AERCO BMK 6000 User Manual
User manual, Benchmark 6000, Gas-fired boiler
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Benchmark 6000 Boiler
Installation, Operation & Maintenance Manual
OMM-0086_0D
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 210
GF-133
Ph.: 800-526-0288
03/20/14
BENCHMARK 6000
Gas-Fired Boiler
USER MANUAL
Installation, Operation and Maintenance
Natural Gas Modulating &
Condensing Hot Water Boiler
Applicable to Serial Numbers:
N-14-0172 and Above
Latest Update: 03/20/14
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Table of contents
Document Outline
- FOREWORD
- CHAPTER 1. SAFETY PRECAUTIONS
- CHAPTER 2. INSTALLATION
- 2.1 INTRODUCTION
- 2.2 RECEIVING THE UNIT
- 2.3 MOVING & UNPACKING THE UNIT
- 2.4 SITE PREPARATION
- 2.5 SUPPLY AND RETURN PIPING
- 2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR 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 Terminal
- 2.10.2 COMBUSTION AIR Terminal
- 2.10.3 O2 SENSOR Terminals
- 2.10.4 SPARK SIGNAL Terminals
- 2.10.5 ANALOG IN Terminals
- 2.10.6 B.M.S. (PWM) IN Terminals
- 2.10.7 SHIELD Terminals
- 2.10.8 ANALOG OUT Terminals
- 2.10.9 RS485 Comm Terminals
- 2.10.10 RS232 Comm Terminals
- 2.10.11 VFD/BLOWER Terminals
- 2.10.12 Interlock Terminals
- 2.10.13 FAULT RELAY Terminals
- 2.10.14 AUX.RELAY Terminals
- 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 TESTs
- 6.3 HIGH GAS PRESSURE FAULT 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 PILOT BURNER
- 7.3 MAIN FLAME DETECTOR
- 7.4 O2 SENSOR
- 7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT
- 7.6 SAFETY DEVICE TESTING
- 7.7 BURNER ASSEMBLY INSPECTION
- 7.8 REFRACTORY REMOVAL & REPLACEMENT
- 7.9 CONDENSATE DRAIN TRAP
- 7.10 AIR FILTER CLEANING & REPLACEMENT
- 7.11 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
- 7.12 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 – INDOOR/OUTDOOR RESET RATIO CHARTS
- APPENDIX E – BOILER DEFAULT SETTINGS
- APPENDIX F – CLEARANCE DRAWINGS
- APPENDIX G – PARTS LIST DRAWINGS
- APPENDIX H – PIPING DRAWINGS
- APPENDIX I: C-MORE WIRING DIAGRAMS
- APPENDIX J: RECOMMENDED PERIODIC TESTING
- APPENDIX K – C-MORE CONTROL PANEL VIEWS
- APPENDIX L: RECOMMENDED SPARES
- APPENDIX M – LONG TERM BLOWER STORAGE
- APPENDIX N – ULTRA-LOW NOx CALIBRATION
- LIMITED WARRANTY