AERCO BMK 2000DF User Manual
User manual, Gas-fired boilers
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Benchmark 1500DF - 2000DF Boilers
Installation, Operation & Maintenance Manual (IOMM)
OMM-0098_0A
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 196
GF-144
Ph.: 800-526-0288
04/01/2014
USER MANUAL
Installation, Operation and Maintenance
BENCHMARK
1500DF / 2000DF
DUAL FUEL
Gas-Fired Boilers
Natural Gas Modulating
& Condensing Hot Water
Boiler Models:
•
BMK 1500DF
•
BMK 2000DF
Applicable to Serial Numbers:
G-14-0304 and Above
Release Date: 04/01/2014
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This manual is related to the following products:
Table of contents
Document Outline
- FOREWORD
- CHAPTER 1. SAFETY PRECAUTIONS
- CHAPTER 2. INSTALLATION
- 2.1 INTRODUCTION
- 2.2 RECEIVING THE UNIT
- 2.3 UNPACKING
- 2.4 SITE PREPARATION
- 2.5 SUPPLY AND RETURN PIPING
- 2.6 PRESSURE RELIEF VALVE INSTALLATION
- 2.7 CONDENSATE DRAIN & PIPING
- 2.8 GAS SUPPLY PIPING
- 2.9 AC ELECTRICAL POWER WIRING
- 2.10 FIELD CONTROL WIRING
- 2.10.1 Outdoor Air In (OUT) & Air Sensor Common (COM)
- 2.10.2 COMBUSTION AIR Terminal
- 2.10.3 O2 Sensor (O2+ & O2-)
- 2.10.4 SPARK SIGNAL (FLW+ & FLW-)
- 2.10.5 Analog In (+ & -)
- 2.10.6 B.M.S. (PWM) In (BMS+ & BMS-)
- 2.10.7 Shield (SHLD & SHLD)
- 2.10.8 Analog Output (+ & -)
- 2.10.9 RS-485 Comm (+, GND, & -)
- 2.10.10 RS-232 Comm (TxD & RxD)
- 2.10.11 VFD/Blower (0-10 & AGND)
- 2.10.12 Interlocks
- 2.10.13 Fault Relay (NC, COM, & NO)
- 2.10.14 Auxiliary Relay Contacts (NC, COM, & NO)
- 2.11 FLUE GAS VENT INSTALLATION
- 2.12 COMBUSTION AIR
- 2.13 DUCTED COMBUSTION AIR
- 2.14 SEQUENCING VALVE INSTALLATION
- CHAPTER 3. OPERATION
- CHAPTER 4. INITIAL START-UP
- CHAPTER 5. MODE OF OPERATION
- CHAPTER 6. SAFETY DEVICE TESTING
- 6.1 TESTING OF SAFETY DEVICES
- 6.2 LOW GAS PRESSURE FAULT TEST
- 6.3 HIGH GAS PRESSURE TEST
- 6.4 LOW WATER LEVEL FAULT TEST
- 6.5 WATER TEMPERATURE FAULT TEST
- 6.6 INTERLOCK TESTS
- 6.7 FLAME FAULT TESTS
- 6.8 AIR FLOW FAULT TESTS
- 6.9 SSOV PROOF OF CLOSURE SWITCH
- 6.10 PURGE SWITCH OPEN DURING PURGE
- 6.11 IGNITION SWITCH OPEN DURING IGNITION
- 6.12 SAFETY PRESSURE RELIEF VALVE TEST
- CHAPTER 7. MAINTENANCE
- 7.1 MAINTENANCE SCHEDULE
- 7.2 IGNITER-INJECTOR
- 7.3 FLAME DETECTOR
- 7.4 O2 SENSOR
- 7.5 SAFETY DEVICE TESTING
- 7.6 BURNER ASSEMBLY INSPECTION
- 7.7 CONDENSATE DRAIN TRAP
- 7.8 AIR FILTER CLEANING & REPLACEMENT
- 7.9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
- 7.10 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN
- CHAPTER 8. TROUBLESHOOTING GUIDE
- CHAPTER 9. RS-232 COMMUNICATION
- CHAPTER 10. Boiler Sequencing Technology
- 10.1 INTRODUCTION
- 10.2 AERCO BST Quick Start Chart
- 10.3 BST Implementation Instruction
- 10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor
- 10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor
- 10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor
- 10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor
- 10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive
- 10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive
- 10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive
- 10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive
- Appendix A: BOILER MENU ITEM DESCRIPTIONS
- Appendix B: STARTUP, STATUS & DISPLAY MESSAGES
- Appendix C: SENSOR RESISTANCE/VOLTAGE CHART
- Appendix D: BOILER DEFAULT SETTINGS
- Appendix E: RECOMMENDED PERIODIC TESTING
- Appendix F: INDOOR/OUTDOOR RESET RATIO CHARTS
- Appendix G: DIMENSIONAL AND CLEARANCE DRAWINGS
- Appendix H: PART DRAWINGS
- Appendix I: WIRING DIAGRAMS
- Appendix J: PIPING DRAWINGS
- Appendix K: C-MORE CONTROL PANEL VIEWS
- Appendix L: RECOMMENDED SPARES