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Benchmark BMK 5000 DF
Aerco Benchmark BMK 5000 DF Manuals
Manuals and User Guides for Aerco Benchmark BMK 5000 DF. We have
3
Aerco Benchmark BMK 5000 DF manuals available for free PDF download: Operation, Service And Maintenance Manual, User Manual, Installation And Startup Manual
Aerco Benchmark BMK 5000 DF User Manual (136 pages)
Benchmark series. Natural Gas, Propane Gas and Dual Fuel Fired Modulating, Condensing Boilers
Brand:
Aerco
| Category:
Boiler
| Size: 9.06 MB
Table of Contents
Table of Contents
2
Foreword
5
Section 1: Safety Precautions
9
Warnings & Cautions
9
Emergency Shutdown
10
Prolonged Shutdown
10
Important - for Massachusetts Installations
11
Section 2: Operation
13
Introduction
13
C-More Controller Description
14
C-More Controller Menus
17
Menu Navigation and Processing Procedure
17
Operating Menu
19
Setup Menu
20
Configuration Menu
21
Tuning Menu
23
Combustion Cal Menu
23
Bst (Boiler Sequencing Technology) Menu
24
Calibration Menu
27
Section 3: Modes of Operation
29
Indoor/Outdoor Reset Mode
29
Reset Ratio
29
Building Reference Temperature
29
Outdoor Air Temperature Sensor Installation
29
Indoor/Outdoor Startup
30
Constant Setpoint Mode
30
Setting the Setpoint
31
Remote Setpoint Modes
31
Remote Setpoint Field Wiring
32
Remote Setpoint Startup
32
Direct Drive Modes
32
Direct Drive Field Wiring
33
Direct Drive Startup
33
Aerco Control System (Acs)
34
ACS External Field Wiring
34
ACS Setup and Startup
34
Combination Control System (Ccs)
35
Combination Control System Field Wiring
36
Combination Control System Setup and Startup
36
Section 4: Maintenance
37
Maintenance Schedule
37
Pilot Burner
38
Main Flame Detector
40
O 2 Sensor
40
Benchmark 5000-6000 Boiler Operation-Service-Maintenance Guide
43
Combustion Calibration & Pilot Regulator Adjustment
43
Pilot Regulator Pressure Testing
43
Pilot Regulator Pressure Calibration
45
Safety Device Testing
46
Burner Inspection
47
Refractory Removal & Replacement
50
Rear Refractory Removal and Replacement
50
Front Refractory Replacement
53
Condensate Drain Trap
54
Air Filter Cleaning and Replacement
55
Water Cutoff (Lwco) Capacitor Integrity Test
56
Low Water Cutoff (LWCO) - Capacitor Electrical Short Test
57
Low Water Cutoff (LWCO) - Standard C-More Controller Test
58
Shutting Boiler down for Extended Period
58
Placing the Boiler Back in Service after Aprolonged Shutdown
59
Gas Valve Actuator Replacement
60
Section 5: Troubleshooting Guide
61
Introduction
61
Additional Faults Without Specific Fault Messages
74
Appendix A: Boiler Menu Item Descriptions
79
Table A-2: Setup Menu Item Descriptions
81
Table A-3: Configuration Menu Item Descriptions
82
Table A-4: Tuning Menu Item Descriptions
85
Table A-5: Combustion Calibration Menu Item Descriptions
86
Table A-6: Calibration Menu Item Descriptions
87
Appendix B: Startup, Status & Display Messages
91
Appendix B1: Startup and Status Messages
91
Appendix B2: Fault Messages
92
Appendix C: Sensor Resistance/Voltage Chart
95
Appendix D: Recommended Periodic Testing
97
Appendix E: Indoor/Outdoor Reset Ratio Charts
99
Appendix F: Part Lists and Drawings
103
Appendix G: Wiring Diagrams
115
Bmk 5000/6000 Standard Fuel Model Wiring Diagrams
127
Appendix H: C-More Controller Views
129
Appendix I: Recommended Spares
131
Appendix J: Long Term Storage
133
Appendix J-I: Long Term Boiler Storage
133
Appendix J-2: Long Term Blower Storage
133
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Aerco Benchmark BMK 5000 DF Operation, Service And Maintenance Manual (136 pages)
Benchmark series Natural Gas, Propane Gas and Dual Fuel Fired Modulating, Condensing Boilers
Brand:
Aerco
| Category:
Boiler
| Size: 10.57 MB
Table of Contents
Table of Contents
2
Section 1: Safety Precautions
9
Warnings & Cautions
9
Emergency Shutdown
10
Prolonged Shutdown
10
Important - for Massachusetts Installations
11
Section 2: Operation
13
Introduction
13
Control Panel Description
14
Control Panel Menus
17
Menu Navigation and Processing Procedure
17
Operating Menu
19
Setup Menu
20
Configuration Menu
21
Tuning Menu
23
Combustion Cal Menu
23
Bst (Boiler Sequencing Technology) Menu
24
Calibration Menu
26
Section 3: Modes of Operation
29
Indoor/Outdoor Reset Mode
29
Reset Ratio
29
Building Reference Temperature
29
Outdoor Air Temperature Sensor Installation
29
Indoor/Outdoor Startup
30
Constant Setpoint Mode
30
Setting the Setpoint
31
Remote Setpoint Modes
31
Remote Setpoint Field Wiring
32
Remote Setpoint Startup
32
Direct Drive Modes
32
Direct Drive Field Wiring
33
Direct Drive Startup
33
Aerco Control System (Acs)
34
ACS External Field Wiring
34
ACS Setup and Startup
34
Combination Control System (Ccs)
35
Combination Control System Field Wiring
36
Combination Control System Setup and Startup
36
Section 4: Maintenance
37
Maintenance Schedule
37
Pilot Burner
38
Main Flame Detector
40
O 2 Sensor
40
Combustion Calibration & Pilot Regulator Adjustment
42
Pilot Regulator Pressure Testing
42
Pilot Regulator Pressure Calibration
44
BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
44
Safety Device Testing
45
Burner Inspection
45
Refractory Removal & Replacement
49
Rear Refractory Removal and Replacement
49
Front Refractory Replacement
52
Condensate Drain Trap
53
Air Filter Cleaning and Replacement
54
Water Cutoff (Lwco) Capacitor Integrity Test
55
Low Water Cutoff (LWCO) - Capacitor Electrical Short Test
56
Low Water Cutoff (LWCO) - Standard C-More Controller Test
57
Shutting Boiler down for Extended Period
57
Placing the Boiler Back in Service after Aprolonged Shutdown
58
Gas Valve Actuator Replacement
59
Section 5: Troubleshooting Guide
61
Introduction
61
Additional Faults Without Specific Fault Messages
74
Appendix A: Boiler Menu Item Descriptions
79
Table A-2: Setup Menu Item Descriptions
81
Table A-3: Configuration Menu Item Descriptions
82
Table A-4: Tuning Menu Item Descriptions
85
Table A-5: Combustion Calibration Menu Item Descriptions
86
Table A-6: Calibration Menu Item Descriptions
87
Appendix B: Startup, Status & Display Messages
91
Table B-2: Fault Messages
92
Appendix C: Sensor Resistance/Voltage Chart
95
Appendix D: Recommended Periodic Testing
97
Appendix E: Indoor/Outdoor Reset Ratio Charts
99
Appendix F: Part Lists and Drawings
103
Appendix G: Wiring Diagrams
115
Bmk 5000/6000 Standard Fuel Model Wiring Diagrams
127
Appendix H: C-More Controller Views
131
Appendix I: Recommended Spares
133
Appendix J: Long Term Storage
134
J-I: Long Term Boiler Storage
134
J-2: Long Term Blower Storage
134
Aerco Benchmark BMK 5000 DF Installation And Startup Manual (98 pages)
Benchmark series Natural Gas, Propane Gas and Dual Fuel Fired Modulating, Condensing Boilers
Brand:
Aerco
| Category:
Boiler
| Size: 3.71 MB
Table of Contents
Table of Contents
2
Foreword
5
Section 1: Safety Precautions
9
Warnings & Cautions
9
Emergency Shutdown
10
Prolonged Shutdown
10
Important - for Massachusetts Installations
11
Section 2: Installation
13
Introduction
13
Receiving the Unit
13
Unpacking
13
Site Preparation
14
Installation Clearances
14
Setting the Unit
16
Lifting Provisions
17
Multiple Unit Installations
17
Supply and Return Piping
18
Pressure Relief Valve Installation
19
Pressure/Temperature Gauge Installation
19
Condensate Drain and Piping
20
Gas Supply Piping
22
Gas Supply Specifications
22
Manual Gas Shutoff Valve
23
External Gas Supply Regulator
23
Ac Electrical Power Wiring
25
Electrical Power Requirements
26
Field Control Wiring
27
Outdoor Air & Air Sensor Common
28
Air Temp Sensor
29
O 2 Sensor (+ & -)
29
Spark Signal (+ & -)
29
Analog in
29
Valve Feedback
29
Shield (Shld & Shld)
30
Analog out
30
RS485 Comm (+, GND, & -)
30
RS232 Comm (Txd & Rxd)
30
Vfd/Blower (0-10 & AGND)
30
Interlocks
30
Fault Relay (NC, COM, & NO)
31
Auxiliary Relay Contacts (NC, COM, & NO)
31
Flue Gas Vent Installation
32
Massachusetts Installations
32
Combustion Air
33
Ducted Combustion Air
33
Benchmark Pump Relay
33
Sequencing Isolation Valve Installation
35
Section 3: Start Sequence
37
Introduction
37
Start Sequence
37
Start/Stop Levels
42
Start/Stop Levels - Air/Fuel & Energy Input
42
Benchmark 5000 Air/Fuel Valve Position and Energy Input
42
Benchmark 6000 Air/Fuel Valve Position and Energy Input
43
Boiler Energy Input Charts
44
Section 4: Initial Start-Up
47
Initial Start-Up Requirements
47
Tools & Instruments for Combustion Calibration
48
Required Tools & Instrumentation
48
Installing Gas Supply Manometer
48
Accessing the Analyzer Probe Port
49
Pilot Ignition
50
Fuel Types and Combustion Calibration
50
Combustion Calibration
51
NATURAL GAS Combustion Calibration
52
Propane Gas Combustion Calibration
55
Reassembly
58
Dual Fuel Switchover
58
Switchover from NATURAL GAS to PROPANE
59
Switchover from PROPANE to NATURAL GAS
60
Over-Temperature Limit Switches
61
Digital Alarm Switch Checks and Adjustments
62
Section 5: Safety Device Testing
63
Testing of Safety Devices
63
Low Gas Pressure Test
64
High Gas Pressure Test
66
Low Water Level Fault Test
68
Water Temperature Fault Test
69
Interlock Tests
70
Remote Interlock Test
70
Delayed Interlock Test
70
Flame Fault Test
71
Air Flow Fault Tests
71
Blower Proof Switch Test
72
Blocked Inlet Switch Test
73
Ssov Proof of Closure Switch Check
74
Purge Switch Open During Purge
75
Ignition Switch Open During Ignition
76
Safety Pressure Relief Valve Test
76
Section 6: Boiler Sequencing Technology
77
Introduction
77
Installation Notes
78
Aerco Bst Quick Start Chart
78
Bst Implementation Instruction
79
OPTION 1 - Constant Setpoint with Direct Wired Header Sensor
79
OPTION 2 - Constant Setpoint with Modbus Wired Header Sensor
80
OPTION 3 - Outdoor Reset with Direct Wired Header Sensor and Direct Wired Outdoor Sensor
81
OPTION 4 - Outdoor Reset with Modbus Header Sensor and Modbus Outdoor Sensor
83
OPTION 5 - Remote Setpoint with Direct Wired Header Sensor and 4-20Ma Setpoint Drive
85
OPTION 6 - Remote Setpoint with Direct Wired Header Sensor and Modbus Setpoint Drive
87
OPTION 7 - Remote Setpoint with Modbus Header Sensor and 4-20Ma Setpoint Drive
89
OPTION 8 - Remote Setpoint with Modbus Header Sensor and Modbus Setpoint Drive
91
Section 7: Onaer Setup
93
Introduction
93
Connecting the Ethernet Cable
93
Confirming the Ethernet Connection
95
Confirm Ethernet DHCP Configuration
95
Appendix A: Dimensional and Clearance Drawings
96
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