Aerco Benchmark BMK 5000 Operation, Service And Maintenance Manual Download Page 64

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BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE

SECTION 7 – TROUBLESHOOTING GUIDE

Page

136

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0124_0A

05/03/2017

Ph.: 800-526-0288

GF-208

TABLE 5-1: BOILER TROUBLESHOOTING PROCEDURES

FAULT

INDICATION

PROBABLE CAUSES

CORRECTIVE ACTION

AIRFLOW FAULT
DURING PURGE

Blower not running or running too slow.

Defective Blocked Inlet switch.

Blockage in air filter or Blocked Inlet switch.

Blocked blower inlet or inlet ductwork.

No voltage to Blocked Inlet switch from C-More
Controller.

PROBABLE CAUSES from 3 to 12 for AIRFLOW
FAULT DURING IGNITION apply for this fault.

Start the unit. If the blower does not run check the blower solid state
relay for input and output voltage. If the relay is OK, check the
blower.

Start the unit. If the blower runs, turn off unit and check the Blocked
Inlet switch for continuity. Replace the switch if continuity does not
exist.

Remove the air filter and Blocked Inlet switch and inspect for signs of
blockage. Clean or replace as necessary.

Inspect the inlet to the combustion blower including any ductwork
leading up to the combustion blower for signs of blockage.

During the start sequence, verify that 24 VAC is present between
each side of the switch and ground. If 24 VAC is not present, refer
fault to qualified service personnel.

See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT
DURING IGNITION.

AIRFLOW FAULT
DURING RUN

Blower stopped running due to thermal or current
overload.

Blocked Blower inlet or inlet ductwork.

Blockage in air filter or Blocked Inlet switch.

Defective Blocked Inlet switch.

Combustion oscillations.

Probable causes from 3 to 16 for AIRFLOW
FAULT DURING IGNITION applies for this fault.

Check combustion blower for signs of excessive heat or high current
draw that may trip thermal or current overload devices.

Inspect the inlet to the combustion blower, including any ductwork
leading up to the combustion blower, for signs of blockage.

Remove the air filter and Blocked Inlet switch and inspect for signs of
blockage, clean or replace as necessary.

Verify that 24 VAC is present between each side of the switch and
ground. If 24 VAC is not present at both sides, replace switch.

Run unit to full fire. If the unit rumbles or runs rough, perform
combustion calibration.

See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT
DURING IGNITION.

Summary of Contents for Benchmark BMK 5000

Page 1: ... Natural Gas Propane Gas and Dual Fuel Fired Modulating Condensing Boilers Latest Update 05 03 2017 This Guide Applies to Models Single Fuel Dual Fuel Natural Gas BMK 5000 BMK 6000 Propane BMK 5000 P BMK 6000 P Natural Gas Propane BMK 5000 DF BMK 6000 DF See also Benchmark 5000 6000 INSTALLATION and STARTUP Guide OMM 0123 GF 207 Applies to Serial Numbers N 17 0100 and above 5000 and 6000 MBH Boile...

Page 2: ...ODES OF OPERATION 29 3 1 INDOOR OUTDOOR RESET MODE 29 3 1 1 Reset Ratio 29 3 1 2 Building Reference Temperature 29 3 1 3 Outdoor Air Temperature Sensor Installation 29 3 1 4 Indoor Outdoor Startup 30 3 2 CONSTANT SETPOINT MODE 30 3 2 1 Setting the Setpoint 31 3 3 REMOTE SETPOINT MODES 31 3 3 1 Remote Setpoint Field Wiring 32 3 3 2 Remote Setpoint Startup 32 3 4 DIRECT DRIVE MODES 32 3 4 1 Direct D...

Page 3: ...EPLACEMENT 59 SECTION 5 TROUBLESHOOTING GUIDE 61 5 1 INTRODUCTION 61 5 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 74 APPENDIX A BOILER MENU ITEM DESCRIPTIONS 79 TABLE A 1 OPERATING 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 DESCRI...

Page 4: ...000 6000 Boiler OPERATION SERVICE MAINTENANCE GUIDE CONTENTS Page 4 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank ...

Page 5: ...cified BMK PLATINUM BOILER INTAKE and OUTPUT RANGES BMK MODEL INPUT RANGE BTU HR OUTPUT RANGE BTU HR MINIMUM MAXIMUM MINIMUM MAXIMUM 5000 400 000 117 kW 5 000 000 1465 kW 348 000 102 kW 4 750 000 1392 kW 6000 400 000 117 kW 6 000 000 1758 kW 348 000 102 kW 5 700 000 1670 kW The output of the boiler is a function of the unit s firing rate valve position and return water temperature When installed a...

Page 6: ... Boiler Management Systems BLDG Bldg Building BST AERCO on board Boiler Sequencing Technology BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound 0 45 kg of water 1 F 0 55 C BTU HR BTUs per Hour 1 BTU hr 0 29 W CCP Combination Control Panel CCS Combination Control System C More Controller A control system developed by AERCO and currently used in all ...

Page 7: ...1000 Series products IP Internet Protocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 1 thousandth of an ampere MAX Max Maximum MBH 1000 BTUs per Hour MIN Min Minimum Modbus A serial half duplex data transmission protocol developed by AEG Modicon NC N C Normally Closed NO N O Normally Open NOx Nitrogen ...

Page 8: ...ull duplex FDX transmission of data based on the RS422 Standard RS485 or EIA 485 A standard for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shield SPDT Single Pole Double Throw a type of switch SSOV Safety Shut Off Valve TEMP Temp Temperature Terminating Resistor A resistor placed at each end of a daisy chain or ...

Page 9: ...legible condition It must be given to the user by the installer and kept in a safe place for future reference WARNING Do not use matches candles flames or other sources of ignition to check for gas leaks Fluids under pressure may cause injury to personnel or damage to equipment when released Be sure to shut off all incoming and outgoing water shutoff valves Carefully decrease all trapped pressures...

Page 10: ...DOWN If there is an emergency turn off the electrical power supply to the boiler and close the manual gas valve located upstream the unit The installer must identify the emergency shut off device If the boiler needs to be shut down for a prolonged period follow the instructions in Section 4 12 Shutting Boiler Down For Extended Period of this manual and review the procedures in Appendix J at the en...

Page 11: ...up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the proper...

Page 12: ...ing system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQ...

Page 13: ...itial startup by factory trained personnel may void the equipment warranty In addition the following WARNINGS and CAUTIONS must be observed at all times WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 208 460 575 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS DO NOT ATTEMPT TO DRY FIRE THE UNIT STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAM...

Page 14: ...lize the C More Controller shown in Figure 2 1 This panel contains all of the controls indicators and displays necessary to operate adjust and troubleshoot the boiler These operating controls indicators and displays are listed and described in Table 2 1 Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section Figure 2 1...

Page 15: ...play flashes shows header temperature 3 VFD Display Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection BST Messages 4 RS232 Port This port is used only by factory trained personnel to monitor onAER communications in combination with...

Page 16: ...ssed and the menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 2 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key i...

Page 17: ...tion is accomplished using the menu keys shown in Figure 2 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures MENU NAVIGATION and PROCESSING PROCEDURE Instructions 1 The Control Panel will normally be in the Operating menu and the VFD will display the current unit status Pressing the or arrow key will di...

Page 18: ... if enabled See Section 6 in the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 for instructions Figure 2 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer to Appendix A in this guide for detailed descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and er...

Page 19: ...2 Outlet Temp 30 F 1 1 C 240 F 116 C Configuration Menu 3 Inlet Temp 30 F 1 1 C 240 F 116 C 4 Air Temp 70 F 56 7 C 245 F 118 C 5 Outdoor Temp 70 F 56 7 C 130 F 54 4 C Configuration Menu 6 Valve Position In 0 100 7 Valve Position Out 0 100 Configuration Menu 8 FFWD Temp 30 F 1 1 C 240 F 115 6 C 9 Exhaust Temp Displays current exhaust temperature 10 Flame Strength 0 100 11 Min Flame Str Not Used 12 ...

Page 20: ...s the Setup menu is also used to enter date and time and units of temperature measurements A view only software version display is also provided to indicate the current C More Controller software version Table 2 3 SETUP Menu MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMITS DEFAULT Minimum Maximum 1 Password 0 9999 0 2 Language English English 3 Time 12 00 am 11 59 pm 4 Date 01 01 00 12 31 99 5 Unit o...

Page 21: ...conditions no changes will be required Table 2 4 CONFIGURATION Menu MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMITS DEFAULT Minimum Maximum 1 Internal Setpt 40 F 4 4 C 240 F 115 6 C 130 F 54 4 C 2 Unit Type BMK Blr Std BMK Blr Std Dual BMK Blr LN BMK Blr LN Dual BMK Boiler LN 3 Unit Size Only the unit sizes available for the Unit Type are displayed 5000 MBH 1465 kW 6000 MBH 1758 kW 5000 MBH 1465 kW ...

Page 22: ... F 5 5 C 5 F 2 75 C 22 Network Timeout 5 sec 999 sec 30 sec 23 Shutoff Dly Temp 0 F 0 C 25 F 13 75 C 10 F 5 5 C 24 Demand Offset 0 F 0 C 25 F 13 75 C 10 F 5 5 C 25 Deadband High 0 F 0 C 25 F 13 75 C 5 F 2 75 C 26 Deadband Low 0 F 0 C 25 F 13 75 C 5 F 2 75 C 27 IGST Version Displays current IGST version V2 02 28 IGN Time Setting Displays 4 sec or 7 sec depending on wiring harness installed 29 Slow ...

Page 23: ...used to vary the speed of the unit s blower motor based on air temperature and air density at prescribed Air Fuel Valve positions open This is accomplished by providing a DC drive voltage to the motor which then adjusts the rotational speed of the blower to maximize combustion efficiency and ensure the unit conforms to the Nitrogen Oxide NOx and Carbon Monoxide CO emissions specified in Section 4 ...

Page 24: ...ontained in group 1 BST Monitor Items are always displayed within the menu as these items are critical for proper system operation Therefore the BST Monitor Items Header itself is not displayed The Items contained in groups 2 5 are not displayed unless that particular item group has been enabled from the C More Controller s keypad Table 2 7 BST Menu MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMITS DE...

Page 25: ...e Disable 29 Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130 F 54 4 C 30 Setback Start 12 00am 11 59pm 12 00am 31 Setback End 12 00am 11 59pm 12 00am 32 Rate Threshold 1 F 0 55 C 30 F 16 5 C 15 F 8 25 C 33 OPERATE MENU Disabled Enabled Disabled 34 BST Next On VP 16 100 50 35 BST Max Boilers 1 8 8 36 BST On Delay 30 sec 300 sec 60 sec 37 BST On Timeout 15 sec 300 sec 60 Sec 38 Valve Over...

Page 26: ...r Threshold 1 9 5 65 SSD Temp Format Degrees Points Degrees 66 BST Upld Timer 0 9999 sec 0 2 10 CALIBRATION MENU The Calibration menu is used by factory trained service personnel to adjust or reset the parameters listed below A full description of each item appears in Table A 6 of Appendix A Table 2 8 Calibration Menu Menu Item Display Available Choices or Limits Default Minimum Maximum 1 Stepper ...

Page 27: ... Purge Blwr Offst 1 0 8 0 Depends on unit type size 22 4 20mA Purge Pct 60 100 70 23 PWM In Adj 5 0 5 0 0 0 24 Analog In Adj 5 0 5 0 0 0 25 Flow In Adj 5 0 5 0 0 0 26 Supply Gas Pressure In Adj 5 0 5 0 0 0 27 Gas Plate dp In Adj 5 0 5 0 0 0 28 mA Out Adj 1 0 mA 1 0 mA 0 0 mA 29 A F Sensitivity 1 5 2 30 Power Reset Automatic or Manual Automatic 31 Water Temp Reset Automatic or Manual Automatic 32 G...

Page 28: ...s Default Minimum Maximum 44 Cal Temp Sensors Off or Start Off 45 FFWD Temp Offset 20 20 0 46 Exhst Tmp Offset 20 20 0 47 Outdr Air Offset 20 20 0 48 Inlet Air Offset 20 20 0 49 Inlet Wtr Offset 20 20 0 50 Outlet Wtr Offset 20 20 0 51 24 hr Max Cycles 0 9999 0 52 24 hr Max Ovrtemp 0 9999 0 53 0 10v Out Test 0 0 10 0 0 54 Spark Monitor Enabled or Disabled Depends on unit type size 55 Min Spark Amps...

Page 29: ...he supply header temperature will increase by that number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreases the supply header temperature will increase by 1 6 degrees 3 1 2 Building Reference Temperature This is a temperature from 40 F to 230 F 4 4 C to 110 C Once selected it is the tempera...

Page 30: ...f necessary refer to section 2 3 for detailed instructions on menu changing 7 Press the CHANGE key The display will begin to flash 8 Use the and arrow keys to select the desired Building Reference Temperature 9 Press ENTER to save any changes 10 Next scroll through the Configuration menu until the display shows RESET RATIO 11 Press the CHANGE key The display will begin to flash 12 Use the and arro...

Page 31: ...actory default setting for the REMOTE SETPOINT mode is 4 20 mA 1 5 VDC With this setting a 4 to 20 mA 1 to 5 VDC signal sent by an EMS or BAS is used to change the unit s setpoint The 4 mA 1V signal is equal to a 40 F 4 4 C setpoint while a 20 mA 5V signal is equal to a 240 F 115 6 C setpoint When a 0 to 20 mA 0 to 5 VDC signal is used 0 mA is equal to a 40 F 4 4 C setpoint In addition to the curr...

Page 32: ... connected at the source When driving multiple units each unit s wiring must conform to the above 3 3 2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled no startup instructions are necessary In this mode the REMOTE LED will light when the external signal is present To operate the unit in the MANUAL mode press the AUTO MAN switch...

Page 33: ...ections necessary for DIRECT DRIVE mode are connection of the remote signal leads from the source to the unit s I O Box For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals in the I O Box The signal must be floating ungrounded at the I O Box and the wire used ...

Page 34: ...GF 114 To enable the ACS mode the following menu settings must be made in the Configuration menu Table 3 4 ACS MODE SETTINGS MENU OPTION SETTING Boiler Mode Direct Drive Remote Signal Network RS485 Refer to section 2 3 for instructions on changing C More Controller menu options 3 5 1 ACS External Field Wiring Wiring connections for RS 485 Modbus control are made between the 485 A and 485 B termina...

Page 35: ...aining up to eight combination boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers OPTION 2 When this option is selected the ACS Relay Panel must be used in conjunction with the ACS For this option the ACS controls a boiler plant co...

Page 36: ...figuration menu Table 3 5 COMBINATION MODE SETTINGS MENU OPTION SETTING Boiler Mode Combination Remote Signal Network Internal Setpt 40 F to 190 F 4 4 C to 87 8 C Refer to section 2 3 for instructions on changing C More Controller menu options While it is possible to change other temperature related functions for COMBINATION mode these functions are preset to their factory default values These def...

Page 37: ...only the 24 Month kit is required when performing the waterside fireside inspections Refer to Appendix I for recommended spare parts WARNING Prior to servicing ensure that the following guidelines are strictly observed Disconnect the AC power supply by turning off the service switch and ac supply circuit breaker Shut off the gas supply at the manual shut off valve provided with the unit Allow the ...

Page 38: ...gas line connected to the bushing Figure 4 1 shows the location of the Pilot Burner and related components Figure 4 1 Pilot Burner Main Pilot Flame Detector Mounting Locations The Pilot Burner may be hot therefore care should be exercised to avoid burns It is easier to remove the Pilot Burner from the unit after it has cooled to room temperature To inspect replace the Pilot Burner perform the foll...

Page 39: ...wn in Figure 4 1 5 First remove the reducer fitting and then the elbow from the Pilot Burner 6 Remove one of the two Pilot Flame Detectors to provide clearance for Pilot Burner removal 7 Using a 1 1 2 open end wrench loosen and remove the Pilot Burner from the Burner Plate 8 Check the Pilot Burner tip for evidence of erosion or carbon build up If there is evidence of substantial erosion the Pilot ...

Page 40: ...all the Main Flame Detector on the Blower Flange 7 Reconnect the Main Flame Detector lead wire 8 Replace the front panel on the unit 4 4 O2 SENSOR The Lean Oxygen Sensor P N 61026 is located on the back plate at the right side of the unit as shown in Figure 4 2 As this figure shows there is also a gas suction line that supplies a sampling of the exhaust gases from the exhaust manifold to ensure ac...

Page 41: ...NY 10913 Page 41 of 136 GF 208 Ph 800 526 0288 05 02 2017 O2 SENSOR MAINTENANCE Instructions 6 Reinstall the O2 sensor and crush washer on the back plate 7 Reconnect the sensor lead wire 8 Reinstall the left rear access panel on the unit Figure 4 2 O2 Sensor Mounting Location O2 SENSOR GAS SUCTION LINE TO EXHAUST MANIFOLD EXHAUST MANIFOLD ...

Page 42: ...EDURE Instructions 1 Ensure that gas supply shut off valve upstream of the unit is still turned OFF 2 Turn OFF electrical power to the system 3 Remove the 1 4 NPT plug from the Tee on the outlet side of the Pilot Regulator Figure 4 3a or Figure 4 3b and insert a NPT to barbed adapter fitting 4 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer 5 Re...

Page 43: ...Fuel Pilot Regulator Mounting Location PROPANE PILOT SOLENOID VALVES NATURAL GAS TEE with 1 4 PLUG Install manometer here for Pilot Regulator test PROPANE TEE with 1 4 PLUG Install manometer here for Pilot Regulator test NATURAL GAS PILOT SOLENOID VALVES PROPANE PILOT REGULATOR NATURAL GAS PILOT REGULATOR PILOT REGULATOR PILOT SOLENOID VALVES TO AIR FUEL VALVE GAS INLET MANUAL SHUT OFF VALVE HIGH ...

Page 44: ...ve the manometer pressure when the Pilot solenoid clicks open after purge The manometer should now provide a reading between 4 6 W C and 5 0 W C 1 15 kPa and 1 25 kPa 9 Pull one of the Pilot Flame Detectors out see Figure 4 1 and look into the port in the front plate You should see the orange glow of the Pilot flame during the ignition trial period NOTE If you do not see the orange glow contact AE...

Page 45: ...on a scheduled basis Test schedules must conform to local jurisdictions The results of the tests should be recorded in a log book See the BMK 5000 6000 Platinum Installation and Start up manual GF 202 for a description and instructions for performing these tests 4 7 BURNER INSPECTION The Burner assembly is located at the front of the unit s heat exchanger The Burner assembly may be hot Therefore a...

Page 46: ...upport turn buckle Figure 4 4a or Figure 4 4b 12 Attach a hoist rig capable of lifting at least 300 pounds to the lifting lug on the blower fan housing The Blower assembly weighs approximately 150 200 lbs depending on which blower motor is installed 13 Remove the two inlet air filters from the galvanized WYE duct 14 Disconnect the wires from the Blower Proof and Blocked Inlet switches Figure 4 4a ...

Page 47: ...ve a nut installed at the base position to keep the Burner level while installing the Blower Figure 4 5 25 Ensure that the Pilot Burner and Pilot Flame Detectors cutouts in the Blower Flange are properly aligned with the Burner Front Plate NOTE Figure 4 4a shows the duel fuel version with the extra lower propane gas train Figure 4 4a Burner Assembly Mounting Details Right Front View Continued AIR ...

Page 48: ...ions Figure 4 4b Burner Assembly Mounting Details Left Side View Figure 4 5 Burner Assembly Exploded View GAS TRAIN AIR FUEL VALVE BLOCKED INLET SWITCH BLOWER 5 8 11 BOLTS 4 A F VALVE TO GAS TRAIN BLOWER PROOF SWITCH AIR FUEL VALVE O RING BLOWER FLANGE BLOWER 3 8 HEX NUTS WASHERS 8 EA BURNER GASKET P N 81159 BURNER FLANGE BURNER GASKET P N 81159 BURNER GAS TRAIN SUPPORT BLOCK Scrap 2X4 3 8 16 NUTS...

Page 49: ...s 4 8 1 and 4 8 2 respectively 4 8 1 Rear Refractory Removal and Replacement REAR REFRACTORY REPLACEMENT Instructions 1 Turn off gas and electrical power to the unit In addition turn off any other units sharing the exhaust flue 2 Disconnect the flue from the exhaust manifold of the boiler being serviced and remove flue sections up to the top of the unit enclosure NOTE At the top the left rear and ...

Page 50: ... package can be removed from the combustion chamber Be careful not to drop or damage the refractory 13 Place the fiber insulation package metal face down in a safe location to avoid damage 14 The combustion chamber can now be viewed and inspected with a full view of the Burner assembly and rear tubesheet A borescope can be used to inspect the front tubesheet as well as under the expansion joints 1...

Page 51: ...3 Page 51 of 136 GF 208 Ph 800 526 0288 05 02 2017 REAR REFRACTORY REPLACEMENT Instructions Figure 4 6 Rear View Showing Rear Panel Nut Latch Locations Figure 4 7 Partial Rear View Showing Rear Burner Plate RIGHT REAR COVER SPRING LATCH LEFT REAR COVER SPRING LATCH THERMAL SWITCH REAR BURNER PLATE O2 SENSOR GAS SUCTION LINE FROM EXHAUST MANIFOLD ...

Page 52: ... assemblies At high temperatures ceramic fibers can be converted to crystalline silica fibers which have been identified as carcinogenic when inhaled 4 8 2 Front Refractory Replacement As previously mentioned it is much easier to remove the rear refractory to inspect the combustion chamber of the unit However if the front refractory must be replaced order the AERCO Front Refractory Replacement kit...

Page 53: ...ENSATE DRAIN TRAP MAINTENANCE Instructions 1 Disconnect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap see Figure 4 10 2 Loosen the four 4 thumbscrews securing the trap s cover and then remove the cover and the O ring from under the cover 3 Remove the float and then thoroughly clean the trap and float Also inspect the dr...

Page 54: ...the unit by grasping the handles and pulling outward 3 Refer to Figure 4 11 and locate the air filters attached to the WYE duct connected to the air fuel valve inlet 4 Using a flat tip screwdriver or 5 16 nut driver loosen the clamp securing the filter to the WYE duct at the air fuel valve inlet Remove the filter and clamp 5 The filters may be cleaned in hot soapy water to remove oil and dirt The ...

Page 55: ...months The LWCO capacitor integrity test consists of two parts as described in the next two sections The first procedure explains how to test for electrical shorting of the LWCO probe capacitor while the second procedure instructs how to perform the standard Low Water Cutoff test using the C More Controller Figure 4 12 shows an illustration of a typical LWCO probe assembly installation Figure 4 12...

Page 56: ...ming the procedure described in this instruction Serious personal injury or death may occur if this warning is not observed 2 Remove the Shell Harness Cable male connector from the P 5 female connector on the rear panel of the C More Controller see Figure 4 13 Figure 4 13 Removing Shell Harness Cable from P5 Conn on C More Rear Panel 3 Using an ohmmeter connect one ohmmeter probe to the LWCO capac...

Page 57: ...F LWCO STANDARD C MORE TEST Instructions 1 Turn the AC power to the unit to the ON position 2 Press the TEST switch on the C More Controller and confirm that the blinking LOW WATER LEVEL message appears on the C More display within 4 seconds 3 Press the RESET key followed by the Clear button and confirm that the LOW WATER LEVEL message is cleared 4 12 SHUTTING BOILER DOWN FOR EXTENDED PERIOD If th...

Page 58: ...07 2 Inspect all piping and connections to the unit 3 Inspect exhaust vent and air inlet duct work if applicable 4 Perform initial startup procedures in Section 4 Initial Startup of the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 5 Perform safety device testing procedures in Section 5 Safety Device Testing of the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF...

Page 59: ...LVE ACTUATOR Instructions 1 Remove the new actuator cover punch out the holes in the plastic to accommodate the wiring then insert the wires through wire conduit and wire it as follows Wire Terminals 4 5 N N L and L identically to the old actuator Remove dispose of the two wires attached to Terminals 1 and 2 and wire nut and the wire connecting Terminal 3 to the Low Gas Pressure Switch three dashe...

Page 60: ...0 Boiler OPERATION SERVICE MAINTENANCE GUIDE SECTION 6 MAINTENANCE Page 60 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank ...

Page 61: ...nd correct the fault FAULT CORRECTION Instructions 1 Observe the fault messages displayed in the C More Controller display 2 Refer to the Fault Indication column in Troubleshooting Table 5 1 which follows and locate the Fault that best describes the existing conditions 3 Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication 4 Perform the checks and pr...

Page 62: ...GUIDE SECTION 6 TROUBLESHOOTING GUIDE Page 62 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 ...

Page 63: ...ckage clean or replace as necessary 4 Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary 5 Check the continuity of the Blower Proof switch with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 6 Turn off unit and check the continuity of the Blocked Inlet switch...

Page 64: ...luding any ductwork leading up to the combustion blower for signs of blockage 5 During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified service personnel 6 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overl...

Page 65: ...g continuity between source and unit 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration menu FLAME LOSS DURING IGN NOTE Before starting the Probable Causes and Corrective Action for this fault refer to the Flow Chart provided in Figure 5 4 at the end of this...

Page 66: ...libration 4 Debris on burner 5 Blocked condensate drain 6 Main Flame Detector is touching burner mesh 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressure into and out of the valve is correct 3 Check combustion calibration using pr...

Page 67: ...ttings 3 Faulty shell temperature sensor 4 Unit in MANUAL mode 5 Unit setpoint is greater than Over Temperature switch setpoint 6 System flow rate changes are occurring faster than units can respond 7 Refractory failure 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against menu default settings in Section 3 If the settings have been c...

Page 68: ...continuity when not in contact with the cam replace the switch 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not repla...

Page 69: ... it is wired correctly GAS PRESSURE FAULT Due to Low Gas Pressure 1 Incorrect supply gas pressure 2 Defective Low Gas Pressure switch 1 Measure NATURAL GAS pressure upstream of the SSOV Actuator s with the unit firing For FM gas trains ensure it is between 4 0 W C and 14 W C 1 0 and 3 5 kPa For DBB gas trains ensure it is between 4 5 W C and 14 W C 1 1 and 3 5 kPa 2 Measure NATURAL GAS pressure at...

Page 70: ...n Analyzer and recalibrate the boiler 2 Unblock air inlet and measure open area for combustion air to the room OUTDOOR TEMP SENSOR FAULT 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 1 Inspect Outdoor Temperature sensor for loose or broken wiring 2 Check resistance of sensor to determine if it is within specification 3 Ensure that the correct sensor is installed PRG SWTCH CLOSED D...

Page 71: ...fuse 5 Defective IGST Board 1 If the air fuel valve does rotate check Purge switch for continuity when closing Replace switch if continuity does not exist 2 Measure for 24 VAC from each side of the switch to ground If 24VAC is not present refer fault to qualified service personnel 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 4 Check DS1 D...

Page 72: ...ts replace actuator SSOV RELAY FAILURE 1 SSOV relay failed on IGST board 2 Floating Neutral 3 Hot and Neutral reversed at SSOV 1 Press CLEAR button and restart unit If fault persists replace Ignition Stepper IGST Board 2 The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two Normally this measurement should be near zero or no more tha...

Page 73: ...ive IGST Board 1 Refer to C More User Manual OMM 0032 GF 112 and perform the Stepper Feedback Calibration procedure in Section 6 section 6 2 1 2 Check that the Air Fuel Valve is connected to the C More Controller 3 Inspect for loose connections between the Air Fuel Valve motor and the wiring harness 4 Replace stepper motor 5 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replac...

Page 74: ... Figure 8 1 and inspect Gas Injector to ensure it is not clogged or damaged 2 Close the 2 Manual Shutoff Valve Attempt to start the unit and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged Ignition Solenoid 3 Refer to Section 4 5 2 above and check the calibration of the Pilot Regulator...

Page 75: ...VALVE TO AIR FUEL VALVE PROPANE TEE with 1 4 PLUG Install manometer here for Pilot Regulator test NATURAL GAS PILOT SOLENOID VALVES PROPANE PILOT REGULATOR NATURAL GAS PILOT GAS VALVE PROPANE PILOT GAS VALVE DOWNSTREAM SSOV NATURAL GAS PILOT REGULATOR PROPANE LOW GAS PRESSURE SWITCH BMK 6000 8 5 W C 2 1 kPa BMK 5000 4 5 W C 1 1 kPa PROPANE HIGH GAS PRESSURE SWITCH BMK 6000 10 5 W C 2 6 kPa BMK 500...

Page 76: ...124_0A 05 03 2017 Ph 800 526 0288 GF 208 Figure 5 2 Pilot Burner Flame Detector Locations Figure 5 3 SSOV Actuator With Gas Pressure Adjustment SKP25 BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw DAMPING ORIFICE COVER SCREW SIGHT GLASS MAIN FLAME DETECTOR TO PILOT GAS LINE BLOWER BLOWER FLANGE BURNER PLATE PILOT BURNER PILOT FLAME DETECTORS 2 EA ...

Page 77: ...ANCE GUIDE SECTION 7 TROUBLESHOOTING GUIDE OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 77 of 136 GF 208 Ph 800 526 0288 05 02 2017 Figure 5 4a Pilot Assembly Troubleshooting Flow Chart Sheet 1 of 2 Continued on Sheet 2 ...

Page 78: ...NCE GUIDE SECTION 7 TROUBLESHOOTING GUIDE Page 78 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Figure 5 4b Pilot Assembly Troubleshooting Flow Chart Sheet 2 of 2 Continued from Sheet 1 ...

Page 79: ...t water temperature 4 Air Temp Air Temp is the air temperature at the input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed 5 Outdoor Temp Outdoor temperature is displayed in ºF or ºC only if outdoor temperature sensor is installed and enabled 6 Flow rate Not Used 7 Valve Position In Desired input valve position This would normally be the same as ...

Page 80: ...0 526 0288 GF 208 TABLE A 1 OPERATING MENU ITEM DESCRIPTIONS MENU OPTIONS DESCRIPTION 19 Spark Current Displays the current going to the ignition transformer 20 Run Cycles Displays the total number of run cycles 21 Run Hours Displays total run time of unit in hours 22 Fault Log Displays information on the last 20 faults 23 Manual Valve Pos Selects valve position Available in Manual mode only ...

Page 81: ... from 01 01 00 to 12 31 99 5 Unit of Temp Permits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C 6 Comm Address For RS 485 communications RS232 should have its own programmable password 7 Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 8 onAER Mode Allows selection of either Ethernet or SD Card 9 Min Upload Timer Mandatory for AERCO...

Page 82: ...te Signal Only available if Mode Remote Setpoint Direct Drive or Combination Used to set the type of external signal which will be used when operating in the Remote Setpoint Direct Drive or Combination Mode 7 Outdoor Sensor Allows outdoor sensor function to be set to Enabled or Disabled 8 Bldg Ref Temp Only available if Boiler Mode Outdoor Reset Allows the building reference temperature to be set ...

Page 83: ...Enabled or Disabled 21 Setpt Limit Band The Setpoint Limit Band can be set from 0 F to 10 F 0 C to 5 5 C 22 Network Timeout Specifies the timeout value in seconds before a Modbus fault is declared up to 999 seconds 23 Shutoff Dly Temp This feature delays the shutdown of a boiler in order to reduce excessive cycling This specifies the temperature value the Outlet Temperature is permitted to rise ab...

Page 84: ...ated and the PID LOOP will again attempt Valve Position corrections Setting range is 0 F 0 C to 25 F 13 75 C Default is 5 F 2 75 C for both Deadband High and Deadband Low 27 IGST Version Displays the version of the IGST Board installed 28 IGN Time Setting Displays the MAX Ignition time of 4 Seconds or 7 Seconds as set in the Safety String Harness 29 Slow Shutdown Set the Slow Shutdown feature to E...

Page 85: ... setting the fire rate will be 100 2 Integral Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 1 0 3 Derivative Time This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output Warmup The ...

Page 86: ...llation and Startup Guide OMM 0123 GF 207 TABLE A 5 COMBUSTION CAL MENU ITEM DESCRIPTIONS MENU OPTION DESCRIPTION 1 CAL Voltage 18 Displays the default DC drive voltage provided to the blower at each Air Fuel Valve position Items 1 6 The drive voltage adjusts the rotational speed of the blower to maximize combustion efficiency 2 CAL Voltage 30 3 CAL Voltage 40 4 CAL Voltage 50 5 CAL Voltage 70 6 C...

Page 87: ...bled or Disabled 8 Outlet Tmp Dsply Enabled or Disabled 9 Inlet Tmp Dsply Enabled or Disabled 10 Valv Pos Out Dsp Enabled or Disabled 11 Exhaust Tmp Dsp Enabled or Disabled 12 Exhaust Safety 13 Flue Material 14 Exhst Fault Temp 15 Exhst Module Temp 16 Exhst Warn Temp 17 Exhst Tmp VP Adj 18 Exhst Adj Rate 19 VP Change Rate 20 VP Up Rate Allows adjustment of the Valve Position Fire Rate increase rat...

Page 88: ... or Disabled When Enabled Breakpoints can be viewed and or changed 37 Stop Level Allows the Stop Level to be set to a valve position ranging from 0 to the presently set Start Level 38 Start Level Allows the Start Level to be set to a valve position ranging from the presently set Stop Level to a maximum of 40 SKIP FEATURE Items 39 41 embody a feature that allows the user to define a Fire Zone the C...

Page 89: ...50 Inlet Wtr Offset Range 20 to 20 either ºF or C 51 Outlet Wtr Offset Range 20 to 20 either ºF or C 52 24 hr Max Cycles 53 24 hr Max Ovrtemp 54 0 10v Out Test 56 Spark Monitor Enables or disables the Spark Monitor function which displays the AC current on the input of the Ignition Transformer 56 Min Spark Amps Allows the adjustment of the minimum spark current required at the spark transformer in...

Page 90: ...r OPERATION SERVICE MAINTENANCE GUIDE APPENDIX A BOILER MENU DESCRIPTIONS Page 90 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank ...

Page 91: ...time am or pm and date that the unit was disabled FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed durin...

Page 92: ... within 5 seconds after ignition FLAME LOSS DURING RUN The Flame signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The Exhaust Temperature has exceeded 200 F 93 3 C GAS PRESSURE FAULT The High Gas Pressure Limit switch is open or the Low Gas Pressure Limit switch is open HIGH WATER TEMPERATURE The ...

Page 93: ...ay Opn indicates sensor is open circuited PRG SWTCH CLOSED DURING IGNITION The Purge Position Limit switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 s...

Page 94: ...ATION SERVICE MAINTENANCE GUIDE APPENDIX B STARTUP STATUS AND DISPLAY MESSAGES Page 94 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank ...

Page 95: ...0 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 40 34 4 28 9 23 3 17 2 12 2 6 7 1 1 4 4 10 15 5 21 1 26 7 32 2 37 8 43 3 48 9 54 4 60 65 6 71 1 76 7 82 2 87 8 93 3 98 9 104 4 110 115 6 121 1 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 1337 7 13...

Page 96: ...ERATION SERVICE MAINTENANCE GUIDE APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Page 96 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank ...

Page 97: ... Check with combustion calibration test equipment See sections 4 2 of the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 and section 4 5 of this guide Flue vent stack or intake air duct Monthly Operator Visually inspection condition and check for obstructions Pilot Burner Weekly Operator See section 5 2 of this guide Air Fuel Valve position Weekly Operator Check position of ind...

Page 98: ...of the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 Air Fuel Valve purge position switch Annual Service Technician See section 5 10 of the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 Air Fuel Valve ignition position switch Annual Service Technician See section 5 11 of the Benchmark 5000 6000 Installation and Startup Guide OMM 0123 GF 207 Safety valves A...

Page 99: ... 170 5 20 6 83 94 105 116 127 138 149 160 171 182 10 23 3 86 98 110 122 134 146 158 170 182 194 15 26 1 89 102 115 128 141 154 167 180 193 206 20 28 9 92 106 120 134 148 162 176 190 204 218 Header Temperature for a Building Reference Temperature 60 F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 60 15 6 60 60 60 60 60 60 60 60 60 60 55 12 8 63 64 65 66 67 68 69 70 71 72 50 10 0 ...

Page 100: ...9 0 17 8 104 117 130 143 156 169 182 195 208 5 20 6 107 121 135 149 163 177 191 205 219 10 23 3 110 125 140 155 170 185 200 215 15 26 1 113 129 145 161 177 193 209 20 28 9 116 133 150 167 201 218 Header Temperature for a Building Reference Temperature 70 F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 70 21 1 70 70 70 70 70 70 70 70 70 70 65 18 3 73 74 75 76 77 78 79 80 81 82 60...

Page 101: ...0 12 2 114 127 140 153 166 179 192 205 218 5 15 0 117 131 145 159 173 187 201 215 0 17 8 120 135 150 165 180 195 210 5 20 6 123 139 155 171 187 203 219 10 23 3 126 143 160 177 194 211 15 26 1 129 147 165 183 201 219 Header Temperature for a Building Reference Temperature 80 F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 80 26 7 80 80 80 80 80 80 80 80 80 80 75 23 9 83 84 85 86 ...

Page 102: ...8 110 112 114 75 23 9 99 102 105 108 111 114 117 120 123 126 70 21 1 102 106 110 114 118 122 126 130 134 138 65 18 3 105 110 115 120 125 130 135 140 145 150 60 15 6 108 114 120 126 132 138 144 150 156 162 55 12 8 111 118 125 132 139 146 153 160 167 174 50 10 0 114 122 130 138 146 154 162 170 178 186 45 7 2 117 126 135 144 153 162 171 180 189 198 40 4 4 120 130 140 150 160 170 180 190 200 210 35 1 ...

Page 103: ...t 55 1 63111 HARNESS CONTROL 56 1 63004 HARNESS 460V TRANSFORMER 23 1 58084 IGNITOR ROD Replacement Kit 57 1 63126 BLOWER CONTROL HARNESS 58 2 69169 JUMPER BAR DIN TERMINALS 25 1 29700 IGNITOR ASSEMBLY 59 1 63121 HARNESS 12V POWER SOURCE 26 2 59192 PILOT FLAME DETECTOR 60 1 63122 GROUND CABLE 12 27 1 59198 TURNBUCKEL 61 1 69186 1 C MORE CONTROLLER 62 1 65085 IGNITION TRANSFORMER BURNER AIR FUEL VA...

Page 104: ...ET BACK PANEL 88 1 69161 2 DIN RAIL 113 1 74039 BENCHMARK LABEL 89 1 61034 SPARK MONITOR 114 2 33148 BRACE DIAGONAL 90 1 63125 1 GAS TRAIN HARNESS 7 SEC IGNITION 115 1 25088 FRONT FRAME ASSEMBLY 91 1 38035 PANEL COVER I O BOX HOSE INSULATION 92 1 38036 POWER PANEL COVER 119 1 80084 INSULATION UPPER 120 2 80098 INSULATION LOWER 94 1 63035 1 DUAL FUEL SELECTION SWITCH 121 1 97005 5 TUBE FLEXIBLE GAS...

Page 105: ...0 Oritani Dr Blauvelt NY 10913 Page 105 of 136 GF 208 Ph 800 526 0288 05 02 2017 FRONT REAR RIGHT SIDE VIEW CROSS SECTION AERCO International Inc Blauvelt NY 10913 Benchmark 5000 5000DF 6000 6000DF Part List 02 02 2017 Whole Boiler P N 28500 TAB BMK 6000 28657 TAB BMK 5000 Sheet 3 of 7 DUAL FUEL ONLY LEFT SIDE VIEW REAR VIEW ...

Page 106: ... 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 NOTE A complete Air Fuel Valve Blower and Burner part list is shown on pages below AERCO International Inc Blauvelt NY 10913 Benchmark 5000 5000DF 6000 6000DF Part List 02 02 2017 Whole Boiler P N 28500 TAB BMK 6000 28657 TAB BMK 5000 Sheet 4 of 7 ...

Page 107: ...GS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 107 of 136 GF 208 Ph 800 526 0288 05 02 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 5000 5000DF 6000 6000DF Part List 02 02 2017 Whole Boiler P N 28500 TAB BMK 6000 28657 TAB BMK 5000 Sheet 5 of 7 ...

Page 108: ...tani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 REAR FRONT OVERHEAD VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 5000 5000DF 6000 6000DF Part List 02 02 2017 Whole Boiler P N 28500 TAB BMK 6000 28657 TAB BMK 5000 Sheet 6 of 7 DOUBLE BLOCK BLEED VENT LINE P N 22219 FRONT VIEW DUAL FUEL MODEL SHOWN 7 ...

Page 109: ...O International Inc 100 Oritani Dr Blauvelt NY 10913 Page 109 of 136 GF 208 Ph 800 526 0288 05 02 2017 RELAY BOARD POWER I O BOX P N 24353 3 AERCO International Inc Blauvelt NY 10913 Benchmark 5000 5000DF 6000 6000DF Part List 02 02 2017 Whole Boiler P N 28500 TAB BMK 6000 28657 TAB BMK 5000 Sheet 7 of 7 ...

Page 110: ...E BALL 2 FULL PORT 20 1 24384 MAXITROL REGULATOR W 2 6 SPRING 4 1 99015 DAMPING ORIFICE SSOV 21 2 95030 FLANGE SSOV 2 NPT 7 4 12951 2 BUSHING CONTROL BOX 22 2 60020 SWITCH GAS PRESSURE 2 20 W C 10 3 9 22 PIPE PLUG 1 4 NPT STEEL 26 1 124138 ACTUATOR SSOV 12 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 27 1 99017 SNUBBER PRESSURE 1 4 14 2 124866 SOLENOID VALVE 1 4 NPT 34 1 97087 20 FLEX HOSE 20 18 1 97005 ...

Page 111: ... 0288 05 02 2017 Benchmark 5000 DF 6000 DF Gas Train P N 22187 Item Qty Part Description 1 1 22185 DUAL FUEL GAS TRAIN NATURAL GAS 2 1 22186 DUAL FUEL GAS TRAIN PROPANE 3 1 970087 26 FLEXIBLE GAS TUBE 26 AERCO International Inc Blauvelt NY 10913 Benchmark 5000 DF 6000 DF Gas Train 01 16 2017 P N 22187 rev D Sheet 1 of 1 2 1 2 1 NATURAL GAS GAS TRAIN P N 22185 PROPANE GAS TRAIN P N 22186 3 ...

Page 112: ...BALL 2 FULL PORT 22 2 95030 FLANGE SSOV 2 NPT 4 1 99015 DAMPING ORIFICE SSOV 24 1 60020 SWITCH GAS PRESSURE 2 20 W C 7 4 12951 2 BUSHING CONTROL BOX 29 1 124138 ACTUATOR SSOV 10 3 9 22 PIPE PLUG 1 4 NPT STEEL 30 1 99017 SNUBBER PRESSURE 1 4 12 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 34 1 97087 20 FLEX HOSE 20 14 2 124866 SOLENOID VALVE 1 4 NPT 35 1 60032 SWITCH GAS PRESSURE 2 20 W C 18 1 64048 ACTUA...

Page 113: ...DAMPING ORIFICE SSOV 19 1 124137 VALVE SSOV DOUBLE BODY 1 1 2 NPT 4 4 12951 2 BUSHING CONTROL BOX 22 1 124138 ACTUATOR SSOV 6 4 9 22 PIPE PLUG 1 4 NPT STEEL 25 1 99017 SNUBBER PRESSURE 1 4 8 2 124866 SOLENOID VALVE 1 4 NPT 29 1 97087 20 FLEX HOSE 20 12 1 24384 MAXITROL REGULATOR W 2 6 SPRING 30 1 60032 SWITCH GAS PRESSURE 2 20 W C 14 2 95029 FLANGE SSOV 1 1 2 NPT 31 1 92134 1 4 NPT MXF BRASS BALL ...

Page 114: ...OF 4 1 See Table BLOWER 15 1 61002 5 BMK 6000 BLOCKED INLET SWITCH 8 0 W C 5 2 59192 OBSERVATION PORT 61002 23 BMK 5000 BLOCKED INLET SWITCH 3 9 W C 6 1 59140 SIGHT GLASS 1 16 1 65150 FLAME ROD ASSY 7 1 24352 BMK 6000 A F VALVE ASSY 19 1 93367 SNUBBER FAN PROVING SWITCH 24496 BMK 5000 A F VALVE ASSY 20 3 9 21 PLUG HEX HEAD 1 8 NPT 8 13 56004 3 8 16 NUT FLANGED 22 1 61024 AIR INLET TEMPERATURE SENS...

Page 115: ...VICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 115 of 136 GF 208 Ph 800 526 0288 05 02 2017 Appendix G WIRING DIAGRAMS Wiring Diagram 68043 rev D Sheet 1 of 2 ...

Page 116: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 116 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Wiring Diagram 68043 rev D Sheet 2 of 2 ...

Page 117: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 117 of 136 GF 208 Ph 800 526 0288 05 02 2017 Wiring Diagram 68048 rev D Sheet 1 of 2 ...

Page 118: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 118 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Wiring Diagram 68048 rev D Sheet 2 of 2 ...

Page 119: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 119 of 136 GF 208 Ph 800 526 0288 05 02 2017 Wiring Diagram 68052 rev C Sheet 1 of 2 ...

Page 120: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 120 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Wiring Diagram 68052 rev C Sheet 2 of 2 ...

Page 121: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 121 of 136 GF 208 Ph 800 526 0288 05 02 2017 Wiring Diagram 68053 rev C Sheet 1 of 2 ...

Page 122: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 122 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Wiring Diagram 68053 rev C Sheet 2 of 2 ...

Page 123: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 123 of 136 GF 208 Ph 800 526 0288 05 02 2017 Wiring Diagram 68076 rev C Sheet 1 of 2 ...

Page 124: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 124 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Wiring Diagram 68076 rev C Sheet 2 of 2 ...

Page 125: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 125 of 136 GF 208 Ph 800 526 0288 05 02 2017 Wiring Diagram 68077 rev B Sheet 1 of 2 ...

Page 126: ... OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 126 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Wiring Diagram 68077 rev B Sheet 2 of 2 ...

Page 127: ...IRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 127 of 136 GF 208 Ph 800 526 0288 05 02 2017 BMK 5000 6000 STANDARD FUEL MODEL WIRING DIAGRAMS Standard BMK 5000 6000 Drawing Number 22222 rev B Gas Train Wiring Diagram Sheet 1 of 1 ...

Page 128: ...ON SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 128 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Drawing Number 63035 2 rev B Duel Fuel Selector Switch ...

Page 129: ...E MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS OMM 0124_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 129 of 136 GF 208 Ph 800 526 0288 05 02 2017 Gas Train Wiring Diagrams 22185 rev C Natural Gas and 22186 rev C Propane ...

Page 130: ...oiler OPERATION SERVICE MAINTENANCE GUIDE APPENDIX G WIRING DIAGRAMS Page 130 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 This page intentionally blank ...

Page 131: ... H 1 Benchmark Series Controller Exploded View ENCLOSURE P N 124951 POWER SUPPLY BOARD P N 124362 IGNITION STEPPER BOARD P N 124361 FISH PAPER INSULATOR P N 124960 V F D DISPLAY MODULE P N 124527 FRONT FACE PLATE BENCHMARK P N 124949 VERTICAL OVERLAY BENCHMARK P N 124718 PUSH BUTTON SWITCHES P N 124954 ROCKER SWITCH P N 124947 GREEN LED P N 124948 DISPLAY BOARD P N 124365 PMC BOARD P N 124364 LOW ...

Page 132: ...lt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 Figure H 2 Benchmark Control Panel Rear View SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX GAS TRAIN HARNESS CONNECTOR 9 PIN SHELL HARNESS CONNECTOR 19 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX ...

Page 133: ...RGENCY SPARE PARTS DESCRIPTION PART NUMBER Actuator Replacement Kit SSOV w o P O C Switch Kit 27086 2 Actuator Replacement Kit SSOV w Regulator POC Switch Damping Orifice 64106 Pilot Regulator w 2 6 Spring 24384 Pilot Solenoid Valve 1 4 NPT 124866 Temperature Switch Manual Reset 123552 TABLE I 2 RECOMMENDED SPARE PARTS FOR MAINTENANCE DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 11 24 mont...

Page 134: ...E Instructions 1 Select a suitable storage site Level well drained firm surface in clean dry and warm location Minimum temperature of 50 F 10 C Isolated from possibility of physical damage from construction vehicles erection equipment etc Accessible for periodical inspection and maintenance 2 The blower should be supported under each corner of its base to allow it to breath Supports 2 x 4 s timber...

Page 135: ... in insulation resistance b DO NOT lubricate the motor bearings during storage Motor bearings are packed with grease at the factory c If the storage location is damp or humid the motor windings must be protected from moisture This can be done by applying power to the motor s space heaters IF AVAILABLE while the motor is in storage If the motor does not have space heaters storing it in a damp or hu...

Page 136: ...TENANCE GUIDE CHANGE LOG Page 136 of 136 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0124_0A 05 03 2017 Ph 800 526 0288 GF 208 AERCO International Inc 2017 CHANGE LOG DATE DESCRIPTION CHANGED BY 05 03 2017 Rev A Initial release ...

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Aerco Benchmark BMK 5000, Operation, Service And Maintenance Manual

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