AERCO BMK 1000 User Manual
User manual, Benchmark series, Gas-fired boilers
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
OMM-0082_0J
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 192
GF-130
Ph.: 800-526-0288
05/21/2014
BENCHMARK Series
Gas-Fired Boilers
USER MANUAL
Installation, Operation and Maintenance
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
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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 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 Terminals
- 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 RS-485 Comm Terminals
- 2.10.10 RS-232 Comm Terminals
- 2.10.11 VFD/Blower (0-10 & AGND)
- 2.10.12 Interlocks
- 2.10.13 FAULT RELAY (NC, COM, & NO) Terminals
- 2.10.14 AUX RELAY CONTACTS (NC, COM, & NO) Terminals
- 2.11 FLUE GAS VENT INSTALLATION
- 2.12 COMBUSTION AIR
- 2.13 DUCTED COMBUSTION AIR
- 2.14 BENCHMARK PUMP RELAY OPTION
- 2.15 SEQUENCING ISOLATION 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 REPLACEMENT
- 7.3 FLAME DETECTOR REPLACEMENT
- 7.4 O2 SENSOR REPLACEMENT
- 7.5 COMBUSTION CALIBRATION
- 7.6 SAFETY DEVICE TESTING
- 7.7 BURNER ASSEMBLY INSPECTION
- 7.8 CONDENSATE DRAIN TRAP MAINTENANCE
- 7.9 AIR FILTER CLEANING & REPLACEMENT
- 7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
- 7.11 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 – DIMENSIONAL DRAWINGS
- APPENDIX G – PART 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 – ULTRA-LOW NOx CALIBRATION
- LIMITED WARRANTY
- LIMITED WARRANTY:
- BENCHMARK 750 - 6000 GAS-FIRED BOILERS