Ph.: 800-526-0288...
  • Page 60 ), nitrogen oxide (NOx) and carbon monoxide (CO) should remain within the same limits for all valve positions as shown in the following table. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 61: Propane Combustion Calibration

    However, recalibration is necessary as part of initial start-up 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 62 Propane Combustion Calibration Readings Nitrogen Oxide Carbon Monoxide Valve Position Oxygen (O (NOx) (CO) 100% 5% - 6% <30 ppm <100 ppm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 63 This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the down ▼ arrow key decreases the oxygen level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 63 of 192 Ph.: 800-526-0288...

  • Page 64: Reassembly After Combustion Calibration

    Shut off the gas supply to the unit. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 65: Over-Temperature Limit Switches

    If desired, the over-temperature alarm switch settings can be checked or adjusted using the procedure in section 4.5.1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 65 of 192 Ph.: 800-526-0288...

  • Page 66: Digital Alarm Switch Checks And Adjustments

    Figure 4-5. Alarm Limit Control Figure 4-5: Digital Alarm Switch Front Panel AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 67 Alarm Switch. 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. Press the SET button again to enter the code. The first parameter label (SP) will appear in the display.
  • Page 68 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 69: Chapter 5. Mode Of Operation

    I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is provided on the cover of the I/O Box. Refer to Chapter 2, section 2.9.1 for additional wiring information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 69 of 192 Ph.: 800-526-0288...

  • Page 70: Indoor/Outdoor Startup

    The setpoint temperature of the unit is adjustable from 40°F to 240°F. To set the unit for operation in the Constant Setpoint Mode, the following menu settings must be made in the Configuration Menu: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 71: Remote Setpoint Modes

    If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 71 of 192 Ph.: 800-526-0288...

  • Page 72: Remote Setpoint Field Wiring

    While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions and their factory defaults, refer to Appendices A and E.

  • Page 73: Direct Drive Field Wiring

    Installations with 1 to 8 boilers can use BST (see Chapter 10). The ACS mode of operation is used in conjunction with the AERCO Control System. The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible.

  • Page 74: Acs External Field Wiring

    A Combination Control System (CCS) is one that uses multiple boilers to cover both space- heating and domestic hot water needs. An AERCO Control System (ACS) and An optional ACS Relay Box are necessary to configure this system. Typically, an adequate number of boilers are installed to cover the space-heating load on the design day, however one or more units are used for the domestic hot water load.

  • Page 75: Combination Control System Field Wiring

    Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay...
  • Page 76 These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Appendix E.

  • Page 77: Chapter 6. Safety Device Testing

    ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 120 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-0082_0J Page 77 of 192 Ph.: 800-526-0288...

  • Page 78: Low Gas Pressure Fault Test

    6. The unit should shut down and display a GAS PRESSURE fault message, and the FAULT indicator should also start flashing at the following approximate pressures: • BMK 750 & 1000 – NATURAL GAS gas trains: 2.6” W.C. • BMK 750 – PROPANE gas train: 4.4” W.C.

  • Page 79: High Gas Pressure Test

    8. Reduce the gas pressure back to the value recorded in step 5. This pressure should be within the range of • BMK 750 & 1000 – NATURAL GAS gas trains: 2.0” W.C. ± 0.4” W.C. • BMK 750 – PROPANE gas train: 3.9” W.C. ± 0.2” W.C.

  • Page 80: 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 80 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 81: Water Temperature Fault Test

    See Detail ‘A’ below Adjustable Temperature Limit Switch (auto-rest) Front view with Panel removed Figure 6-2: Temperature Limit Switch Location and Setting AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 81 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 82: 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 7. The unit should start. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 83: Flame Fault Tests

    BLOWER BLOCKED INLET VALVE AIR/FUEL VALVE AIR FILTER MANUAL SHUT- OFF VALVE SSOV Figure 6-3: Bare Boiler – Partial View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 83 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 84: Air Flow Fault Tests

    (see Figure 6.4, below). For units that have an air filter in place of a Combustion Air Duct (not shown), remove the air filter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 85 9. Remove the jumper wires installed in step 2 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-0082_0J Page 85 of 192 Ph.: 800-526-0288...

  • Page 86: Ssov Proof Of Closure Switch

    11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. SSOV ACTUATOR ACTUATOR COVER COVER SCREW Figure 6-5: SSOV Actuator Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 87: Purge Switch Open During Purge

    6. The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION. 7. Replace the wire on the Ignition Switch and press the CLEAR button. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 87 of 192 Ph.: 800-526-0288...

  • Page 88: Safety Pressure Relief Valve Test

    6.12 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 88 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 89: Chapter 7. Maintenance

    Gaskets Gaskets Air Filter (59139) Clean Replace 15 mins. * Only performed after initial 6 month period after initial startup. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 89 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 90: Igniter-Injector Replacement

    2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 91 If needed, 3 indexing washers are also included These washers may be needed to properly position the gas injector tube of the igniter-injector within the 120° angle range shown in Figure 7-3. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 91 of 192 Ph.: 800-526-0288...

  • Page 92: Flame Detector Replacement

    7. Reinstall the flame detector and flame detector gasket. 8. Reconnect the flame detector lead wire. 9. Reinstall the shroud on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 93: O 2 Sensor Replacement

    The following parts will be required for reassembly after burner inspection: Part No. Description 81143 Burner Gasket 81048 Flame Detector Gasket 81064 Blower Gasket AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 93 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 94 14. Remove the blower and air/fuel valve from the burner plate by lifting straight up. Also, remove the blower gasket. 15. Remove the eight (8) 3/8-16 nuts from the burner flange (Figure 7-4) using a 9/16” wrench. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 95 BLOWER O2 SENSOR FLAME DETECTOR STAGED IGNITION SOLENOID IGNITER/INJECTOR BURNER GASKET BURNER PLATE BURNER Figure 7-5: Burner Assembly Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 95 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 96: Condensate Drain Trap Maintenance

    4. Remove the float from the condensate trap. 5. Remove the O-ring and orifice gaskets from the trap. AERCO recommends that these items be replaced annually. 6. Thoroughly clean the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap.
  • Page 97 Trap O-Ring GUIDE FLOAT Float Guide INLET Float Adapter Opening O-Rings CONDENSATE TRAP OUTLET (P/N 24060) Figure 7-6: External Condensate Trap AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 97 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...

  • Page 98: Air Filter Cleaning & Replacement

    AIR FILTER HOSE CLAMP BLOWER AIR/FUEL VALVE AIR FILTER MIRROR/VIEWPORT HEAT EXCHANGER GAS TRAIN ASSEMBLY Figure 7-7: Air Filter Replacement AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 99: Shutting The Boiler Down For An Extended Period Of Time

    4. Perform initial startup per Chapter 4. 5. Perform safety device testing and scheduled maintenance procedures per Chapters 6 and 7 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 99 of 192 Ph.: 800-526-0288...
  • Page 100 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 101: Chapter 8. Troubleshooting Guide

    If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 101 of 192 Ph.: 800-526-0288...
  • Page 102 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 103 Defective Air-Fuel Valve Check igniter-injector for soot or erosion of electrode. Check potentiometer. injector solenoid valve to insure proper open/close operation. Hard light. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 103 of 192 Ph.: 800-526-0288 GF-130...
  • Page 104 AIRFLOW FAULT DURING See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW IGNITION applies for this fault. FAULT DURING IGNITION. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...
  • Page 105 If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 105 of 192 Ph.: 800-526-0288...
  • Page 106 Carboned heat exchanger due to If exhaust temperature is greater than 200 F, check incorrect combustion calibration combustion calibration. Calibrate or repair as necessary. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...
  • Page 107 Press CLEAR button and restart unit. If fault persists, IGN BOARD between the PMC board and contact qualified Service Personnel. COMM FAULT Ignition/Stepper (IGST) board AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 107 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 108 Defective IGST Board Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 109 DURING IGNITION calibration is okay, the problem may be in the Air/Fuel Valve or the Control Box. Refer fault to qualified service personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 109 of 192 Ph.: 800-526-0288...
  • Page 110 O2 % OUT OF RANGE Blocked inlet air duct or louver. Unblock air inlet and measure open area for combustion air to the room. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 111 Normally this measurement should be near zero or no more than a few millivolts. Hot and Neutral reversed at Check SSOV power wiring. SSOV. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 111 of 192 Ph.: 800-526-0288 GF-130...
  • Page 112 Defective IGST Board Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 113: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 80% Valve Position in Control Box are outdated. are Rev. E or higher. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 113 of 192 Ph.: 800-526-0288...
  • Page 114 INDEXING WASHERS (Quantity = 0-3 as required) O2 SENSOR & WASHERS INJECTOR-IGNITOR Figure 8-2: Staged Ignition Connection to Gas Injector Tube AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 115 (Remove to access Gas Pressure Adjustment screw) COVER SCREW SSOV ACTUATOR COVER Figure 8-3: SSOV Actuator With Gas Pressure Adjustment & Damping Orifice AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 115 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 116 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 117: Chapter 9. Rs-232 Communication

    For further configuration options (data bits, stop bits, parity, flow control), you can use the Serial Configuration panel (right image in Figure 9-1) by selecting “Serial” in the left navigation pane. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 117 of 192 Ph.: 800-526-0288...

  • Page 118: Running A Command On A Remote Machine Using Putty

    Open button at the bottom of the dialog. You will have to provide an account name and password in the terminal window to complete the process. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 119: Communication Setup

    At the prompt, enter the valid RS-232 password (jaguar) in lower case letters and press Enter. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices: M = Display next Menu...

  • Page 120: Data Logging

    Time Direct Drive Signal Fault 609 1/10/02 8:42am Low Gas Pressure 366 7/04/01 5:29pm Loss of Power 0 1/01/01 11:50am AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 121: Operation Time Log

    Enter (i.e. S0 <Enter>). To view earlier records in reverse chronological order, enter S and press Enter. To go back 200 or 700 records, enter S200 or S700, etc. and press Enter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 121 of 192 Ph.: 800-526-0288...

  • Page 122: Sensor Log

    OPEN OPEN OPEN OPEN OPEN 1/15/02 5:16pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:11pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:06pm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 123: Chapter 10. Boiler Sequencing Technology

    A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 9-1 below. Figure 10-1. Simplified BST Block Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 123 of 192 Ph.: 800-526-0288...

  • Page 124: Aerco Bst Quick Start Chart

    Option 7 – 4-20ma Drive AND Modbus Header Complete section 10.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 10.3.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 125: Bst Implementation Instruction

    10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...

  • Page 126: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    Step 1: MODbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.

  • Page 127: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    Step 1 - Direct Wired Header Sensor Wiring 1. On the MASTER Unit, connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor” in the I/O Box.
  • Page 128 When ALL C-More units have been configured: 9. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 129: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    Step 1 - Modbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 130 When ALL C-More units have been configured: 13. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 131: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor” in the I/O Box.
  • Page 132 When ALL C-More units have been configured: 8. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 133: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor” in the I/O Box.

  • Page 134: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Step 1: MODbus Header Sensor 1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 135 When ALL C-More units have been configured: Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 135 of 192 Ph.: 800-526-0288...

  • Page 136: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Step 1: MODbus Header Sensor 1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 137 When ALL C-More units have been configured: 10. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 137 of 192 Ph.: 800-526-0288...
  • Page 138 Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 139: Appendix A: Boiler Menu Item Descriptions

    Displays total run time of unit in hours from 0 to 9,999,999. Fault Log Displays information on the last 20 faults. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 139 of 192 Ph.: 800-526-0288 GF-130...
  • Page 140 Allows selection of KC Boiler, KC Boiler LN, BMK Boiler Std, BMK Blr Std Dual, BMK Boiler LN, BMK Blr LN Dual, KC Water Heater, KC Wtr Heater LN, Innovation WH AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 141 Pump Delay Timer Specifies the amount of time (0 to 30 min.) to keep the pump running after the unit turns off. Default is zero. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 141 of 192 Ph.: 800-526-0288...
  • Page 142 Allows the Failsafe mode to be set to either Constant Setpoint or Shutdown. Default is Shutdown. Analog Output Must be set to Valve Pos 0-10V for BMK 750 & 1000. Lo Fire Timer Specifies how long (2 to 600 sec.) to remain in the low fire position after ignition, before going to the desired output.
  • Page 143 Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature. Span is 40% to 100%, Default is 60%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 143 of 192 Ph.: 800-526-0288...
  • Page 144 Range = 1-240 Default = 20 Reset Defaults? Allows Tuning Menu options to be reset to their Factory Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 145: Appendix B: Startup, Status & Display Messages

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 145 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 146 The RS-485 network information is not present or is corrupted. FAULT % OUT OF RANGE The O % has gone below 3% or above 8%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 147 A failure has been detected in one of the relays that control the SSOV. FAILURE STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to the desired position. FAILURE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 147 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 148 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...

  • Page 149: Appendix C: Sensor Resistance/Voltage Chart

    1185.2 2.41 1209.5 2.43 1234.7 2.45 1260.0 2.47 1285.6 2.50 1311.4 2.52 1337.7 2.54 1364.2 2.56 1391.0 2.58 1418.2 1445.7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 149 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 150 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 151: Appendix D - Indoor/Outdoor Reset Ratio Charts

    -10F -15F -20F Table D-2. Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 151 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 152 RESET RATIO Temp Table D-4. Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 153 RESET RATIO Temp -10F -15F Table D-6. Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 153 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 154 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX D – INDOOR/OUTDOOR RATIO CHARTS Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...

  • Page 155: Appendix E - Boiler Default Settings

    Aux Start On Dly 0 sec Failsafe Mode Shutdown Valve Position 0-10V Analog Output CAUTION: DO NOT Change Lo Fire Timer 2 sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 155 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 156 Hi DB Setpt En Demand Offset Deadband High Deadband Low Tuning Menu Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 157: Appendix F - Dimensional Drawings

    Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS APPENDIX F – DIMENSIONAL DRAWINGS Drawing Number: AP-A-891 rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 157 of 192 Ph.: 800-526-0288...
  • Page 158 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS Drawing Number: SD-A-871 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 159 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS Drawing Number: SD-A-872 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 159 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 160 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 161: Appendix G - Part List Drawings

    Benchmark 750-1000 Part List 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 1 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 161 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 162 Benchmark 750-1000 Part List 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 2 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 163 Benchmark 750-1000 Part List 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 3 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 163 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 164 Benchmark 750-1000 Part List 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 4 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 165 Benchmark 750-1000 Part List 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 5 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 165 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 166 Benchmark 750-1000 Part List 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 6 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 167 Benchmark 750-1000 FM Gas Train 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 22140-1 rev E (reference PL-A-169) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 167 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 168 Benchmark 750-1000 DBB Gas Train 03/07/2014 AERCO International, Inc. Blauvelt, NY 10913 22140-2 rev D (reference PL-A-170) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 169 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS BMK 750-1000 PROPANE Gas Train – p/n 22140-3 rev C Item Qty Part # Description Item Qty Part # Description 95026 1.25"NPT 125#: THREADED FLANGE 90104 NIPPLE: PIPE ½' NPT SCH 40 x 7.00 LG BLK STL...
  • Page 170 A/F VALVE ASSY BMK 1000 Benchmark 750-1000 Burner Assembly 08/06/2013 AERCO International, Inc. Blauvelt, NY 10913 24276 rev F (AP-A-171) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 171: Appendix H - Piping Drawings

    Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-870 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 171 of 192 Ph.: 800-526-0288...
  • Page 172 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-868 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 173 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-869 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 173 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 174 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-874 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 175: Appendix I - C-More Wiring Diagrams

    Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68038 rev E Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 175 of 192 Ph.: 800-526-0288...
  • Page 176 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...
  • Page 177 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68038 rev E Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 177 of 192 Ph.: 800-526-0288...
  • Page 178 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 179: Appendix J - Recommended Periodic Testing

    Section IV. High water Service temperature safety Annually See section 6.5 Technician control test Operating controls Annually Operator See section 3.2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 179 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 180 See section 7.8 Annually Verify oxygen level is between 3% and 8% Oxygen (O ) Level Monthly Operator during boiler operation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 181: Appendix K - C-More Control Panel Views

    SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure K–1: Benchmark Control Panel Exploded View BENCHMARK CONTROL PANEL EXPLODED VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 181 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 182 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure K–2: Benchmark Control Panel Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 183: Appendix L: Recommended Spares

    If the unit is installed in the state of Kentucky, contact your local AERCO Sales Representative for a Temperature Switch rated for 200ºF. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 183 of 192 Ph.: 800-526-0288...
  • Page 184 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX K – RECOMMENDED SPARES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014 GF-130...

  • Page 185: Appendix M - Ultra-Low Nox Calibration

    (Figure L-1). Make gas pressure adjustments using a flat-tip screwdriver to obtain a gas pressure within the range of 2.0 ± 0.4” W.C. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 185 of 192 Ph.: 800-526-0288...
  • Page 186 16. Once the oxygen level is within the specified range at 100%, record the O , NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 187 *NOTE Set the Valve Position at 18% but make adjustments to the Combustion Calibration value designated as 16%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 187 of 192 Ph.: 800-526-0288...
  • Page 188 5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold. Replace the 1/4” NPT plug in the manifold. 6. Replace all previously removed sheet metal enclosures on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 192 OMM-0082_0J Ph.: 800-526-0288...

  • Page 189: Limited Warranty

    Any claim relating to the product must be filed with AERCO not later than 14 days after the event-giving rise to such claim. Any claims relating to this product shall be limited to the sale price of the product at the time of sale. The sale of the product is specifically conditioned upon acceptance of these terms.
  • Page 190 18 months from date of shipment or 12 months from startup, whichever comes first. Rev. 11/22/2013 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 190 of 192 OMM-0082_0J Ph.: 800-526-0288...
  • Page 191 Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J Page 191 of 192 Ph.: 800-526-0288 GF-130 05/21/2014...
  • Page 192 22140-3 drawings to Appendix G. PIR 934-65: Added explanatory paragraph & note to section 2.15 – Sequencing Isolation Valve Installation © AERCO International, Inc., 2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 192 OMM-0082_0J Ph.: 800-526-0288 05/21/2014...

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