Benchmark 5000-6000 Operation-Service-Maintenance

Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
GF-208-I
USER MANUAL (2 of 2)
OPERATION, SERVICE, and MAINTENANCE GUIDE
®
Natural Gas Fired Modulating and Condensing Heating Boilers
5000 and 6000 MBH Boilers
This Guide Applies to Models:
• BMK 5000
• BMK 6000
This manual applies to China low
pressure (0.9 bar) applications
only
See also:
Benchmark 5000 – 6000
Installation and Startup GuideINTERNATIONAL
OMM-0129 (GF-207-I)
Applies to Serial Numbers:
N-17-0850 and above
China Patent No. ZL 201280040168.4
Latest Update: 1/30/2018
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 1 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
CONTENTS
TABLE OF CONTENTS
FOREWORD ......................................................................................................5
SECTION 1: SAFETY PRECAUTIONS ...................................................................9
1.1 WARNINGS & CAUTIONS ..................................................................................................................... 9
1.2 EMERGENCY SHUTDOWN ................................................................................................................. 10
1.3 PROLONGED SHUTDOWN ................................................................................................................. 10
SECTION 2: OPERATION ................................................................................. 11
2.1 INTRODUCTION................................................................................................................................... 11
2.2 C-MORE CONTROLLER DESCRIPTION ............................................................................................ 12
2.3 C-MORE CONTROLLER MENUS ........................................................................................................ 15
2.3.1 Menu Navigation and Processing Procedure ..................................................................................................15
2.4 OPERATING MENU ............................................................................................................................. 17
2.5 SETUP MENU ....................................................................................................................................... 18
2.6 CONFIGURATION MENU .................................................................................................................... 19
2.7 TUNING MENU ..................................................................................................................................... 22
2.8 COMBUSTION CAL MENU .................................................................................................................. 23
2.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU ....................................................................... 24
2.10 CALIBRATION MENU......................................................................................................................... 28
SECTION 3: MODES OF OPERATION ............................................................... 31
3.1 INDOOR/OUTDOOR RESET MODE ................................................................................................... 31
3.1.1 Reset Ratio ......................................................................................................................................................31
3.1.2 Building Reference Temperature ....................................................................................................................31
3.1.3 Outdoor Air Temperature Sensor Installation ................................................................................................31
3.1.4 Indoor/Outdoor Startup .................................................................................................................................32
3.2 CONSTANT SETPOINT MODE ........................................................................................................... 32
3.2.1 Setting the Setpoint ........................................................................................................................................33
3.3 REMOTE SETPOINT MODES ............................................................................................................. 33
3.3.1 Remote Setpoint Field Wiring .........................................................................................................................34
3.3.2 Remote Setpoint Startup ................................................................................................................................34
3.4 DIRECT DRIVE MODES....................................................................................................................... 34
3.4.1 Direct Drive Field Wiring .................................................................................................................................35
3.4.2 Direct Drive Startup ........................................................................................................................................35
3.5 AERCO CONTROL SYSTEM (ACS) .................................................................................................... 36
3.5.1 ACS External Field Wiring................................................................................................................................36
3.5.2 ACS Setup and Startup ....................................................................................................................................36
3.6 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 37
3.6.1 Combination Control System Field Wiring ......................................................................................................38
3.6.2 Combination Control System Setup and Startup ............................................................................................38
SECTION 4: MAINTENANCE ............................................................................ 39
4.1 MAINTENANCE SCHEDULE ............................................................................................................... 39
4.2 PILOT BURNER .................................................................................................................................... 40
4.3 MAIN FLAME DETECTOR ................................................................................................................... 42
4.4 O2 SENSOR .......................................................................................................................................... 42
4.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT ............................................. 45
Page 2 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
CONTENTS
4.5.1 Pilot Regulator Pressure Testing .....................................................................................................................45
4.5.2 Pilot Regulator Pressure Calibration ...............................................................................................................46
4.6 SAFETY DEVICE TESTING ................................................................................................................. 47
4.7 BURNER INSPECTION ........................................................................................................................ 48
4.8 REFRACTORY REMOVAL & REPLACEMENT ................................................................................... 51
4.8.1 Rear Refractory Removal and Replacement ...................................................................................................51
4.8.2 Front Refractory Replacement .......................................................................................................................54
4.9 CONDENSATE DRAIN TRAP .............................................................................................................. 55
4.10 AIR FILTER CLEANING AND REPLACEMENT ................................................................................ 56
4.11 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST............................................................. 57
4.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test .........................................................................58
4.11.2 Low Water Cutoff (LWCO) - Standard C-More Controller Test .....................................................................59
4.12 SHUTTING BOILER DOWN FOR EXTENDED PERIOD ................................................................... 59
4.13 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ....................... 60
4.14 GAS VALVE ACTUATOR REPLACEMENT ....................................................................................... 61
SECTION 5: TROUBLESHOOTING GUIDE ......................................................... 63
5.1 INTRODUCTION................................................................................................................................... 63
5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................... 77
APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ............................................. 83
TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS ......................................................................... 83
TABLE A-2: SETUP MENU ITEM DESCRIPTIONS ................................................................................... 85
TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS ................................................................ 86
TABLE A-4: TUNING MENU ITEM DESCRIPTIONS ................................................................................. 89
TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS ............................................. 90
TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS ....................................................................... 91
APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES .................................... 95
APPENDIX B1: STARTUP AND STATUS MESSAGES ............................................................................ 95
APPENDIX B2: FAULT MESSAGES .......................................................................................................... 96
APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART........................................ 99
APPENDIX D: RECOMMENDED PERIODIC TESTING .......................................... 101
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS ................................ 103
APPENDIX F: PART LISTS AND DRAWINGS ...................................................... 107
APPENDIX G: WIRING DIAGRAMS ................................................................... 117
BMK 5000/6000 WIRING DIAGRAMS ...................................................................................................... 119
APPENDIX H: C-MORE CONTROLLER VIEWS .................................................... 121
APPENDIX I: RECOMMENDED SPARES ........................................................... 123
APPENDIX J: LONG TERM STORAGE ............................................................... 125
APPENDIX J-I: LONG TERM BOILER STORAGE .................................................................................. 125
APPENDIX J-2: LONG TERM BLOWER STORAGE ............................................................................... 125
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 3 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
CONTENTS
(This page intentionally blank)
Page 4 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
FORWARD
FOREWORD
The AERCO Benchmark (BMK) 5000 MBH (1465 kW) and 6000 MBH (1758 kW) natural gas
fueled boilers are modulating and condensing units. They represent a true industry advance that
meets the needs of today's energy and environmental concerns. Designed for application in any
closed loop hydronic system, their modulating capability relates energy input directly to
fluctuating system loads. The maximum turn down ratio for the BMK 5000 and 6000 is 15:1.
These Benchmark models provide extremely high efficiency, which makes them ideally suited
for modern low temperature, as well as conventional heating systems.
IMPORTANT!
Unless otherwise specified, all descriptions provided in this document apply to Benchmark
Series boilers.
The Benchmark 5000 and 6000 operate within the following input and output ranges:
Boiler Intake and Output Ranges
INPUT RANGE (BTU/HR.)
MODEL
MINIMUM
MAXIMUM
OUTPUT RANGE (BTU/HR.)
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 and operated in accordance with this Instruction Manual, these boilers comply
with the NOx emission standards outlined in: South Coast Air Quality Management District
(SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the BMK 1500 and BMK 2000 boilers offer
the maximum venting flexibility with minimum installation space requirements. These boilers are
Category II and IV, positive pressure appliances. Single and/or multiple breeched units are
capable of operation in the following vent configurations:
•
Room Combustion Air:
o
o
•
Vertical Discharge
Horizontal Discharge
Ducted Combustion Air:
o
o
Vertical Discharge
Horizontal Discharge
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 5 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
FORWARD
AERCO Technical Terminology
TERMINOLOGY
MEANING
A (Amp)
Ampere
ACS
AERCO Control System, AERCO’s boiler management systems
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ANSI
American National Standards Institute,
ASME
American Society of Mechanical Engineers
AUX
Auxiliary
BAS
Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate
Symbol rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BMK (Benchmark)
AERCO’s Benchmark series boilers
BMS or BMS II
AERCO 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
Benchmark and Innovation product lines.
CFH
Cubic Feet per Hour (1 CFH = 0.028 m3/hr)
CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
CNTL
Control
CPU
Central Processing Unit
DIP
Dual In-Line Package, a type of switch
ECU
Electronic Control Unit (O2 sensor)
EMS
Energy Management System; often used interchangeably with BAS
FM
Factory Mutual. Used to define boiler gas trains.
GF-xxxx
Gas Fired (an AERCO document numbering system)
GND
Ground
HDR
Header
Page 6 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
FORWARD
AERCO Technical Terminology
TERMINOLOGY
MEANING
Hex
Hexadecimal Number (0 – 9, A – F)
HP
Horse Power
HX
Heat Exchanger
Hz
Hertz (Cycles Per Second)
I.D.
Inside Diameter
IGN
Ignition
IGST Board
Ignition/Stepper Board, contained in C-More Controller
INTLK (INTL’K)
Interlock
I/O
Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark and Innovation
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
MIN (Min)
1000 BTUs per Hour
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 Oxide
NPT
National Pipe Thread
O2
Oxygen
O.D.
Outside Diameter
OMM & O&M
Operation and Maintenance Manual
onAER
AERCO’s on-line remote monitoring system
PCB
Printed Circuit Board
PMC Board
Primary Micro-Controller (PMC) board, contained in the C-More
P/N
Part Number
POC
PPM
Proof of Closure
Parts per Million
PSI
Pounds per Square Inch (1 PSI = 6.89 kPa)
PTP
Point-to-Point (usually over RS232 networks)
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 7 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
FORWARD
AERCO Technical Terminology
TERMINOLOGY
MEANING
P&T
Pressure and Temperature
ProtoNode
Hardware interface between BAS and a boiler or water heater
PVC
Poly Vinyl Chloride, a common synthetic plastic
PWM
Pulse Width Modulation
REF (Ref)
Reference
RES.
Resistive
RS232
(or EIA-232)
A standard for serial, full-duplex (FDX) transmission of data based
on the RS232 Standard
RS422
(or EIA-422)
A standard for serial, full-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 multi-drop network
in order to prevent reflections that may cause invalid data in the
communication
Tip-N-Tell
A device that indicates if a package was tipped during shipping
UL
A business that tests and validates products
VAC
Volts, Alternating Current
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, also Variable Frequency Drive
W
Watt
W.C.
Water Column, a unit of pressure (1 W.C. = 249 Pa)
µA
Micro amp (1 millionth of an ampere)
Page 8 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 1: SAFETY PRECAUTIONS
SECTION 1: SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
IMPORTANT!
This Guide is an integral part of the product and must be maintained in 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 to zero before performing maintenance.
Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
The exhaust vent pipe of the unit may operate under a positive pressure and therefore
must be completely sealed to prevent leakage of combustion products into living spaces.
Electrical voltages of 120, 380 and 24 may be used in this equipment. Therefore the
cover on the unit’s power box (located behind the front panel door) must be installed at all
times, except during maintenance and servicing.
A three-pole switch must be installed on the electrical supply line of the unit. The switch
must be installed in an easily accessible position to quickly and safely disconnect
electrical service. Do not affix switch to unit sheet metal enclosures.
CAUTION!
•
•
Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
DO NOT use this boiler if any part has been under water. Call a qualified service
technician to inspect and replace any part that has been under water.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 9 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 1: SAFETY PRECAUTIONS
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
NOTE:
The Installer must identify and indicate the location of the emergency shutdown manual gas
valve to operating personnel.
MANUAL GAS SHUT-OFF VALVE
VALVE
OPEN
VALVE
CLOSED
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
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 end of this manual.
After prolonged shutdown, it is recommended that the procedures in Section 4: Initial Startup
and Section 5: Safety Device Testing of the Benchmark 5000 – 6000 Installation and Startup
Guide-INTERNATIONAL OMM-0129 (GF-207-I) be performed to verify that all system-operating
parameters are correct.
Page 10 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
SECTION 2: OPERATION
2.1 INTRODUCTION
The information in this section provides a guide to the operation of the Benchmark Boiler using
the C-More Controller mounted on the front of the unit. It is imperative that the initial startup of
this unit be performed by factory trained personnel. Operation prior to initial 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, 380 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 DAMAGE THE UNIT AND MAY RESULT IN
INJURY TO PERSONNEL OR PROPERTY DAMAGE. THIS SITUATION WILL VOID
ANY WARRANTY.
CAUTION!
All of the installation procedures in Section 2 of the Benchmark 5000 – 6000 Installation and
Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I) must have been completed before
attempting to start the unit.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 11 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.2 C-MORE CONTROLLER DESCRIPTION
All Benchmark boilers utilize the C-More Controller’s front panel, 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.
2
1
3
4
12
5
11
6
10
7
8
9
Figure 2-1: C-More Controller Front View
Page 12 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-1: Controls, Indicators, and Displays (ref. Figure 2-1)
ITEM
CONTROL, INDICATOR
or DISPLAY
FUNCTION
LED STATUS INDICATORS
Four Status LEDs indicate the current operating status as follows:
COMM =
1
Lights when RS232 communication is occurring – see Item 4.
MANUAL =
Lights when the valve position (fire rate) is being controlled using the front
panel keypad. This mode of operation is for service technician use only.
REMOTE =
Lights when the unit is being controlled by an external signal from an Energy
Management System.
DEMAND =
Lights when there is a demand for heat.
OUTLET
TEMPERATURE
Display
3–Digit, 7–Segment LED display continuously displays the outlet
water temperature. The °F or °C LED next to the display lights to
indicate whether the displayed temperature is in degrees Fahrenheit
or degrees Celsius. The °F or °C blinks when operating in the
DEADBAND mode.
On a BST Manager, display 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 the RS232 Adaptor
Cable (P/N 124675).
5
FAULT Indicator
Red FAULT LED indicator lights when a boiler alarm condition
occurs. An alarm message will appear in the VFD.
6
CLEAR Key
Turns off the FAULT indicator and clears the alarm message if the
alarm is no longer valid. Lockout type alarms will be latched and
cannot be cleared by simply pressing this key. Troubleshooting
may be required to clear these types of alarms.
7
READY Indicator
Lights when ON/OFF switch is set to ON and when all Pre-Purge
conditions have been satisfied.
8
ON/OFF switch
Enables and disables boiler operation.
9
LOW WATER
LEVEL
TEST/RESET
switches
2
OMM-0130_0A
GF-208-I
•
•
•
•
Allows operator to test operation of the water level monitor.
Pressing TEST opens the water level probe circuit and
simulates a Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 13 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-1: Controls, Indicators, and Displays (ref. Figure 2-1)
ITEM
CONTROL, INDICATOR
or DISPLAY
FUNCTION
MENU KEYPAD
Six (6) keys which provide the following functions for the C-More Controller menus:
10
MENU
Steps through the main menu categories, shown in Figure 2-2, below. The
menu categories wrap around in the order shown.
BACK
Allows you to go back to the previous menu level without changing any
information. Continuously pressing this key will bring you back to the
default status display in the VFD. Also, this key allows you to go back to
the top of a main menu category.
▲
(UP)
Arrow
When in one of the main menu categories (Figure 2-2), pressing the ▲
arrow key will select the displayed menu category. If the CHANGE key was
pressed 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.
Permits a setting to be changed (edited). When the CHANGE key is
pressed, the displayed menu item will begin to flash. Pressing the ▲ or ▼
CHANGE
arrow key when the item is flashing will increment or decrement the
displayed setting.
ENTER
Saves the modified menu settings in memory.
flashing.
The display will stop
11
AUTO/MAN switch
This switch toggles the boiler between the AUTOMATIC and
MANUAL modes of operation. When in the MANUAL (MAN) mode,
the front panel controls are enabled and the MANUAL status LED
lights. Manual operation is for service only.
When in the AUTOMATIC (AUTO) mode, the MANUAL status LED
will be off and the front panel controls disabled.
12
VALVE POSITION
Bargraph
20 segment red LED bargraph continuously shows the Air/Fuel
Valve position in 5% increments from 0 to 100%
Page 14 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.3 C-MORE CONTROLLER MENUS
The C-More Controller incorporates an extensive menu structure which permits the operator to
set up, and configure the unit. The menu structure consists of five major menu categories which
are applicable to this manual. These categories are shown in Figure 2-2, below. Each of the
menus shown, contain options which permit operating parameters to be viewed or changed.
The menus are protected by password levels to prevent unauthorized use.
Prior to entering the correct password, the options contained in the Operation, Setup,
Configuration and Tuning menu categories can be viewed. However, with the exception of
Internal Setpoint Temperature (Configuration menu), none of the viewable menu options can be
changed.
Once the valid level 1 password (159) is entered, the options listed in the Setup, Configuration
and Tuning menus can be viewed and changed, if desired. The Combustion Cal menu is
protected by the level 2 password (6817); its settings are used to perform combustion
calibration prior to service use (see Section 4.4 in Benchmark 5000 – 6000 Installation and
Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I)).
2.3.1 Menu Navigation and Processing Procedure
Accessing and initiating each menu and option 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 C-More Controller will normally be in the Operating menu and the VFD will display the
current unit status. Pressing the ▲ or ▼ arrow key will display the other available data
items in the Operating menu.
2. Press the MENU key. The display will show the Setup menu, which is the next menu
category shown in Figure 2-2. This menu contains the Password option which must be
entered if other menu options will be changed.
3. Continue pressing the MENU key until the desired menu is displayed.
4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the
selected menu will be displayed.
5. Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.
Pressing the ▲ arrow key will display the available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence.
The menu options will wrap-around after the first or last available option is reached.
6. To change the value or setting of a displayed menu option, press the CHANGE key. The
displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the
available menu option choices for the option to be changed. The menu option choices do
not wrap around.
7. To select and store a changed menu item, press the ENTER key.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 15 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
* Boiler Sequencing
Technology
*
Boiler Sequencing Technology (BST) appears only if enabled. See Section 6 in the
Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF207-I) 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 error messages.
Page 16 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.4 OPERATING Menu
The Operating menu displays a number of key operating parameters for the unit. All items in this
menu except O2 Monitor (item 15) are “Read-Only” and cannot be changed. This menu can be
accessed without entering a password.
A full description of each item appears in Appendix A-1.
TABLE 2-2: OPERATING Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
1
Active Setpoint
40°F (4.4°C)
240°F (116°C)
2
Outlet Temp
30°F (-1.1°C)
240°F (116°C)
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)
6
Valve Position In
0%
100%
7
Valve Position Out
0%
100%
8
FFWD Temp
30°F (-1.1°C)
240°F (115.6°C)
9
Exhaust Temp
10
Flame Strength
11
Min Flame Str
12
O2 Monitor
13
Configuration Menu
Configuration Menu
Configuration Menu
Displays current exhaust temperature
0%
100%
Not Used
Enable
Disable
Oxygen Level
0%
21%
14
Ignition Time
0.00
10.00
15
SSOV Time to OPN
0.00
10.00
16
Air Pump Voltage
0.20 V
1.2 V
17
Run Cycles
0
999,999,999
18
Run Hours
0
999,999,999
OMM-0130_0A
GF-208-I
Appears Only If
Enabled in:
O2 Monitor = Enabled
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 17 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
19
Fault Log
0
19
20
Manual Valve Pos *
0
100
* NOTE
Manual Valve Pos does not appear in this menu unless you push the Auto/Man button on
the C-More Controller’s front face.
2.5 SETUP Menu
The Setup menu (Table 2-3) permits the operator to enter the unit password (159) which is
required to change the menu options. To prevent unauthorized use, the password will time-out
after 1 hour. Therefore, the correct password must be reentered when required. In addition to
permitting password entries, 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
Minimum
Maximum
0
9999
DEFAULT
1
Password
2
Language
3
Time
12:00 am
11:59 pm
4
Date
01/01/00
12/31/99
5
Unit of Temp
6
Comm Address
0
7
Baud Rate
2400, 4800, 9600, 19.2K
9600
8
onAER Mode
Ethernet or SD Card
Ethernet
9
Min Upload Timer
10
Unit Alpha
11
Unit Year
12
Unit Serial #
13
Software
Page 18 of 128
1/30/2018
0
English
English
Fahrenheit or Celsius
Fahrenheit
127
0
0
9,999 Sec
0
E, G, H, R, N or A
A
0
99
0
0
9999
0
Ver 0.00
Ver 9.99
Current software
version
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.6 CONFIGURATION Menu
The Configuration menu shown in Table 2-4 permits adjustment of the Internal Setpoint (Setpt)
temperature regardless of whether the valid password has been entered. Setpt is required for
operation in the CONSTANT SETPOINT mode. The remaining options in this menu require the
valid password to be entered, prior to changing existing entries. This menu contains a number
of other configuration settings which may or may not be displayed, depending on the current
operating mode setting.
NOTE:
The Configuration menu settings shown in Table 2-4 are Factory-Set in accordance with the
requirements specified for each individual order. Therefore, under normal operating
conditions, no changes will be required.
TABLE 2-4: CONFIGURATION Menu
MENU ITEM DISPLAY
1
Internal Setpt
2
Unit Type
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
40°F (4.4°C)
240°F (115.6°C)
DEFAULT
130°F (54.4°C)
BMK Blr Std, BMK Blr Std Dual,
BMK Blr LN, BMK Blr LN Dual
BMK Boiler LN
5000 MBH (1465 kW)
5000 MBH (1465 kW)
6000 MBH (1758 kW)
6000 MBH (1758 kW)
Natural Gas or Propane
Natural Gas
Constant Setpoint, Remote Setpoint,
Direct Drive, Combination,
Outdoor Reset
Constant Setpoint
Unit Size
3
4
(Only the unit sizes
available for the Unit
Type are displayed)
Fuel Type
5
Boiler Mode
6
Remote Signal
(If Mode = Remote
Setpoint, Direct Drive
or Combination)
7
Outdoor Sensor
8
* Bldg Ref Temp
(If Mode = Outdoor
Reset)
OMM-0130_0A
GF-208-I
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
PWM Input (Legacy BMS), Network
4 – 20 mA,
Enabled or Disabled
Disabled
40°F
(4.4°C)
230°F
(110°C)
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
1-5V
70°F
(21.1°C)
Page 19 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-4: CONFIGURATION Menu
MENU ITEM DISPLAY
9
* Reset Ratio
(If Mode = Outdoor
Reset)
10
* System Start Tmp
(If Outdoor Sensor =
Enabled)
11
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
DEFAULT
0.1
9.9
1.2
30°F
(-1.1°C)
100°F
(37.8°C)
60°F
(15.6°C)
Setpt Lo Limit
40°F (4.4°C)
Setpt Hi Limit
60°F (15.6°C)
12
Setpt Hi Limit
Setpt Lo Limit
210°F (98.9°C)
180°F (82.2°C)
13
Temp Hi Limit
40°F (4.4°C)
210°F (98.9°C)
195°F (90.6°C)
14
Max Valve Position
40%
100%
100%
15
Pump Delay Timer
0 min.
30 min.
0 min.
16
Aux Start On Dly
0 sec.
120 sec.
0 sec.
17
Failsafe Mode
Shutdown or Constant Setpt
Constant Setpt
Analog Output
Off, Setpoint, Outlet Temp, Valve Pos
4-20mA, valve Pos 0-10v
Valve Pos 0-10v
18
(Do NOT change)
19
Low Fire Timer
20
Setpt Limiting
21
Setpt Limit Band
0°F (0°C)
10°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)
Page 20 of 128
1/30/2018
2 sec.
600 sec.
Enabled or Disabled
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
2 sec.
Disabled
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-4: CONFIGURATION Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
0°F (0°C)
25°F (13.75°C)
DEFAULT
26
Deadband Low
5°F (2.75°C)
27
IGST Version
28
IGN Time Setting
29
Slow Shutdown
30
Slow Sht Duration
31
Slow Sht Threshold
32
O2 Warnings
33
O2 Trim ID
34
Fixed ID
35
O2 Trim Key
36
O2 Trim Menu
Enabled or Disabled
Disabled
37
BST Menu
Enabled or Disabled
Disabled
Displays current IGST version
V2.02
Displays 4 sec. or 7 sec. depending on wiring harness installed
Enabled or Disabled
Disabled
0 sec.
9,999 sec.
60 sec.
40%
100%
60%
Enabled or Disabled
Disabled
Displays 4 digit AERtrim ID
Displays unit’s fixed 4 digit ID
Displays AERtrim 4 digit license key
*NOTE
The Bldg Ref Temp and Reset Ratio menu Items are only displayed when the Outdoor
Sensor menu item is set to Enabled.
CAUTION!
DO NOT change the Analog Output menu item from its default setting (Valve Position 010V).
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 21 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.7 TUNING Menu
The Tuning menu items in Table 2-5 are Factory set for each individual unit. Do not change
these menu entries unless specifically requested to do so by factory-trained personnel.
TABLE 2-5: TUNING Menu
MENU ITEM DISPLAY
1
Prop Band
2
Integral Gain
3
Derivative Time
4
Warmup Prop Band
5
Warmup Int Gain
6
7
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
DEFAULT
1°F (0.55°C)
120°F (66°C)
70°F (38.5°C)
0.00
2.00
1.00
0.0 min
2.00 min
0.0min
1°F (0.55°C)
120°F (66°C)
95 °F (52°C)
0.00
2.00
0.50
Warmup PID timer
0 sec.
240 sec.
20 sec.
Reset Defaults?
Yes, No, Are You Sure?
Page 22 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
No
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.8 COMBUSTION CAL Menu
The Combustion Cal (Calibration) menu is protected by the level 2 password (6817) which must
be entered to view or change the menu items shown in Table 2-6. These menu items are 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 4.4: Combustion Calibration of the Benchmark
5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I). The valve
positions (%) and default drive voltages are listed in Table 2-6.
TABLE 2-6: COMBUSTION CAL Menu
MENU ITEM DISPLAY
BENCHMARK 6000 *
BENCHMARK 5000 *
1
CAL Voltage 18%
Minimum
1.70
2
CAL Voltage 30%
1.90
2.50
2.00
3.0
5.0
3.80
3
CAL Voltage 40%
1.90
3.40
2.25
3.8
5.5
4.50
4
CAL Voltage 50%
2.20
3.50
2.70
3.8
5.3
4.30
5
CAL Voltage 70%
3.20
4.40
3.95
4.0
6.0
4.80
6
CAL Voltage 100%
7.20
10.00
8.00
6.7
9.0
7.70
7
SET Valve Position
0%
100%
Variable
0%
100%
Variable
8
Blower Output
9
Set Stdby Volt
10 Oxygen Level
OMM-0130_0A
GF-208-I
Maximum
2.70
Default
2.20
Minimum
1.9
Maximum
2.5
Default
2.05
Monitor Blower Output Voltage
0
4.00 V
0/2.00 V
0
4.00 V
0/2.00 V
0%
25%
Variable
0%
25%
Variable
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 23 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
2.9 BST (Boiler Sequencing Technology) Menu
The BST menu must be enabled in order to be displayed and accessed. The BST Menu item,
located at the end of the Configuration menu (item 37 in Table 2-4), must be se to Enabled.
The BST menu contains all of the items required to configure, operate and monitor the
functionality of the BST System. There are over 50 items in this menu, and selecting any
particular item from the list, for inspection or modification, could be time consuming. As a result,
the BST menu has been segmented into FIVE logical groups based on functionality.
The five Item groups are:
1.
2.
3.
4.
5.
BST Monitor Items
*BST SETUP MENU*
*OPERATE MENU*
*TEMP CTRL MENU*
*BST COMM MENU*
These displayed item groups are displayed in UPPER CASE letters, and are bounded by an
asterisk * in order to readily identify them within the item list.
The Items contained 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
AVAILABLE CHOICES OR LIMITS
MENU ITEM DISPLAY
1
Minimum
Off
BST Mode
Maximum
BST Client
BST Manager
DEFAULT
Off
2
BST Setpoint
BST Setpt Lo Limit
3
Header Temp
Read Only – current Header temperature in
°F
4
BST Fire Rate
0
100%
Fire rate %
5
BST Ave Fire Rate
0
100%
Avg Fire Rate %
6
BST Outdoor Temp
7
Units Available
0
8
Units Present
8
Units Ignited
0
8
Units firing
9
BST Valve State
0 (CLOSED)
1 (OPEN)
0
0
9
0
0 – 8 (see * NOTE below)
0
10
11
1 BST Comm Errors
8
1 BST Units 8
Page 24 of 128
1/30/2018
BST Setpt Hi Limit
Read Only – current outdoor temperature in
°F
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
130°F (54.4°C)
N/A
N/A
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-7: BST Menu
AVAILABLE CHOICES OR LIMITS
MENU ITEM DISPLAY
Minimum
Maximum
Disabled
Enabled
DEFAULT
Disabled
12
*BST SETUP MENU*
13
BST Setpoint Mode
14
BST Remote Signl
15
Head Temp Source
16
Mdbus Temp Units
Degrees C or Degrees F
17
Header Temp Addr
0
255
240
18
Header Temp Point
0
255
14
19
BST Outdoor Sens
Disabled
Enabled
Disabled
20
Outdr Tmp Source
Outdoor Temp
Network
Outdoor Temp
21
Outdoor Tmp Addr
0
255
240
22
Outdoor Tmp Pnt
0
255
215
Constant
Setpoint
4-20 mA/1-5
VDC
Remote
Setpoint
0-20 mA/0-5
VDC
Network
Outdoor
Reset
Constant Setpt
Network
Network
FFWD Temp
Yes
NOTE! A Modbus
temperature
transmitter must be
installed in
conjunction with this
feature.
FFWD Temp
Degrees C
23
BST Auto Mstr
24
BST Auto Timer
10 sec
120 sec
30 sec
25
Remote Intlk Use
Boiler Shutdown
System Shutdown
System Shutdown
26
One Boiler Mode
27
1 Blr Threshold
28
No
On-Outlet
Temp
Off
On-Avg
Temp
No
Off
10
35
25
Setpoint Setback
Disable
Enable
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)
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 25 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-7: BST Menu
AVAILABLE CHOICES OR LIMITS
MENU ITEM DISPLAY
Minimum
Maximum
DEFAULT
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 Override
39
Valve Off Delay
40
BST Sequencing
41
Select Lead Unit
0
127
0
42
Select Lag Unit
0
127
0
43
Lead/Lag Hours
25 hours
225 hours
72 hours
Off
Closed
Open
0
Run Hours
15 min
Unit Size
Select Lead
Off
1 min
Run Hours
44
*TEMP CTRL MENU*
Disabled
Enabled
Disabled
45
BST Temp Hi Limit
40°F (4.4°C)
210°F (98.9°C)
210°F (98.9°C)
46
BST Setpt Lo Limit
40°F (4.4°C)
BST Setpt HI Limit
60°F (15.5°C)
47
BST Setpt HI Limit
BST Setpt Lo Limit
220°F (104.4°C)
195°F (90.6°C)
48
BST Prop Band
1°F (-17.2°C)
120°F (48.9°C)
100°F (37.8°C)
49
BST Intgral Gain
0.00
2.00
0.50
50
BST Deriv Time
0.00 Min
2.00 Min
0.10 Min
51
BST Deadband Hi
0
25
1
52
BST Deadband Lo
0
25
1
53
Deadband En Time
0
120 Sec
30 Sec
54
BST FR Up Rate
1
120
20
55
BST Bldg Ref Tmp
40°F (4.4°C)
230°F (110°C)
70°F (21.1°C)
56
BST Reset Ratio
0.1
9.9
1.2
Page 26 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-7: BST Menu
AVAILABLE CHOICES OR LIMITS
MENU ITEM DISPLAY
Minimum
Maximum
DEFAULT
57
System Start Tmp
30°F (-1.1°C)
120°F (48.9°C)
60°F (15.6°C)
58
*BST COMM MENU*
Disabled
Enabled
Disabled
59
Comm Address
0
127
0
60
BST Min Addr
1
128
1
61
BST Max Addr
1
128
8
62
SSD Address
0
250
247
63
SSD Poll Control
0
1000
0
64
Err Threshold
1
9
5
65
SSD Temp Format
Degrees
Points
Degrees
66
BST Upld Timer
0
9999 sec
0
* NOTE:
The 1 BST Units 8 menu item shows the current status for each unit controlled by BST, up
to a maximum of 8 units. The possible characters displayed are:
- = Off Line
* = Not Available (fault, etc.)
0 = Off
1 = On,
A = Lead On
a = Lead Off
B = Lag On
b = Lag Off
S = Setpoint Limit Active
The following example shows the status of 5 units being controlled by BST where:
Unit 1 & 3 are On
Unit 2 is Off
Unit 4 is Not Available
Unit 5 is Lead On
Unit 6 is Lag Off
1 BST Units 8
1
OMM-0130_0A
GF-208-I
0
1
*
A
b
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 27 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
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
Minimum
Maximum
DEFAULT
1
Stepper Fbk
2
Purge Timer
5 sec.
60 sec
Depends on unit type/size
3
Post Purge Timer
0 sec.
60 sec.
0 sec.
4
IGN Position
5%
60%
Depends on unit type/size
5
Ign Pos Hold Tmr
0 sec.
60 sec.
0 sec.
6
FFWD Temp Disply
Enabled or Disabled
Disabled
7
Outlet Tmp Dsply
Enabled or Disabled
Disabled
8
Inlet Tmp Dsply
Enabled or Disabled
Disabled
9
Valv Pos Out Dsp
Enabled or Disabled
Enabled
10
Exhaust Tmp Dsp
Enabled or Disabled
Disabled
11
Exhaust Safety
Enabled or Disabled
Enabled
12
Flue Material
13
Cal 0%, Verify 50%, Cal 100%
Cal 0%
PVC
Stainless
PVC
Exhst Fault Temp
100 °F
500 °F
200 °F
14
Exhst Module Temp
100 °F
500 °F
190 °F
15
Exhst Warn Temp
100 °F
500 °F
180 °F
16
Exhst Tmp VP Adj
0
10
5
17
Exhst Adj Rate
1
600
30
18
VP Change Rate
5
600
25
19
VP Up Rate
0.5
60.0
Depends on unit type/size
20
VP Down Rate
0.5
60.0
Depends on unit type/size
21
Purge Blwr Offst
-1.0
8.0
Depends on unit type/size
22
4-20mA Purge Pct
60%
100%
70%
Page 28 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-8: Calibration Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
DEFAULT
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
Gas Press Reset
Automatic or Manual
Manual
33
Min Off Time
34
0 Min
15 Min
0 Min
Stop Level
0%
Start Level
16
35
Start Level
Stop Level
40%
20
36
Skip Range Cntr
10
95
40
37
Skip Range Span
0
3
0
38
Skip Speed
0.5
2.0
0.5
39
O2 Gain
0.500
1.500
1.024
40
O2 Offset
-24.0
+2.0
0
41
O2 Sensor
42
Cal Temp Sensors
43
FFWD Temp Offset
-20
+20
0
44
Exhst Tmp Offset
-20
+20
0
45
Outdr Air Offset
-20
+20
0
46
Inlet Air Offset
-20
+20
0
47
Inlet Wtr Offset
-20
+20
0
OMM-0130_0A
GF-208-I
Enabled or Disabled
Depends on unit type/size
Off or Start
Off
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 29 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 2: OPERATION
TABLE 2-8: Calibration Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMITS
Minimum
Maximum
DEFAULT
48
Outlet Wtr Offset
-20
+20
0
49
24 hr Max Cycles
0
9999
0
50
24 hr Max Ovrtemp
0
9999
0
51
0-10v Out Test
0.0
10.0
0
52
Spark Monitor
53
Min Spark Amps
0 Amps
2.5 Amps
0.1 Amps
54
Max Spark Amps
0 Amps
2.5 Amps
0.4 Amps
Page 30 of 128
1/30/2018
Enabled or Disabled
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Depends on unit type/size
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
SECTION 3: MODES OF OPERATION
Benchmark boilers are capable of being operated in any one of six different modes. The
following sections provide descriptions of each of these operating modes. Each boiler is shipped
from the factory tested and configured for the ordered mode of operation. All temperature
related parameters are at their factory default values, which work well in most applications.
However, it may be necessary to change certain parameters to customize the unit to the system
environment. After reading this section, parameters can be customized to suit the needs of the
specific application. A complete listing and descriptions of the temperature related parameters
are included in Appendix A, while factory defaults are listed in Sections 2.4 – 2.10, above.
3.1 INDOOR/OUTDOOR RESET MODE
This mode of operation is based on outside air temperatures. As the outside air temperature
decreases, the supply header temperature will increase and vice versa. For this mode, it is
necessary to install an outside air sensor as well as select a building reference temperature and
a reset ratio.
3.1.1 Reset Ratio
Reset ratio is an adjustable number from 0.1 to 9.9. Once adjusted, the 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 temperature
that the system references to begin increasing its temperature. For instance, if a reset ratio of
1.6 is used, and we select a building reference temperature of 70°F (21.1°C), then at an outside
temperature of 69°F (20.6°C), the supply header temperature will increase by 1.6° to 71.6°F
(0.9°C to 22°C).
3.1.3 Outdoor Air Temperature Sensor Installation
The outdoor air temperature sensor must be mounted on the North side of the building in an
area where the average outside air temperature is expected. The sensor must be shielded from
the sun's direct rays, as well as direct impingement by the elements. If a cover or shield is used,
it must allow free air circulation. The sensor may be mounted up to 200 feet (61m) from the
unit. Sensor connections are made at the Input/Output (I/O) Box on the front of the boiler.
Connections are made at the terminals labeled OUTDOOR AIR IN and AIR SENSOR COM
inside the I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is
provided on the cover of the I/O Box. Refer to Section 2.10: AC Electrical Power Wiring of the
Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207I) for additional information on wiring..
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 31 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
3.1.4 Indoor/Outdoor Startup
Startup in the INDOOR/OUTDOOR RESET mode is accomplished as follows:
NOTE:
A design engineer typically provides design outdoor air temperature and supply header
temperature data.
Indoor / Outdoor Setup Instructions
1. Refer to the Indoor/Outdoor reset ratio charts in Appendix E.
2. Choose the chart corresponding to the desired Building Reference Temperature.
3. Go down the left column of the chart to the coldest design outdoor air temperature
expected in your area.
4. Once the design outdoor air temperature is chosen, go across the chart to the desired
supply header temperature for the design temperature chosen in step 3.
5. Next, go up that column to the RESET RATIO row to find the corresponding reset ratio.
6. Access the Configuration menu and scroll through it until the display shows BLDG REF
TEMP (Building Reference Temperature). If necessary, refer to Section 2.3, above, 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 ▼ arrow keys to select the Reset Ratio determined in step 5.
13. Press ENTER to save the change.
3.2 CONSTANT SETPOINT MODE
The CONSTANT SETPOINT mode is used when a fixed header temperature is desired.
Common uses of this mode of operation include water source heat pump loops, and indirect
heat exchangers for potable hot water systems or processes.
No external sensors are required to operate in this mode. While it is necessary to set the
desired setpoint temperature, it is not necessary to change any other temperature-related
functions. The unit is factory preset with settings that work well in most applications. Prior to
changing any temperature-related parameters, other than the setpoint, it is suggested that an
AERCO representative be contacted. For descriptions of temperature-related functions, see
Appendix A; their factory defaults are included in Sections 2.4 – 2.8.
Page 32 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
3.2.1 Setting the Setpoint
The setpoint temperature of the unit is adjustable from 40°F to 240°F (4.4°C to 115.6°C). To set
the unit for operation in the CONSTANT SETPOINT mode, the following menu settings must be
made in the Configuration menu:
TABLE 3-1: Constant Setpoint Mode Settings
MENU OPTION
SETTING
Boiler Mode
Constant Setpoint
Internal Setpt
Select desired setpoint using ▲ and ▼ arrow
keys (40°F to 240°F, 4.4°C to 115.6°C)
Refer to Section 2.3, above, for detailed instructions on changing C-More Controller menu
options.
3.3 REMOTE SETPOINT MODES
The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or
Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage
signal within the following ranges:
•
4-20 mA/1-5 VDC
•
0-20 mA/0-5 VDC
The factory 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 current and voltage signals described above, the REMOTE SETPOINT mode
can also driven by a RS-485 Modbus Network signal from an EMS or BAS.
The REMOTE SETPOINT modes of operation can be used to drive single as well as multiple
units.
NOTE:
If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch
adjustment must be made on the PMC Board located in the C-More Controller assembly.
Contact your local AERCO representative for details.
In order to enable the REMOTE SETPOINT mode, the following menu setting must be made in
the Configuration menu:
TABLE 3-2: Remote Setpoint Mode Settings
MENU OPTION
SETTING
Boiler Mode
Remote Setpoint
Remote Signal
4-20mA/1-5V, 0-20mA/0-5V, or Network
Refer to Section 2.3 for detailed instructions on changing C-More Controller menu options.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 33 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be
entered in the Setup menu. Refer to Modbus Communication Manual GF-114 for additional
information.
While it is possible to change the settings of temperature related functions, the unit is factory
preset with settings that work well in most applications. It is suggested that an AERCO
representative be contacted, prior to changing any temperature related function settings. For
descriptions of temperature-related functions, see Appendix A; their factory defaults are
included in Sections 2.4 – 2.8.
3.3.1 Remote Setpoint Field Wiring
The only wiring connections necessary for the REMOTE SETPOINT mode are connection of the
remote signal leads from the source to the unit’s I/O Box. The I/O Box is located on the front
panel of the boiler. 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 must be a two wire shielded pair from 18 to 22 AWG. Polarity
must be observed. The source end of the shield must be 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. The REMOTE LED
will go off and the MANUAL LED will light.
To change back to the REMOTE SETPOINT mode, simply press the AUTO/MAN switch. The
REMOTE LED will again light and the MANUAL LED will go off.
3.4 DIRECT DRIVE MODES
The unit’s air/fuel valve position (% open) can be changed by a remote signal which is typically
sent from an Energy Management System (EMS) or from a Building Automation System (BAS).
The Direct Drive mode can be driven by a current or voltage signal within the following ranges:
•
4-20 mA/1-5 VDC
•
0-20 mA/0-5 VDC
The factory default setting for the DIRECT DRIVE mode is 4-20 mA/1-5 VDC. With this setting,
a 4 to 20 mA signal, sent by an EMS or BAS is used to change the unit’s valve position from 0%
to 100%. A 4 mA/1V signal is equal to a 0% valve position, while a 20 mA /5V signal is equal to
a 100% valve position. When a 0-20 mA/0-5 VDC signal is used, zero is equal to a 0% valve
position.
In addition to the current and voltage signals described above, the DIRECT DRIVE mode can
also driven by a RS-485 Modbus Network signal from an EMS or BAS.
When in a DIRECT DRIVE mode, the unit is a slave to the EMS or BAS and does not have a
role in temperature control. DIRECT DRIVE can be used to drive single, or multiple units.
Page 34 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
NOTE:
If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch
adjustment must be made on the CPU Board located in the C-More Controller Assembly.
Contact your local AERCO representative for details.
To enable the DIRECT DRIVE mode, the following menu setting must be made in the
Configuration menu:
TABLE 3-3: Direct Drive Mode Settings
MENU OPTION
SETTING
Boiler Mode
Direct Drive
Remote Signal
4-20mA/1-5V, 0-20mA/0-5V, or Network
Refer to Section 2.3 for instructions on changing C-More Controller menu options.
If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be
entered in the Setup menu. Refer to Modbus Communication Manual GF-114 for additional
information.
3.4.1 Direct Drive Field Wiring
The only wiring connections 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 must be a two wire shielded
pair from 18 to 22 AWG. Polarity must be observed. The source end of the shield must be
connected at the source. When driving multiple units, each unit’s wiring must conform to the
above.
3.4.2 Direct Drive Startup
Since this mode of operation is factory preset and the valve position is being externally
controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when
the signal is present.
To operate the unit in MANUAL mode, press the AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light (password required).
To change back to the DIRECT DRIVE mode, simply press the AUTO/MAN switch. The
REMOTE LED will again light and the MANUAL LED will go off. This will happen automatically
after 1 hour after the password has expired.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 35 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
3.5 AERCO CONTROL SYSTEM (ACS)
NOTE:
ACS is for installations with 9 or more boilers. It utilizes only RS-485 signaling to the boiler.
Installations with 1 to 8 boilers can use Boiler Sequencing Technology (see Section 6 in
Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF207-I)).
The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS
mode is used when it is desired to operate multiple units in the most efficient manner possible.
For this mode of operation, an ACS Header Sensor must be installed between 2 and 10 feet
(0.61 and 3m) downstream of the LAST boiler in the boiler plant's supply water header. The
ACS can control up to 40 boilers; Up to 32 via Modbus (RS-485) network communication. For
ACS programming, operation, and Header Sensor installation details, see ACS Operations
Guide, GF-131. For operation via an RS-485 Modbus network, refer to Modbus Communication
Manual 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+
terminals on the ACS (boilers 9 through 40) and the RS-485 COMM terminals in the I/O Box on
the front of the boilers.
Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the proper
polarity for the ACS RS-485 COMM wiring connections. Shields should be terminated only at
the ACS and the boiler end must be left floating. Each unit’s wiring must conform to the above.
3.5.2 ACS Setup and Startup
This mode of operation is factory preset and the ACS controls the firing rate (air/fuel valve %
open position). There are no setup instructions for each individual unit.
To operate the unit in MANUAL mode, press the AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light
To change back to the ACS mode, simply press the AUTO/MAN switch. The REMOTE LED will
again light and the MANUAL LED will go off.
Page 36 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
3.6 COMBINATION CONTROL SYSTEM (CCS)
NOTE:
Only ACS can be utilized for the Combination Control System.
A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. The theory behind this type of system is that the
maximum space-heating load and the maximum domestic hot water load do not occur
simultaneously. Therefore, boilers used for domestic hot water are capable of switching
between constant setpoint and ACS control.
For a typical CCS, an adequate number of boilers are installed to cover the space-heating load
on the design-day. However, one or more units are used for the domestic hot water load as well.
These boilers are the combination units and are referred to as the combo boilers. The combo
boilers heat water to a constant setpoint temperature. That water is then circulated through a
heat exchanger in a domestic hot water storage tank.
Only the AERCO Control System (ACS) is necessary to configure this system if only a single
valve is used to switch from space heating to domestic hot water. However, the ACS Relay
Panel is required in combination with the ACS when there are up to two isolation valves, boiler
interlocks, and/or a Domestic Hot Water (DHW) pump in a Combination heating plant where
AERCO boilers are being used for both Building Heat and Domestic Hot Water heating.
The following two options are available for using a combination system; one that uses only the
ACS, and one that requires the optional ACS Relay Box:
•
OPTION 1 - This option is selected when the ACS controls a boiler plant containing 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 containing up
to eight combination boilers that are divided up into Building Priority (BLDG PRIORITY)
boilers and Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building
heat (BLDG HEAT) boilers, and using two hydronic isolation valves in the main header,
one between the BLDG HEAT and BLDG PRIORITY boilers, and the other between the
BLDG PRIORITY and the DHW PRIORITY boilers.
In Option 2, when the space-heating load is such that when all the space-heating boilers are at
the 100% valve position, the ACS will then ask the ACS Relay Box for the domestic boilers to
become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot
water) boilers will then become space-heating boilers. If the domestic hot water load is not
satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch
over to space heating, but there is a call for domestic hot water, the ACS Relay Box switches
the combo units back to the domestic load. The ACS in combination with the ACS Relay Box
will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW
PRIORITY boilers are not able to satisfy the domestic hot water demand.
When the combo units are satisfying the domestic load, they are in the CONSTANT SETPOINT
mode of operation. When the combo units switch over to space heating, their mode of operation
changes to follow the ACS command.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 37 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 3 – MODES OF OPERATION
3.6.1 Combination Control System Field Wiring
Wiring for this system is between the ACS, the ACS Relay Box, and the terminals in the I/O
Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple
units, each unit’s wiring must conform to the above.
3.6.2 Combination Control System Setup and Startup
Setup for the COMBINATION mode requires entries to be made in the Configuration menu for
boiler mode, remote signal type and setpoint. The setpoint is adjustable from 40°F to 190°F
(4.4°C to 87.8°C).
Enter the following settings in the Configuration 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 default settings work well in
most applications. It is suggested that AERCO be contacted prior to changing settings other
than the unit’s setpoint. For descriptions of temperature-related functions, see Appendix A; their
factory defaults are included in Sections 2.4 – 2.8.
To set the unit to the MANUAL mode, press the AUTO/MAN switch. The MANUAL LED will
light.
To set the unit back to the AUTO mode, press the AUTO/MAN switch. The MANUAL LED will
go off and the REMOTE LED will light.
When the boiler is switched to ACS control, the ACS controls the valve position. There are no
setup requirements to the boiler(s) in this mode.
Page 38 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
SECTION 4: MAINTENANCE
4.1 MAINTENANCE SCHEDULE
The unit requires regular routine maintenance to keep up efficiency and reliability. For best
operation and life of the unit, routine maintenance procedures should be performed in the time
periods specified in Table 4-1. For a complete inspection check list see ASME CSD-1 chart.
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 unit to cool to a safe water temperature to prevent burning or scalding
TABLE 4-1: Maintenance Schedule
ITEM
SEC
6 MOS.
12 MOS.
24 MOS.
LABOR
TIME
4.2
Pilot Burner Ignitor Rod
(P/N 66100)
*Inspect
Inspect, replace
if necessary
Replace
15 mins.
4.3
Main Flame Detector FRU
(P/N 65182)
*Inspect
Inspect, replace
if necessary
Replace
15 mins.
4.4
Lean O2 Sensor
(P/N 61026)
*Inspect
Inspect
-
15 mins.
4.5
Combustion Calibration &
pilot regulator adjustment
*Check
Check
-
1 hr.
4.6
Testing of Safety Devices
-
See ASME
CSD-1 Chart
-
45 mins.
4.7
Burner
-
-
Inspect
2 hrs.
4.9
Condensate Drain Trap
*Inspect
Inspect, Clean
& Replace
Gaskets
Inspect, Clean
& Replace
Gaskets
30 mins.
-
Clean
Replace
15 mins.
4.10 Air Filter (P/N 88014)
* Only performed after initial 6 month period after initial startup.
The following maintenance kits are available through your local AERCO Sales Representative:
NOTE:
The 24-Month Waterside/Fireside Inspection Kits includes the items contained in the Annual
Maintenance Kit (P/N 58025-11). Therefore, when performing the waterside/fireside
inspections, only the 24-Month kit is required. Refer to Appendix I for recommended spare
parts.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 39 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Kit
Kit P/N
Description
12 Month service
58025-11
24-Month Waterside/
Fireside service
58025-12
Services Pilot Burner, Flame Rod & Condensate trap
58025-11 plus: Burner, LWCO, Air Pump Filter & Air Filter
replacement
Same as 58025-12 except clean (not replace) Air Filter
58025-11 plus: LWCO, replace Air Pump Filter & Air Filter
Same as 58025-14 except clean (not replace) Air Filter
24-Month Waterside
service
58025-15
58025-14
58025-16
4.2 PILOT BURNER
The Pilot Burner (P/N 29700) is located on the right-front of the Burner Plate. It contains an
ignition cable, the Pilot gas line connected to the bushing, and the Pilot Burner Rod (P/N
66100), which should be inspected and/or replaced according the schedule in Table 4-1a.
Figure 4-1a shows the location of the Pilot Burner and related components.
BURNER PLATE
BLOWER FLANGE
SIGHT GLASS
MAIN FLAME
DETECTOR
PILOT BURNER &
PILOT IGNITION ROD
PILOT FLAME
DETECTORS
TO PILOT
GAS LINE
BLOWER
Figure 4-1a: 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.
PILOT BURNER
ROD TIP
PILOT BURNER ROD
(P/N 66100)
Figure 4-1b: Pilot Burner & Pilot Ignition Rod – Cross-Section
Page 40 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
To inspect/replace the Pilot Burner and/or Pilot Burner Rod, perform the following procedure:
Pilot Burner Maintenance Instructions
1. Set the C-More Controller’s ON/OFF switch to the OFF position. Disconnect AC power
from the unit.
2. For easy access, open the front panel and right side door. If you are working on the left unit
of a two-unit, zero side clearance installation, you may want to remove the top panel and
service the unit from above.
3. Disconnect the ignition cable from the Pilot Burner (Figure 4-1a).
4. Using a 1/2” open-end wrench, disconnect the Pilot gas line from the reducer fitting and
elbow shown in Figure 4-1a.
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 tip of Pilot Ignition Rod (P/N 66100) for evidence of erosion or carbon build-up
(see Figure 4-1b, above). If carbon build-up is present, clean the component using a wire
brush, however, if there is evidence of substantial erosion, the Pilot Ignition Rod should be
replaced. If the Pilot Burner itself is damaged or deformed, replace the Pilot Burner (P/N
29700).
9. Prior to reinstalling the Pilot Burner, a high temperature, conductive, anti-seize compound
must be applied to the threads.
10. Reinstall the Pilot Burner on the Burner Plate. Torque to 170 - 180 in-lbs. (19.2 – 20.3
Nm). DO NOT over tighten.
11. Reassemble the remaining components in the reverse order that they were removed.
12. Reconnect the ignition cable.
13. Close the right side door and front panel. Replace the top panel if the unit was serviced
from above.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 41 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.3 MAIN FLAME DETECTOR
The Main Flame Detector (field replacement unit P/N 65182) is located on the Blower Flange
near the top of the unit (see Figure 4-1a, above). The Main Flame Detector may be hot. Allow
the unit to cool sufficiently before removing the Main Flame Detector. Inspect or replace the
Main Flame Detector as follows:
Main Flame Detector Maintenance Instructions
1. Set the C-More Controller’s ON/OFF switch to the OFF position. Disconnect AC power
from the unit.
2. Remove the front panel from the unit by grasping the top handle and pulling straight out.
3. Disconnect the Main Flame Detector lead wire. Be careful not to yank the wire when it
pops off the Main Flame Detector.
4. Remove the Main Flame Detector from the Blower Flange.
5. Thoroughly inspect the Main Flame Detector. If eroded, the detector should be replaced.
Otherwise clean the detector with a fine emery cloth. Replacement is necessary every 24
months.
6. Apply a small amount of high temperature TFE-Based thread sealant and reinstall 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 burner’s rear plate, on the rear 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 accurate sampling of the O2
levels. The sensor and the suction line may be hot, therefore allow the unit to cool sufficiently
before removing or replacing the O2 sensor.
NOTE:
The O2 Sensor needs to be replaced only once every 5 years.
The O2 Sensor is removed and inspected by performing the following procedural steps:
O2 Sensor Maintenance Instructions
1. Set the C-More Controller’s ON/OFF switch to the OFF position. Disconnect AC power
from the unit.
2. Remove the O2 Sensor Cover from the unit’s back panel by removing the cover’s 4 Phillips
head screws (see Figure 4-2).
WARNING!
DO NOT remove the units back panel without first lifting the Air Eductor assembly off the
opening behind the 02 Sensor Cover and holding it in place with a length of cord or wire.
3. Disconnect the O2 sensor lead wire by pushing in on the release tab and pulling apart the
connector.
Page 42 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
O2 Sensor Maintenance Instructions
4. Next, loosen and remove the O2 sensor and crush washer from the back plate using a
15/16" open-end wrench.
5. Thoroughly inspect the O2 sensor. If corroded, the sensor should be replaced. Ensure that
the hole in the refractory is clean and that the gas sample suction tube is not clogged.
6. Reinstall the O2 sensor and crush washer on the back plate.
7. Reconnect the sensor lead wire.
8. Continue by completing the instructions in the next section to maintain the Air Eductor
assembly.
O2 SENSOR
COVER
(Removed from
original position)
O2 SENSOR
(P/N 61026)
GAS LINE TO
EXHAUST
MANIFOLD
AIR EDUCTOR
ASSY.
For AERtrim
(P/N 24508-TAB)
Figure 4-2: O2 Sensor Mounting Location – Back Panel Semi-Transparent
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 43 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.4.1 Air Eductor Air Pump Maintenance
Benchmark 5000 and 6000 units contain an Air Eductor assembly, mounted on the opening in
unit’s back panel, just behind the 02 Sensor Cover (see Figure 4-2, above). It includes an air
pump, which draws an air sample from the combustion chamber, causing it to flow past the
Oxygen sensor mounted on the burner’s rear plate, ensuring its accuracy (see Air Pump
Voltage setting in the Operating menu, Appendix A1 for more information).
While the 02 Sensor Cover is removed, complete the instructions below to maintain the Air
Eductor’s air pump.
Air Pump Maintenance and Troubleshooting Instructions
1. Remove the Air Pump’s plastic air filter cover and clean or replace the air filter (see Figure
4-3).
2. If the Air Eductor or the Air Pump is not operating properly, try the following troubleshooting
steps:
a. Check the connector to the Air Pump for corrosion or contamination, clean as needed.
b. If the Air Pump is not running, check 120 VAC power to the Air Pump. If 120 VAC
power is OK, replace the Air Pump.
c. If the Air Pump is running, check current drawn in series with one power wire. If the
current is within the range of 0.1 to 0.6 amps, the Air Pump is operating properly.
d. Check the signal from current sensor. If it is within the range of 0.20 to 1.20 VDC, there
may be a connector problem or IGST board issue. Check all connectors and wires first.
Try swapping IGST board with known good board before ordering a new one.
3. Reattach the O2 Sensor Cover to the unit’s back panel.
GAS SUCTION LINE TO
EXHAUST MANIFOLD
AIR FILTER COVER
BRACKET
(Hangs on opening in back panel)
Figure 4-3: Air Eductor Assembly – Shown Removed from Unit
Page 44 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.5 COMBUSTION CALIBRATION & PILOT REGULATOR
ADJUSTMENT
Combustion settings must be checked at the intervals shown in Table 4-1 as part of the
maintenance requirements. Refer to Section 4.4 of the Benchmark 5000 – 6000 Installation and
Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I) for combustion calibration instructions.
Pilot Regulator tests and adjustments are performed using the procedures in Section 4.5.1 and
Section 4.5.2, below.
4.5.1 Pilot Regulator Pressure Testing
Benchmark 5000 & 6000 hot water boilers feature a Pilot Regulator system in the Natural Gas
gas train (see Figure 4-4).
The Pilot Regulator should be pressure tested annually as described below. If the gas pressure
is below 4.6” W.C. (1.1 kPa) or above 5.0” W.C. (1.2 kPa), then the regulator must be
recalibrated using the instructions in Section 4.5.2.
Pilot Regulator Pressure Test Procedure 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 44) 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.
(4.0 kPa) manometer.
5. Remove the cap from the Pilot Regulator to access the gas pressure adjustment. Rotate
the regulator adjustment (beneath cap) clockwise (CW) to its highest possible pressure
setting.
6. Next, rotate the adjustment screw 2 turns counterclockwise (CCW).
7. OPEN the main gas supply upstream of the unit.
8. Turn ON electrical power to the system.
9. Start the boiler in MANUAL mode. Observe the manometer pressure when the Pilot
solenoid “clicks” open after purge. It should now provide a reading of 4.8 ± 0.2” W.C. (1.2
kPa ± 50 Pa).
10. Pull out one of the Pilot Flame Detectors (see Figure 4-1a, above) and look into the
observation port on the front plate. You should see the orange glow of the Pilot flame
during the ignition trial period.
11. If the pressure is within specifications, remove the manometer and replace the cap on the
Pilot Regulator, then return the unit to service. Make sure that the unit is operating in
AUTO mode. The “MAN” light in the upper left of the C-More Controller should NOT be lit
when in AUTO mode.
12. If the Pilot Regulator is NOT within specifications, proceed to Section 4.5.2 and perform the
Pilot Regulator Pressure Calibration procedure.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 45 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Pilot Regulator Pressure Test Procedure Instructions
MANUAL
SHUT-OFF
VALVE
TO AIR/FUEL
VALVE
PILOT
SOLENOID
VALVES
PILOT
REGULATOR
TEE WITH
1/4" NPT PLUG
Install manometer
here for Pilot
Regulator tests
GAS INLET
HIGH GAS PRESSURE SWITCH
- BMK 6000 – 10.5” W.C., 2.6 kPa
- BMK 5000 – 11.0” W.C., 2.7 kPa
UPSTREAM LOW
GAS PRESSURE SWITCH
- BMK 6000 – 8.5” W.C., 2.1 kPa
- BMK 5000 – 8.0” W.C., 2.0 kPa
Figure 4-4: BMK 5000/6000 Single Fuel Pilot Regulator Mounting Location
4.5.2 Pilot Regulator Pressure Calibration
If the Pilot Regulator pressure is below 4.6” W.C. (1.15 kPa) or above 5.0” W.C. (1.25 kPa)
the Pilot Regulator pressure must be calibrated using the following procedure:
Pilot Regulator Pressure Calibration Procedure 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 pipe plug from the 1/4” NPT port on the outlet side of the Pilot Regulator
(Figure 4-4, above) 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.
(4.0 kPa) manometer.
5. Remove the cap from the Pilot pressure regulator and rotate the regulator adjustment
(beneath cap) clockwise (CW) to its highest possible pressure setting.
6. OPEN the main gas supply upstream of the unit.
7. Turn ON electrical power to the system.
8. Start the boiler in the MANUAL mode. Observe 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).
Page 46 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Pilot Regulator Pressure Calibration Procedure Instructions
9. Pull one of the Pilot Flame Detectors out (see Figure 4-1a) 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 AERCO technical support to ascertain the
problem. If you DO see it, proceed to the next step.
10. If the manometer reading is below 4.6” W.C. (1.15 kPa), increase the regulator setting by
rotating the adjustment screw clockwise (CW).
11. Repeat steps 8 through 10 until the gas pressure at the outlet of the Pilot Regulator
pressure reads between 4.6” W.C. and 5.0” W.C. (1.15 kPa and 1.25 kPa) on the
monometer.
12. Once the pressure reading is between 4.6” W.C. and 5.0” W.C. (1.15 kPa and 1.25 kPa),
conduct at least three safe Pilot ignitions while observing the observation port. Assure the
igniter lights immediately with a strong orange flame after the Pilot ignition solenoid valve
opens.
NOTE:
Clear any Flame Loss During Ignition messages during the tests by pressing the CLEAR
key on the C-More Controller.
13. CLOSE the external gas supply valve.
14. Disconnect the manometer, tubing and barbed fitting from the 1/4” NPT port hole.
15. Replace the 1/4” plug where the barbed fitting was removed
16. Replace the Pilot Flame Detector.
17. OPEN the external gas supply upstream of the unit.
18. Ensure power is restored and the boiler is turned on in the MANUAL mode.
19. Perform the Combustion Calibration procedure in Section 4.4 of the Benchmark 5000 –
6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I).
20. Return the unit to service following successful completion of the Combustion Calibration
procedures. Make sure that the unit is operating in the AUTO mode. The “MAN” light in the
upper left of the C-More Controller should NOT be lit in AUTO mode.
4.6 SAFETY DEVICE TESTING
Systematic and thorough tests of the operating and safety devices should be performed to
ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1,
require that these tests be performed 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 Benchmark
5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I) for a
description and instructions for performing these tests.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 47 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
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, allow the unit to cool sufficiently before removing the Burner assembly.
The following parts will be required for reassembly after Burner inspection:
BMK 750/1000 Burner Inspection Parts
PART NO.
DESCRIPTION
81159
Burner Gaskets (2)
BMK 5000/6000 Burner Inspection Instructions
1. Set the C-More Controller’s ON/OFF switch to the OFF position. Disconnect AC power
from the unit and turn off the gas supply.
2. Remove the front panel, top panel and front side panels from the unit by grasping and
lifting straight up and outward. This will expose the blower assembly for removal.
3. Remove the harnesses attached to the C-More Controller, remove 4 nuts (2 above and 2
below) from the C-More bracket and then remove the C-More and set it aside.
4. Disconnect the lead wire from the Main Flame Detector installed on the Blower Flange
(Figure 4-1a).
5. Remove the Main Flame Detector from the Blower Flange.
6. Remove the Pilot sensors and observation ports from the Burner Plate (Figure 4-5a,
below).
7. Disconnect the cable from the Pilot Burner by pulling straight out.
8. Using a 1/2” open-end wrench, disconnect the Pilot gas line from the reducer fitting and
elbow shown in Figure 4-1a.
9. First, remove the reducer fitting and then the elbow from the Pilot Burner.
10. Next, loosen and remove the Pilot Burner from the Burner Plate using a 1-1/2" open-end
wrench.
11. Remove the blower support turn-buckle (Figure 4-5a or Figure 4-5b).
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.
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 4-5b).
15. Disconnect the Molex connector from the temp sensor.
16. Place a support block of any appropriate material (such as a scrap 2X4 cut to length) under
the gas train (see Figure 4-5b), and then remove the four 5/8-11 bolts & washers
connecting the gas train to the Air/Fuel valve.
17. Remove the 6 3/8-16 nuts attaching the Air/Fuel valve to the Blower and then pull the
Air/Fuel valve off and set it aside.
18. Loosen and remove the eight (8) 3/8” hex nuts and washers from the Blower Flange where
it is attached to the Burner’s Front Plate (see Figure 4-5a).
Page 48 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
BMK 5000/6000 Burner Inspection Instructions
19. Remove the Blower from the Burner by pulling outward. Be careful not to allow it to swing
and damage other equipment components. Refer to the exploded view in Figure 4-6.
20. Lower the Blower assembly down approximately 16” until it is clear of the Burner Flange.
21. Remove the Burner by pulling straight out.
22. Gently slide the Burner out of the boiler using care to avoid tearing the mesh burner fabric,
or cock the Burner to one side or the other.
23. Remove and replace the two (2) Burner Gaskets (see Figure 4-6) and clean the gasket
surface on the burner front plate.
24. To reassemble, begin with the Burner assembly and reinstall all the components in the
reverse order that they were removed. The Burner may have a nut installed at the base
position to keep the Burner level while installing the Blower (Figure 4-6).
25. Ensure that the Pilot Burner and Pilot Flame Detectors cutouts in the Blower Flange are
properly aligned with the Burner Front Plate.
BURNER FRONT PLATE
TURN-BUCKLE
3/8-16 HEX NUTS
& WASHERS (8)
BLOWER FLANGE
MAIN FLAME
DETECTOR
PILOT FLAME
DETECTORS
PILOT
BURNER
BLOWER
Figure 4-5a: Burner Assembly Mounting Details – Right-Front View
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 49 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
BMK 5000/6000 Burner Inspection Instructions
TURNBUCKLE
BLOCKED INLET SWITCH
BLOWER
3/8-16 NUTS (6)
BLOWER PROOF SWITCH
5/8-11 BOLTS (4)
(A/F VALVE TO GAS TRAIN)
AIR/FUEL VALVE
GAS TRAIN
SOME
COMPONENTS
REMOVED FOR
CLARITY
GAS TRAIN
SUPPORT BLOCK
(Scrap 2X4)
Figure 4-5b: Burner Assembly Mounting Details – Left Side View
BURNER GASKET (P/N 81159)
BURNER FLANGE
BURNER GASKET (P/N 81159)
3/8” HEX NUTS/WASHERS (8 EA.)
O-RING
AIR/FUEL
VALVE
BURNER
BLOWER FLANGE
BLOWER
Figure 4-6: Burner Assembly – Exploded View
Page 50 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.8 REFRACTORY REMOVAL & REPLACEMENT
WARNING!
The heat exchanger insulation utilizes ceramic fiber material. Wear a fitted NIOSH-approved
particulate respirator (3m n95 or equiv.) When servicing the heat exchanger and burner
assemblies. At high temperatures, ceramic fibers can be converted to crystalline silica fibers,
which have been identified as carcinogenic when inhaled.
Low mass, fiber-based material insulates the front and rear end plates of the combustion
chamber. This material has very low thermal conductivity and is not susceptible to thermal
shock conditions that cause failures of hard-faced refractory materials.
In the event that access to the unit’s combustion chamber is required, the preferred method is to
remove the rear refractory first, since it is much a less complicated procedure; removing the
front refractory requires first removing the blower, burner and air/fuel valve assemblies before
reaching the refractory material.
The procedures for removal of the rear refractory and front refractory materials are provided in
Sections 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.
3. Remove the small O2 Sensor cover panel from the left-rear panel. The Air Eductor
assembly is clipped to the bottom edge of this opening. Lift the Air Eductor assembly up off
the left-rear panel, then secure it in place with a length of cord or wire. DO NOT REMOVE
THE LEFT-REAR PANEL without first securing the Air Eductor assembly in place.
NOTE:
At the top, the left and right-rear panels are attached to the left and right top rails by nuts. At
the bottom, each rear panel is attached to the base with one nut each. Access the nuts for
removal through the side panel, as shown in Figure 4-7.
4. Remove the left-rear panel, which is held in place by 2 spring latches and 7/16” bolts,
inside the panel on the top rail and bottom lip. See Figure 4-7, below.
5. With the panels removed, the rear plate of the combustion chamber can be accessed as
shown in Figure 4-8, below.
CAUTION!
The surfaces of the heat exchanger may be hot. Allow the unit to cool sufficiently before
proceeding to the next step.
6. Remove the O2 sensor and the 1/4” stainless steel tube from the rear plate.
7. Disconnect the wires from the thermal switch on the rear plate.
8. Remove all of the nuts from the rear plate, EXCEPT for the one at the top of the plate.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 51 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Rear Refractory Replacement Instructions
O2 SENSOR COVER
LOCATION
(cover removed)
SPRING LATCH
AIR EDUCTOR
RIGHT REAR PANEL
LEFT REAR PANEL
SPRING LATCH
Figure 4-7: Rear View Showing Rear Panel Nut & Latch Locations
9. Loosen (but DO NOT REMOVE) the top nut and slide a thin metal object (such as a
hacksaw blade) between the rear plate and the fiber material of the rear refractory to
separate the material from the plate.
CAUTION!
The rear plate weighs approximately 40 pounds. It is therefore recommended that 2 people
remove the plate.
10. Remove the top nut from the plate and remove it from the unit.
11. Optionally, you can thread 2 small nipples into the rear plate to act as handles, which will
ease removal and reinstallation.
12. Refer to Figure 4-8 and note the position of the rear refractory. Prior to refractory removal,
mark as necessary using a permanent marker or tape.
13. Gently pull on the two opposing metal tabs located on the outer edge of the fiber blanket,
then alternately pull on the other two opposing tabs. Continue this process until the fiber
refractory package can be removed from the combustion chamber. Be careful not to drop
or damage the refractory.
14. Place the fiber insulation package, metal face down, in a safe location to avoid damage.
15. 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.
16. Following inspection, reinstall the components in the reverse order in which they were
removed.
Page 52 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Rear Refractory Replacement Instructions
IMPORTANT!
If the rear refractory (P/N 83027) was damaged during removal, it should be replaced with a
new part. If rear refractory replacement is required, a 2 hour burn-in period at a 30% fire
rate must be performed to drive off organic binders. These organic binders are not
hazardous materials, however they may emit an odor similar to burning wood.
17. Tighten the bolts on the rear plate using an alternating pattern to ensure a uniform seal.
Torque bolts to approximately 20 ft-lbs.
18. To avoid exhaust leaks, ensure that a uniform seal is established when reconnecting the
flue system to the boiler.
THERMAL SWITCH
O2 SENSOR
REAR BURNER PLATE
AIR EDUCTOR
ASSEMBLY
GAS SUCTION LINE
FROM EXHAUST
MANIFOLD
Figure 4-8: Partial Rear View Showing Rear Burner Plate
METAL TABS
(4 EACH)
REFRACTORY
REFLECTOR
Figure 4-9: Partial Rear View – Rear Plate and Refractory Removed
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 53 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Rear Refractory Replacement Instructions
WARNING!
The heat exchanger insulation utilizes ceramic fiber material. Wear a fitted NIOSHapproved particulate respirator (3m n95 or equiv.) When servicing the heat exchanger and
burner 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, P/N 27103, which includes full instructions in Technical Instruction Document
TID-0117. In addition AERCO provides a Front Refractory Replacement Tool Kit, P/N 27105,
which includes tools and safety equipment useful in replacing the front refractory.
Page 54 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.9 CONDENSATE DRAIN TRAP
Benchmark boilers contain a condensate trap (P/N 24441), located external to the unit and
attached to the drain connection from the exhaust manifold (the location on the unit is shown in
Figure 2-8 of the Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I). This trap should be inspected and cleaned in accordance with the
maintenance schedule shown in Table 4-1 to ensure proper operation.
To inspect and clean the trap, proceed as follows:
Condensate 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 drain piping
for blockage. If the trap cannot be thoroughly cleaned, replace the entire trap (P/N 24441).
4. Replace the float, install the O-ring (P/N 84017), and then replace the trap cover.
5. Reassemble all piping and hose connections to the condensate trap inlet and outlet.
THUMB SCREWS (4)
COVER
3/4" NPT Port
Thumb
Screw
CONDENSATE
TRAP O-RING
(P/N 84017)
FLOAT
INLET
OUTLET
O-Rings
(2)
CROSS-SECTION
3/4" NPT Port
EXPLODED
VIEW
Figure 4-10: External Condensate Trap – Cross-Section & Exploded View
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 55 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.10 AIR FILTER CLEANING and REPLACEMENT
Benchmark 5000 and 6000 boilers are equipped with two air filters (P/N 88014), which should
be cleaned and re-oiled every 12 months and replaced every 24 months. The air filter is located
at the air fuel valve inlet, as shown in Figure 4-11.
To inspect/replace the air filter, proceed as follows:
Air Filter Cleaning and Replacement Instructions
1. Set the C-More Controller’s ON/OFF switch to the OFF position. Disconnect AC power
from the unit.
2. Remove the front panel from 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 filter should be
thoroughly dried and then sprayed with a light coating of oil, (NOT WD-40), prior to
reinstallation.
6. Each replacement air filter is equipped with its own clamp. Therefore, simply install the
replacement air filter on WYE duct and tighten the clamp with a flat-tip screwdriver or 5/16”
nut driver.
7. Replace the front panel on the unit and return boiler to service use.
AIR FILTER CLAMPS
AIR FILTERS
Figure 4-11: Air Filter Location
Page 56 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.11 LOW WATER CUTOFF (LWCO) CAPACITOR TEST
The LWCO capacitor should be tested for electrical shorts every 12 months and replaced,
then tested, every 24 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.
Hot Water Outlet
Lift Top Cover
LWCO Probe
LWCO Probe
Terminal
Connector
(to Shell Harness)
Capacitor Assembly
(Covered By Shrink Tubing)
Figure 4-12: LWCO Probe Location
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 57 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test
This test determines if there is an electrical short between the LWCO capacitor and the heat
exchanger. Perform the capacitor electrical short test as described below.
Low Water Cutoff – Capacitor Electrical Short Test Instructions
1. Turn the AC power to the unit to OFF.
WARNING!
High voltages are used to power these units and so it is required that power applied to
these units is removed first before performing 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).
UNPLUG SHELL HARNESS CABLE
FROM C-MORE’S P5 CONNECTOR
Figure 4-13: Removing Shell Harness Cable from C-More’s Rear Panel
3. Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on
the unit shell as shown on left in Figure 4-14.
4. Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed
from the C-More Controller) as shown on right in Figure 4-14.
CONNECT 2ND LEAD
TO PIN #6
CONNECT 1ST LEAD
TO LWCO TERMINAL
Ohmmeter
LWCO Probe Assembly Connector
19-Pin Shell Harness Cable Connector
Figure 4-14: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable
Page 58 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
Low Water Cutoff – Capacitor Electrical Short Test Instructions
5. Confirm that the ohmmeter does NOT read a short.
NOTE:
If the ohmmeter reads a short, the capacitor assembly needs to be replaced. Refer to
document TID-0096, provided with the 24-month maintence kit, for LWCO replacement
instructions.
6. Remove both ohmmeter probes and reconnect the Shell Harness connector to the P5
connector on the rear of the C-More Controller.
4.11.2 Low Water Cutoff (LWCO) - Standard C-More Controller Test
Perform the standard Low Water Cutoff test using the C-More Controller as described below.
Low Water Cutoff (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 the boiler is to be taken out of service for an extended period of time (one year or more), the
following instructions must be followed.
Shutting Boiler Down For An Extended Period Instructions
1. Set ON/OFF switch on the front panel to the OFF position to shut down the boiler’s
operating controls.
2. Disconnect AC power from the unit.
3. Close the water supply and return valves to isolate boiler.
4. Close external gas supply valve.
5. Open relief valve to vent water pressure.
6. Open the drain valve and drain all water from the unit.
7. Refer to Appendix J for maintenance of blower during shut down.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 59 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.13 PLACING THE BOILER BACK IN SERVICE AFTER A
PROLONGED SHUTDOWN
After a prolonged shutdown (one year or more), the following procedures must be followed:
Placing the Boiler Back In Service After Prolonged Shutdown Instructions
1. Review installation requirements included in Section 2 of the Benchmark 5000 – 6000
Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I).
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-INTERNATIONAL OMM-0129 (GF-207-I).
5. Perform safety device testing procedures in Section 5: Safety Device Testing of the
Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129 (GF207-I).
6. Perform scheduled maintenance procedures as described in Section 4: Maintenance of
this guide.
IMPORTANT!
The blower can be damaged if it is unused for a prolonged period of time. If this occurs, it is
critical that you complete the instructions for Long Term Blower Storage in Appendix J.
Failure to complete these instructions will void all warranties.
Page 60 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
4.14 GAS VALVE ACTUATOR REPLACEMENT
If you need to replace the gas valve actuator, see TID-0092 for Actuator Replacement Kit P/N
27086-TAB. If you are replacing a newer actuator (P/N 124138), the wiring is unchanged.
However, complete the instructions below only if you are replacing an older actuator (P/N
69171, shown in Figure 4-15 below) to change the wiring to accept the new actuator.
Changing The Wiring From Old To New Gas Valve 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 dashed lines).
WIRE 153 – TO C-MORE
Remove and Discard Both
Remove
And Discard
Terminals 1, 2 & 3
appear only on older
actuator P/N 69171
(Current Actuator, P/N 124138, not shown)
Figure 4-15: Wiring Compartment on Older Actuator (P/N 69171)
2. Disconnect Wire 153 (dotted line) from Terminal 3 and connect it to the Low Gas Pressure
Switch.
WIRE 153 – FROM C-MORE
LOW GAS
PRESSURE
SWITCH
Figure 4-16: Wiring Diagram After Replacing Actuator
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 61 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 4 – MAINTENANCE
(This page intentionally blank)
Page 62 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
SECTION 5: TROUBLESHOOTING GUIDE
5.1 INTRODUCTION
This troubleshooting guide is intended to aid service/maintenance personnel in isolating the
cause of a fault in Benchmark boilers. The troubleshooting procedures contained herein are
presented in tabular form on the following pages. These tables are comprised of three columns
labeled: Fault Indication, Probable Cause and Corrective Action. The numbered items in the
Probable Cause and Corrective Action columns correspond to each other. For example,
Probable Cause No. 1 corresponds to Corrective Action No. 1, etc.
When a fault occurs in the unit, proceed as follows to isolate and 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 procedures listed in the Corrective Action column for the first
Probable Cause candidate.
5. Continue checking each additional Probable Cause for the existing fault until the fault is
corrected.
6. Section 5.2 and Table 5-2 contain additional troubleshooting information which may apply
when a no fault message is displayed.
If the fault cannot be corrected using the information provided in the Troubleshooting Tables,
contact your local AERCO Representative.
NOTE:
The front panel of the C-More Controller contains an RS232 port. This port is used only by
factory-trained personnel to monitor onAER communications via a portable computer.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 63 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
(This page intentionally blank)
Page 64 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
1. Blower stopped running due to thermal or
1. Check combustion blower for signs of excessive heat or high
current overload.
2. Blocked Blower inlet or inlet air filter.
2. Inspect the inlet to the combustion blower including the air filter at
3. Blockage in Blower Proof switch.
3. Remove the Blower Proof switch and inspect for signs of blockage,
current drain that may trip thermal or current overload devices.
the air/fuel valve for signs of blockage.
4. Blockage in Blocked Inlet switch.
5. Defective Blower Proof switch.
6. Defective Blocked Inlet switch.
AIRFLOW
FAULT
DURING
IGNITION
7. Loose temperature to AUX connection in I/O
Box.
8. Defective temperature sensor.
9. Loose wire connection between the 0-10V
signal from I/O box to the Blower input.
10. Defective I/O Box.
11. Wrong 0-10V output selection on the C-More
Controller.
12. Defective Air-Fuel Valve potentiometer.
13. Hard light.
OMM-0130_0A
GF-208-I
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. If
there is an erratic resistance reading or the resistance reading is
greater than zero ohms, replace the switch.
7. Check the actual inlet air temperature and measure voltage at AUX
input in the I/O Box. Verify that the voltage conforms to the values
shown in the tabular listing provided in Appendix C.
8. Refer to CORRECTIVE ACTION 7 and verify that the voltage
conforms to the values shown in Appendix C.
9. Check wire connection from I/O Box 0-10V signal to the Blower
Motor.
10. Measure voltage at the I/O box 0-10V output. A voltage of 10V
equates to a 100% open valve position.
11. Check the Analog Out option on the C-More Configuration menu.
Valve Position 0-10V should be selected.
12. Check Air/Fuel Valve position at 0%, 50% and 100% open
positions. The positions on the VALVE POSITION bargraph should
match the readings on the Air/Fuel Valve dial.
13. Check igniter-injector for soot or erosion of electrode. Check
injector solenoid valve to insure proper open/close operation.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 65 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. Blower not running or running too slow.
CORRECTIVE ACTION
1. 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.
2. Start the unit. If the blower runs, turn off unit and check the
Blocked Inlet switch for continuity. Replace the switch if continuity
3. Blockage in air filter or Blocked Inlet switch.
does not exist.
3. Remove the air filter and Blocked Inlet switch and inspect for signs
4. Blocked blower inlet or inlet ductwork.
of blockage. Clean or replace as necessary.
4. Inspect the inlet to the combustion blower including any ductwork
5. No voltage to Blocked Inlet switch from C-More
leading up to the combustion blower for signs of blockage.
Controller.
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 AIRFLOW FAULT DURING IGNITION Corrective Actions
6. Probable Causes items 3 to 12 for AIRFLOW
items 3 to 12.
FAULT DURING IGNITION apply for this fault.
1. Blower stopped running due to thermal or
1. Check combustion blower for signs of excessive heat or high
current overload.
current draw that may trip thermal or current overload devices.
2. Inspect the inlet to the combustion blower, including any ductwork
2. Blocked Blower inlet or inlet ductwork.
leading up to the combustion blower, for signs of blockage.
3. Remove the air filter and Blocked Inlet switch and inspect for signs
3. Blockage in air filter or Blocked Inlet switch.
of blockage, clean or replace as necessary.
4. Verify that 24 VAC is present between each side of the switch and
4. Defective Blocked Inlet switch.
ground. If 24 VAC is not present at both sides, replace switch.
5. Run unit to full fire. If the unit rumbles or runs rough, perform
5. Combustion oscillations.
combustion calibration.
6. See Corrective Actions for AIRFLOW FAULT DURING IGNITION
6. Probable causes from 3 to 16 for AIRFLOW
items 3 to 12.
FAULT DURING IGNITION applies for this
2. Defective Blocked Inlet switch.
AIRFLOW
FAULT
DURING
PURGE
AIRFLOW
FAULT
DURING RUN
fault.
Page 66 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
DELAYED
INTERLOCK
OPEN
PROBABLE CAUSES
1. Delayed Interlock Jumper not properly installed
1. Check to insure jumper is properly installed across the delayed
or missing.
2. Device proving switch hooked to interlocks is
not closed.
interlock terminals in the I/O Box.
2. If there are 2 external wires on these terminals, check to see if an
end switch for a proving device (such as a pump, louver, etc.) is
tied these interlocks. Ensure that the device and/or its end switch
is functional. A jumper may be temporarily installed to test the
interlock.
3. Check/correct gas leak, reset Valve Proving device
1. Check I/O Box to ensure signal is hooked up.
--Hook up if not installed.
--If installed, check polarity.
--Measure signal level.
--Check wiring 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.
3. Valve Proving device tripped unit off.
1. Direct drive signal is not present:
DIRECT DRIVE
SIGNAL FAULT
CORRECTIVE ACTION
--Not yet installed.
--Wrong polarity.
--Signal defective at source.
--Broken or loose wiring.
2. Signal is not isolated (floating).
3. C-More Controller signal type selection
switches not set for correct signal type (voltage
or current).
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 67 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. Worn Flame Detector.
1. Remove and inspect the Flame Detector for signs of wear.
2. No spark from Spark Igniter.
3. Defective Ignition Transformer.
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
Chapter.
4. Defective Ignition/Stepper (IGST) Board.
5. Defective SSOV.
6. Pilot Scanner failed.
7. Pilot View Port is blocked.
8. Carbon or other debris on Burner.
9. Pilot gas valve is closed.
10. Pilot ignition solenoid valve does not open.
11. Clogged Pilot ignition piece
Page 68 of 128
1/30/2018
CORRECTIVE ACTION
Replace if necessary.
2. Close the internal gas valve in the unit. Install and arc a spark
igniter outside the unit.
3. If there is no spark, check for 120VAC at the primary side to the
ignition transformer during the ignition cycle.
4. If 120VAC is not present, the IGST Board in the C-More Controller
may be defective. Refer fault to qualified service personnel.
5. While externally arcing the spark igniter, observe the open/close
indicator in the Safety Shut-Off Valve to ensure it is opening. If the
valve does not open, check for 120VAC at the valve input
terminals. If 120VAC is not present, the IGST board in the C-More
Controller may be defective. Refer fault to qualified service
personnel.
6. Check scanner Red LED. It should change from flashing to steady
when pointed at a small flame from a match or lighter.
7. Remove ad clean Pilot View Port. Also, ensure that the hole in the
refractory is clear.
8. Remove View-Port and inspect Burner with Boroscope. If it is fouled
or black with soot, remove the Burner and inspect for any carbon
build-up or debris. Clean and reinstall.
9. Open the Pilot gas valve on the upstream side of the SSOV (see
Figure 5-1).
10. When unit goes to ignition, listen for a clicking sound at the Pilot
ignition solenoid valve to ensure it is opening.
11. Remove and inspect the ignition piece for blockage.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. Worn Flame Detector or cracked ceramic.
2. Defective Regulator.
FLAME LOSS
DURING RUN
3. Poor combustion calibration.
4. Debris on burner.
5. Blocked condensate drain.
6. Main Flame Detector is touching burner mesh.
1. The Heat Demand Relays on the
HEAT DEMAND
FAILURE
HIGH EXHAUST
TEMPERATURE
Ignition/Stepper (IGST) board failed to activate
when commanded.
2. Relay is activated when not in Demand.
1. Poor combustion calibration.
2. Carboned heat exchanger due to incorrect
combustion calibration.
1. Incorrect supply gas pressure.
2. Defective SSOV Actuator.
GAS
PRESSURE
FAULT
(Due to High
Gas Pressure)
3. Defective High Gas Pressure switch.
OMM-0130_0A
GF-208-I
CORRECTIVE ACTION
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 procedures in Section 4.4 of
the Benchmark 5000 – 6000 Installation and Startup GuideINTERNATIONAL OMM-0129 (GF-207-I).
4. Remove the burner and inspect for any carbon build-up or debris.
Clean and reinstall.
5. Remove blockage in condensate drain.
6. Straighten or replace Main Flame Detector
1. Press CLEAR button and restart the unit. If the fault persists,
replace Ignition/Stepper (IGST) Board.
2. Defective relay. Replace IGST Board.
1. Check combustion calibration using procedures in Section 4.4 of
the Benchmark 5000 – 6000 Installation and Startup GuideINTERNATIONAL OMM-0129 (GF-207-I).
o
o
2. If exhaust temperature is greater than 200 F (93.3 C), check
combustion calibration. Calibrate or repair as necessary.
1. Check to ensure gas pressure at inlet of SSOV does not exceed 2
PSI (13.79 kPa).
2. If NATURAL GAS supply pressure downstream of SSOV Actuator
cannot be lowered using the gas pressure adjustment screw to the
range specified in the Benchmark 5000 – 6000 Installation and
Startup Guide-INTERNATIONAL OMM-0129 (GF-207-I), Section
4.4, Table 4-1, the SSOV Actuator may be defective.
3. Remove the leads from the High Gas Pressure switch. Measure
continuity across the common (C) and normally closed (NC)
terminals with the unit not firing. Replace the switch if continuity
does not exist.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 69 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
1. Faulty Water temperature switch.
1. Test the temperature switch to insure it trips at its actual water
2. Incorrect PID settings.
2. Check PID settings against menu default settings in Section 2,
temperature setting.
3. Faulty shell temperature sensor.
HIGH WATER
TEMP
SWITCH OPEN
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.
8. VFD is in “Local” mode, or voltage dropped
HIGH WATER
TEMPERATURE
IGN BOARD
COMM FAULT
below threshold.
1. See HIGH WATER TEMPERATURE SWITCH
OPEN.
2. Temp HI Limit setting is too low.
1. Communication fault has occurred between
the PMC board and Ignition/Stepper (IGST)
board.
Page 70 of 128
1/30/2018
above. If the settings have been changed, record the current
readings then reset them to the default values.
3. Using the resistance charts in the Appendix C, Measure the
resistance of Shell sensor and BTU sensor at a known water
temperature.
4. If unit is in MANUAL mode, switch to AUTO mode.
5. Check setpoint of unit and setpoint of Temperature switch; Ensure
that the temperature switch is set higher than the unit’s setpoint.
6. If the system is a variable flow system, monitor system flow
changes to ensure that the rate of flow change is not faster than
what the units can respond to.
7. Refractory temperature switches on the end plates are in series
with the water temperature limit control to shut down the boiler if
the end plates get too hot. Replace the refractory at the hottest end
plate.
8. Check incoming voltage, set VFD to “Remote” mode.
1. See HIGH WATER TEMPERATURE SWITCH OPEN.
2. Check Temp HI Limit setting.
1. Press CLEAR button and restart unit. If fault persists, contact
qualified Service Personnel.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. Air/Fuel Valve not rotating.
2. Defective or shorted switch.
IGN SWTCH
CLOSED
DURING
PURGE
3. Switch wired incorrectly.
4. Defective Power Supply Board or fuse.
5. Defective IGST Board.
1. Air/Fuel Valve not rotating to ignition position.
IGN SWTCH
OPEN
DURING
IGNITION
2. Defective Ignition switch.
3. Defective Power Supply Board or fuse.
4. Defective IGST Board.
OMM-0130_0A
GF-208-I
CORRECTIVE ACTION
1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)
position. If the valve does not rotate at all or does not rotate fully
open, check the Air/Fuel Valve calibration. If calibration is okay,
the problem may be in the Air-Fuel Valve or the C-More Controller.
Refer to qualified service personnel.
2. If the Air/Fuel Valve does rotate to purge, check the ignition switch
for continuity between the N.O. and COM terminals. If the switch
shows 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, replace IGST Board.
1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)
position, then back to ignition position (towards closed) during the
ignition cycle. If the valve does not rotate back to the ignition
position, check the Air/Fuel Valve calibration. If calibration is okay,
the problem may be in the Air/Fuel Valve or the C-More Controller.
Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check the
ignition position switch for continuity between the N.O. and COM
terminals when in contact with the cam.
3. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 71 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. Interlock jumper not installed or removed.
INTERLOCK
OPEN
LINE VOLTAGE
OUT OF PHASE
GAS
PRESSURE
FAULT
(Due to Low Gas
Pressure)
LOW WATER
LEVEL
MODBUS
COMMFAULT
CORRECTIVE ACTION
1. Check for a jumper properly installed across the interlock terminals
in the I/O box.
2. Energy Management System does not have
2. If there are two external wires on these terminals check any
unit enabled.
Energy Management system to see if they have the units disabled
(a jumper may be temporarily installed to see if the interlock circuit
is functioning).
3. Device proving switch hooked to interlocks is
3. Check that proving switch for any device hooked to the interlock
not closed.
circuit is closing and that the device is operational.
1. Line and Neutral switched in AC Power Box.
1. Check hot and neutral in AC Power Box to ensure they are not
reversed.
2. Incorrect power supply transformer wiring.
2. Check transformer wiring, in AC Power Box, against the power box
transformer wiring diagram to ensure it is wired correctly.
1. Incorrect supply gas pressure.
1. Measure NATURAL GAS pressure upstream of the SSOV
Actuator(s) with the unit firing. The minimum is 14” W.C. (3.5 kPa),
although the BMK 6000 can operate with derating at 11” W.C. (2.7
kPa) and the BMK 5000 can operate with derating at 10” W.C.
(2.5 kPa) .
2. Defective Low Gas Pressure switch.
2. Measure NATURAL GAS pressure at the Low Gas Pressure
switch. If it is greater than 10” W.C. (2.5 Pa), measure continuity
across the switch and replace if necessary.
1. Insufficient water level in system.
1. Check system for sufficient water level.
2. Defective water level circuitry.
2. Test water level circuitry using the C-More Controller front panel
LOW WATER TEST and RESET buttons. Replace water level
circuitry if it does not respond.
3. Defective water level probe.
3. Check continuity of probe end to the shell, change probe if there is
no continuity.
1. Unit not seeing information from Modbus 1. Check network connections. If fault persists, contact qualified
Service Personnel.
network.
Page 72 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
1. Dirty air filter.
1. Remove air filter and clean per Section 4.10, above.
2. Blockage in the inlet air duct.
2. Inspect all sections of the duct for foreign materials.
3. Gas pressure too high.
3. Measure the gas pressure between the SSOV and the Air/Fuel
Valve. It should be 7.9” W.C. ± 0.2” W.C. (2.0 kPa ± 50 Pa).
O2
PERCENTAGE
LOW
4. Check flue for foreign material.
4. Blocked flue.
5. Blocked condensate trap.
6. Blower failure
5. Check condensate trap per Section 4.9, above.
6. Check blower rotational speed with strobe light and compare to
VFD Hz output: RPM = 57.5 x Hz.
7. Check VFD faceplate (available from AERCO after-market) using
the VFD manufacturer’s troubleshooting documentation.
7. VFD failure
O2 SENSOR
MALFUNCTION
1. O2 % reading <-4%, or >24%
O2 % OUT OF
RANGE
1. Combustion Calibration incorrect.
1. Check Combustion Analyzer and recalibrate the boiler.
2. Blocked inlet air duct or louver.
2. Unblock air inlet and measure open area for combustion air to the
OUTDOOR
TEMP SENSOR
FAULT
1. Loose or broken wiring.
2. Defective Sensor.
2. Check resistance of sensor to determine if it is within specification.
1. Check the O2 offset and gain values in the Calibration menu. If set
to 1.0 and 1024 respectively, replace O2 sensor
3. Incorrect Sensor.
OMM-0130_0A
GF-208-I
room.
1. Inspect Outdoor Temperature sensor for loose or broken wiring.
3. Ensure that the correct sensor is installed.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 73 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. A/F Valve rotated open to purge and did not
rotate to ignition position.
PRG SWTCH
CLOSED
DURING
IGNITION
2. Defective or shorted switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or fuse.
5. Defective IGST Board.
1. Defective Purge switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or fuse
5. Defective IGST Board.
RECIRC PUMP
FAILURE
1. Internal recirculation pump failed.
Page 74 of 128
1/30/2018
1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)
position, then back to ignition position (towards closed) during the
ignition cycle. If the valve does not rotate back to the ignition
position, check the Air/Fuel Valve calibration. If calibration is okay,
the problem may be in the Air/Fuel Valve or the C-More Controller.
Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check the
purge switch for continuity between the N.O. and COM terminals.
If the switch shows continuity when not in contact with the cam,
check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
3. 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, replace IGST Board.
1. If the air-fuel valve does rotate, check Purge switch for continuity
2. No voltage present at switch.
PRG SWTCH
OPEN
DURING
PURGE
CORRECTIVE ACTION
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 & 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, replace IGST Board.
1. Replace recirculation pump.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
REMOTE
SETPT
SIGNAL FAULT
PROBABLE CAUSES
1. Remote setpoint signal not present:
1. Check I/O Box to ensure signal is hooked up.
Not yet installed.
Wrong polarity.
Signal defective at source.
Broken or loose wiring.
2. Signal is not isolated (floating) if 4 to 20 mA.
Hook up if not installed.
If installed, check polarity.
Measure signal level.
Check continuity of wiring between source and unit.
2. Check signal at source to ensure it is isolated.
3. C-More Controller signal type selection switches
3. Check DIP switch on PMC board to ensure it is set correctly for the
not set for correct signal type (voltage or
current).
1. Defective Flame Detector.
2. SSOV not fully closed.
type of signal being sent. Check control signal type set in
Configuration menu.
1. Replace Flame Detector.
2. Check open/close indicator window of Safety Shut-Off Valve (SSOV)
and ensure that the SSOV is fully closed. If not fully closed, replace
the valve and or actuator.
Close the 2” Gas Shut-Off Valve downstream of SSOV (Figure 5-1).
Install a manometer or gauge at the leak detection port between the
SSOV and Gas Shut Off Valve. If a gas pressure reading is observed
replace the SSOV Valve and/or Actuator.
RESIDUAL
FLAME
SSOV FAULT
DURING
PURGE
SSOV FAULT
DURING RUN
See SSOV SWITCH OPEN
1. SSOV switch closed for 15 seconds during run.
1. Replace or adjust micro-switch in SSOV actuator. If fault persists,
replace actuator.
1. SSOV relay failed on IGST board.
SSOV RELAY
FAILURE
CORRECTIVE ACTION
2. Floating Neutral.
3. Hot and Neutral reversed at SSOV.
OMM-0130_0A
GF-208-I
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 than a few millivolts.
3. Check SSOV power wiring.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 75 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
1. Actuator not allowing for full closure of gas
valve.
SSOV
SWITCH OPEN
2. SSOV powered when it should not be.
3. Defective switch or Actuator.
4. Incorrectly wired switch.
1. Air/Fuel Valve out of calibration.
2. Air/Fuel Valve unplugged.
STEPPER
MOTOR
FAILURE
3. Loose wiring connection to the stepper motor.
4. Defective Air/Fuel Valve stepper motor.
5. Defective Power Supply Board or fuse.
6. Defective IGST Board.
SSOV FAULT
DURING
IGNITION
1. SSOV didn’t open
Page 76 of 128
1/30/2018
CORRECTIVE ACTION
1. Observe operation of the Safety Shut-Off Valve (SSOV) through
indicator on the Valve actuator and ensure that the valve is fully
and not partially closing.
2. If the SSOV never closes, it may be powered continuously. Close
the gas supply and remove power from the unit. Refer fault to
qualified service personnel.
3. Remove the electrical cover from the SSOV and check switch
continuity. If the switch does not show continuity with the gas valve
closed, either adjust or replace the switch or actuator.
4. Ensure that the SSOV Proof of Closure switch is correctly wired.
1. Refer to C-More User Manual, OMM-0032 (GF-112) and perform
the Stepper Feedback Calibration procedure in Section 6.2.1 in
that manual.
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, replace Power Supply Board.
6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. Check pilot assembly for carbon buildup.
2. Check scanners sensed pilot flame.
3. Check power through ignition relay.
4. Scanners close neutral side of relay coil.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
Refer to Table 5-2 to troubleshoot faults which may occur without a specific fault message being displayed.
TABLE 5-2: Boiler Troubleshooting Procedures with No Fault Message Displayed
OBSERVED INCIDENT
PROBABLE CAUSES
CORRECTIVE ACTION
1. Clogged/damaged Gas Injector on
1. Disconnect the Ignition Assembly solenoid from the Gas injector Tube
Igniter-Injector (Figure 5-1).
2. Defective Ignition Solenoid (Figure
5-1).
HARD LIGHT-OFF
3. Pilot Regulator not calibrated
correctly.
1. Gas pressure going into unit is
fluctuating.
FLUCTUATING GAS
PRESSURE
2. Damping Orifice not installed.
of the Igniter-Injector (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 Ignition Solenoid makes during Ignition
Trial. If “clicking” sound is not heard after 2 or 3 attempts, replace the
Ignition Solenoid.
3. Refer to Section 4.5.2, above, and check the calibration of the Pilot
Regulator.
1. Stabilize gas pressure going into unit. If necessary, troubleshoot
Building Supply Regulator.
2. Check to ensure that the Damping Orifice is installed in the SSOV
Actuator shown in Figure 5-3.
Air/Fuel Valve “hunting” at
the 70% Valve Position
1. IGST and Power Supply Boards in
C-More Controller are outdated.
OMM-0130_0A
GF-208-I
1. Check to ensure that the IGST and Power Supply Boards are Rev. E
or higher.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 77 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
NATURAL GAS
PILOT SOLENOID VALVES
NATURAL GAS
PILOT REGULATOR
TO AIR/FUEL
VALVE
DOWNSTREAM
SSOV
MANUAL SHUTOFF VALVE
NATURAL GAS
TEE with 1/4" PLUG
(Install manometer
here for Pilot
Regulator test)
NATURAL GAS
PILOT GAS VALVE
NATURAL GAS HIGH GAS
PRESSURE SWITCH
NATURAL GAS LOW GAS
PRESSURE SWITCH
- BMK 6000 – 8.5” W.C., 2.1 kPa
- BMK 5000 – 8.0” W.C., 2.0 kPa
- BMK 6000 – 10.5” W.C., 2.6 kPa
- BMK 5000 – 11.0” W.C., 2.7 kPa
Figure 5-1: Gas Train Component and Pilot Gas Valve Location
Page 78 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
BURNER PLATE
MAIN FLAME
DETECTOR
BLOWER FLANGE
SIGHT GLASS
PILOT
BURNER
PILOT FLAME
DETECTORS (2 EA.)
TO PILOT
GAS LINE
BLOWER
Figure 5-2: Pilot Burner & Flame Detector Locations
DAMPING ORIFICE
BRASS HEX HEAD
(Remove to access the
Gas Pressure Adjustment
Screw).
COVER SCREW
Figure 5-3: SSOV Actuator With Gas Pressure Adjustment (SKP25)
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 79 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
Continued on Sheet 2
Figure 5-4a: Pilot Assembly Troubleshooting Flow Chart (Sheet 1 of 2)
Page 80 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
Continued from Sheet 1
Figure 5-4b: Pilot Assembly Troubleshooting Flow Chart (Sheet 2 of 2)
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 81 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
SECTION 5 – TROUBLESHOOTING GUIDE
(This page intentionally blank)
Page 82 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
Appendix A: BOILER MENU ITEM DESCRIPTIONS
TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS
See Section 2-4 OPERATING Menu for a range of choices and the default values.
TABLE A-1: OPERATING Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
1
Active Setpoint
This is the setpoint temperature to which the control is set
when operating in the Constant Setpoint, Remote Setpoint or
Outdoor Reset Mode. When in the Constant Setpoint Mode,
this value is equal to the Internal Setpoint setting in the
Configuration Menu. When in the Remote Setpoint Mode, this
value is the setpoint equivalent to the remote analog signal
supplied to the unit. When in the Outdoor Reset Mode, this is
the derived value from the charts in Appendix E.
2
Outlet Temp
Displays the outlet water temperature.
3
Inlet Temp
Displays the inlet 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
Valve Position In
Desired input valve position. This would normally be the same
as the fire valve position shown on the bar graph (valve
position out) when the boiler is operating.
7
Valve Position Out
Displays actual real time Valve Position.
8
FFWD Temp
Displays BST header temperature
9
Exhaust Temp
Displays the exhaust temperature in °F (default) or ºC.
10
Flame Strength
Displays flame strength from 0% to 100%.
11
Min Flame Str
Not Used
12
O2 Monitor
Enables or disables the O2 Monitor.
13
Oxygen Level
Displays the real-time combustion oxygen (O2) level (%)
measured by the O2 sensor.
14
Ignition Time
Displays the elapsed time between confirmation of gas valve
opening (POC) until a stable flame is detected.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 83 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-1: OPERATING Menu Item Descriptions
MENU OPTIONS
15
DESCRIPTION
SSOV Time to OPN
Displays the elapsed time between 120VAC being applied to
the Gas Valve and confirmation of gas valve opening (POC).
A voltage signal proportional to the current drawn by the Air
Eductor’s Air Pump. This pump draws a sample of gas across
the O2 sensor anytime the boiler has proven flame operation.
16
Air Pump Voltage
If Air Pump voltage is less than 0.20V or greater than 1.20V for
more than 10 seconds, a AIR PUMP FAILED / O2 TRIM
DISABLED message is generated. It can only be cleared by
pressing the CLEAR button on C-More Controller.
17
Run Cycles
Displays the total number of run cycles.
18
Run Hours
Displays total run time of unit in hours.
19
Fault Log
Displays information on the last 20 faults.
20
Manual Valve Pos
Selects valve position. Available in Manual mode only!
Page 84 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-2: SETUP MENU ITEM DESCRIPTIONS
See Section 2-5 for a range of choices and the default values.
TABLE A-2: SETUP Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
1
Password
Allows Level 1 or Level 2 password to be entered.
Entering the Level 1 Password (159) allows options in the Setup,
Configuration and Tuning menus to be modified.
Entering the Level 2 Password (6817) allows options in the
Calibration and Diagnostics Menus to be changed or activated, in
addition to all Level 1 Menu options.
2
Language
Permits selection of the language of displayed messages. English is
the only option at this time.
3
Time
Displays time from 12:00 am to 11:59 pm.
4
Date
Displays dates 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 onAER Remote Data Collection (ORDC).
This parameter enables ORDC and defines the minimum amount of
time between heartbeat data uploads in seconds. The COMM LED
will light during the upload.
10
Unit Alpha
Mandatory for AERCO onAER Remote Data Collection. This value
must match the first alpha digit on the Code Plate, e.g., G-12-1234.
11
Unit Year
Mandatory for AERCO onAER Remote Data Collection. This value
must match the 2-digit year on the Code Plate, e.g., G-12-1234.
12
Unit Serial #
Mandatory for AERCO onAER. Remote Data Collection. This value
must match the 4-digit serial # on the Code Plate, e.g., G-12-1234.
13
Software Version
Identifies the current software version of the C-More Controller.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 85 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS
See Section 2-6 for a range of choices and the default values.
The Configuration menu settings are Factory-Set in accordance with the requirements specified
with each individual order. No changes will be required under normal operating conditions.
TABLE A-3: CONFIGURATION Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
1
Internal Setpoint
Allows internal setpoint to be set from Lo Temp Limit of 40°F to
Hi Temp Limit of 240°F (4.4°C to 115.6°C).
2
Unit Type
Can be one of the following: BMK Blr Std, BMK Blr Std Dual,
BMK Blr LN, BMK Blr LN Dual.
Sets unit size, depending on the Unit Type:
3
Unit Size
4
Fuel Type
Allows selection of Natural Gas or Propane.
5
Boiler Mode
Only available if Unit Type = Boiler. Allows selection of:
Constant Setpoint, Remote Setpoint, Direct Drive,
Combination, or Outdoor Reset Mode.
6
Remote 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 when operating a
boiler in the Outdoor Reset Mode.
9
Reset Ratio
Only available if Boiler Mode = Outdoor Reset. Permits setting
of Reset Ratio when operating boiler in the Outdoor Reset
Mode.
10
System Start Tmp
Only if Outdoor Sensor = Enabled. This menu item allows the
system start temperature to be set.
11
Setpt Lo Limit
Used to set the minimum allowable setpoint, from 40°F (4.4°C)
up to the Setpt Hi Limit.
12
Setpt Hi Limit
Used to set the maximum allowable setpoint, from the Setpt Lo
Limit up to 210°F (98.9°C).
Temp Hi Limit
This is the maximum allowable outlet temperature, up to 210°F
(98.9°C). Any temperature above this setting will turn off the
unit. The temperature must then drop 5°F (2.75°C) below this
setting to allow the unit to run.
13
Page 86 of 128
1/30/2018
Benchmark 5000 – 5000 MBH (1465 kW)
Benchmark 6000 – 6000 MBH (1758 kW)
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-3: CONFIGURATION Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
14
Max Valve Position
Sets the maximum allowable valve position for the unit.
15
Pump Delay Timer
Specifies the amount of time, up to 30 minutes, to keep the
pump running after the unit turns off.
16
Aux Start On Dly
Specifies the amount of time to wait, up to 120 seconds,
between activating the Aux Relay (due to a demand) and
checking the pre-purge string to start the boiler.
17
Failsafe Mode
Allows the Failsafe mode to be set to either Constant Setpoint
or Shutdown.
18
Analog Output
Must be set to Valve Pos 0-10V for both BMK 5000 and BMK
6000. DO NOT CHANGE from its default value.
19
Lo Fire Timer
Specifies how long, from 2 to 600 seconds, to remain in the low
fire position after ignition, before going to the desired output.
20
Setpt Limiting
Setpoint Limiting can be 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.
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 above setpoint before
being shut down.
Demand Offset
This entry will reduce excessive ON/OFF cycling in AUTO
mode. When this entry is a non-zero value, the unit will not turn
on again until Valve Position In (Operating menu item 7)
reaches the Start Level value AND the Outlet Temperature
goes below the Active Setpoint – Demand Offset. In addition,
the boiler will fire at the 29% Valve Position level or below for a
period of one minute.
When this entry is set to zero, the unit will turn on again as
soon as the Valve Position In reaches the Start Level value
(Calibration menu item 37). There will not be a one minute
delay when firing at the 29% Valve Position level.
23
24
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 87 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-3: CONFIGURATION Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
Deadband High and Deadband Low settings create an “Outlet
Temperature” Zone in which no Valve Position corrections will
be attempted.
The Deadband ZONE is defined as operating with an Outlet
Temperature between Active Setpoint + Deadband High and
Active Setpoint – Deadband Low.
When the Outlet Temperature reaches Active Setpoint and
remains there for a period of 15 seconds, the unit will go into a
DEADBAND MODE at which point no Valve Position
corrections will be attempted while the Outlet Temperature
remains anywhere within the Deadband ZONE. When the unit
is in the DEADBAND MODE, the °F or °C LED will flash on and
off. When the Outlet Temperature drifts out of the Deadband
ZONE, the DEADBAND MODE will be terminated 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).
25
Deadband High
26
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 Enabled or Disabled.
30
Slow Sht Duration
If Slow Shutdown = Enabled, sets the time a boiler will
continue to run at the Stop Level after running above the Slow
Sht Threshold level, up to 9,999 seconds.
31
Slow Sht Threshold
Sets the Fire Rate above which a boiler will trigger the Slow
Shutdown feature.
32
O2 Warnings
A component of AERCO’s AERtrim functionality, not included
on this model.
33
O2 Trim ID
A component of AERCO’s AERtrim functionality, not included
on this model.
34
Fixed ID
A component of AERCO’s AERtrim functionality, not included
on this model.
35
O2 Trim Key
A component of AERCO’s AERtrim functionality, not included
on this model.
36
O2 Trim Menu
A component of AERCO’s AERtrim functionality, not included
on this model.
37
BST Menu
When set to Enabled, the BST menu options appears.
Page 88 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-4: TUNING MENU ITEM DESCRIPTIONS
See Section 2-7 for a range of choices and the default values.
TABLE A-4: TUNING Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
Prop Band
Generates a fire rate based on the error that exists between
the setpoint temperature and the actual outlet temperature.
If the actual error is less than the proportional band setting
(1°F to 120°F, 0.55°C to 66°C), the fire rate will be less than
100%. If the error is equal to or greater than the
proportional band 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.
1
Warmup – The feature embodied in menu items 4, 5 and 6 eliminates Temperature
Overshoots during the “Warmup” period of a cold ignition cycle on all boilers by
temporarily modifying the PID Gain parameter during warmup and for a period defined
in the Tuning menu.
4
Warmup Prop Band
Range = 1 – 120°F (0.55°C to 66°C)
Default = 95 (52°C)
5
Warmup Int Gain
Range = 0.00 – 2.00
Default = .50
6
Warmup PID Timer
Range = 0 - 240 seconds
Default = 20 seconds
7
Reset Defaults?
OMM-0130_0A
GF-208-I
Allows Tuning menu options to be reset to their Factory
Default values.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 89 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-5: COMBUSTION CALIBRATION MENU ITEM
DESCRIPTIONS
See Section 2-8 for a range of choices and the default values.
NOTE:
The Level 2 Password must be entered to view the options in the Combustion Cal menu.
This Menu is used during the Combustion Calibration procedures described in Section 4.4 of
the Benchmark 5000 – 6000 Installation and Startup Guide-INTERNATIONAL OMM-0129
(GF-207-I).
TABLE A-5: COMBUSTION CAL Menu Item Descriptions
MENU OPTION
DESCRIPTION
1
CAL Voltage 18%
2
CAL Voltage 30%
3
CAL Voltage 40%
4
CAL Voltage 50%
5
CAL Voltage 70%
6
CAL Voltage 100%
7
Set Valve Position
Permits selection of the Air/Fuel Valve position (%
open) to be set from 0 to 100%.
8
Blower Output
Permits the DC drive voltage to the blower to be
monitored.
9
Set Stby V out
Permits the Standby Voltage to be set from 0 to 4.00
Volts.
10
Oxygen Level
Permits the combustion oxygen level to be displayed
(0% to 25%).
Page 90 of 128
1/30/2018
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.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS
See Section 2-10 for a range of choices and the default values.
TABLE A-6: CALIBRATION Menu Item Descriptions
1
MENU OPTION
DESCRIPTION
Stepper Fbk
Allows the Air/Fuel Valve stepper motor feedback current to be
calibrated at the 0% (fully closed) and 100% (fully open) positions.
Verification can also be accomplished at the 50% position.
2
Purge Timer
Allows adjustment of the pre-ignition purge time.
3
Post Purge Timer
Allows adjustment of the purge time when a unit shuts down.
4
IGN Position
Allows adjustment of the valve position (Fire Rate) during the
ignition sequence.
5
Ign Pos Hold Tmr
6
FFWD Temp Disply
Enabled or Disabled.
7
Outlet Tmp Dsply
Enabled or Disabled.
8
Inlet Tmp Dsply
Enabled or Disabled.
9
Valv Pos Out Dsp
Enabled or Disabled.
10
Exhaust Tmp Dsp
Enabled or Disabled.
11
Exhaust Safety
Enabled or Disabled.
12
Flue Material
Select flue material: PVC, Polypropylene, or stainless
13
Exhst Fault Temp
Fault threshold temperature
14
Exhst Module Temp
Decreases Valve Position to lower exhaust temperature.
15
Exhst Warn Temp
Flue temperature high warning
16
Exhst Tmp VP Adj
VP adjust value
17
Exhst Adj Rate
VP adjust rate
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 91 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-6: CALIBRATION Menu Item Descriptions
MENU OPTION
DESCRIPTION
18
VP Change Rate
19
VP Up Rate
Allows adjustment of the Valve Position (Fire Rate) increase rate
when raising the Valve Position. VP Up Rate is defined as
Seconds per Step.
20
VP Down Rate
Allows adjustment of the Valve Position (Fire Rate) decrease rate
when lowering the Valve Position. VP Down Rate is defined as
Seconds per Step.
21
Purge Blwr Offst
Allows adjustment of the blower speed (Blower Output Voltage)
during the Purge cycle.
22
4-20mA Purge Pct
Allows adjustment of the blower speed (Blower Output Voltage)
during the Purge cycle when using an Emerson VFD Drive to
control the Blower Motor.
23
PWM In Adj
Allows the Pulse Width Modulation (PWM) duty cycle to be
adjusted from -5.0% to +5.0% in 0.1% increments.
24
Analog In Adj
Allows adjustment of the analog input from -5.0% to +5.0%.
25
Flow In Adj
Allows adjustment of the water Flow Rate Input from
-5.0% to +5.0%.
26
Supply Gas Pressure
In Adj
Allows adjustment of the Supply Gas Pressure level from
-5.0% to +5.0% in 0.1 % increments.
27
Gas Plate dp In Adj
Allows adjustment of the Gas Plate dp level from -5.0% to +5.0% in
0.1% increments.
28
mA Out Adj
Allows adjustment of the milliamp output from -5.0 mA to +5.0 mA.
29
A/F Sensitivity
Allows adjustment of the Air/Fuel (A/F) Valve stepper motor
sensitivity to be adjusted from 1% to 5% in 1% increments.
30
Power Reset
Allows the Power Reset Option to be set to AUTO or MANUAL.
31
Water Temp Reset
Allows the Water Temperature Reset function to be set to AUTO or
MANUAL.
32
Gas Press Reset
Allows the Gas Pressure Reset function to be set to AUTO or
MANUAL.
33
Min Off Time
Allows the minimum Off time to be set from 0 to 10 minutes.
Page 92 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-6: CALIBRATION Menu Item Descriptions
MENU OPTION
DESCRIPTION
34
Stop Level
Allows the Stop Level to be set to a valve position ranging from 0%
to the presently set Start Level.
35
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 36 – 38 embody a feature that allows the user to define a Fire Zone the C-More will avoid. In
the rare instance when a unit emits an objectionable noise at a certain Fire Rate and no other
remedy solves the problem, a Fire Rate skip zone may be defined to command the C-More to SkipOver the defined Fire Rate.
36
– Skip Range CNTR
Defines the Center (Fire Rate) of the skip band.
37
– Skip Range Span
Defines the + and – band of the Skip Zone Size.
38
– Skip Speed
Defines the speed (Seconds/Fire Rate) at which the band will be
skipped.
O2 Settings:
Items 39 – 41 allow calibration of oxygen readings.
39
– O2 Gain
Range = 0.5 to 1.5. (Unity Gain, No Mods)
40
– O2 Offset
Range = -3.0 to +3.0.
41
– O2 Sensor
Enables the O2 Sensor
42
Cal Temp Sensors
Allows calibration of the temperature sensor
Temperature Channel Offset:
Items 43 – 48 embody the feature, which allow the user to field calibrate all six temperature
channels by entering an offset corresponding to the desired temperature channel.
43
– FFWD Temp Offset
Range: -20 to + 20 (either ºF or °C)
44
– Exhst Tmp Ofset
Range: -20 to + 20 (either ºF or °C)
45
– Outdr Air Offset
Range: -20 to + 20 (either ºF or °C)
46
– Inlet Air Offset
Range: -20 to + 20 (either ºF or °C)
47
– Inlet Wtr Offset
Range: -20 to + 20 (either ºF or °C)
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 93 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-6: CALIBRATION Menu Item Descriptions
MENU OPTION
DESCRIPTION
48
– Outlet Wtr Offset
Range: -20 to + 20 (either ºF or °C)
49
24 hr Max Cycles
Maximum cycles in 24 hour period.
50
24 hr Max Ovrtemp
Maximum over-temp in 24 hour period.
51
0-10v Out Test
Set the blower voltage at 0-10v for testing.
52
Spark Monitor
Enables or disables the Spark Monitor function, which displays the
AC current on the input of the Ignition Transformer.
53
Min Spark Amps
Allows the adjustment of the minimum spark current required at the
spark transformer input.
54
Max Spark Amps
Allows the adjustment of the maximum spark current required at
the spark transformer input.
Page 94 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX B – STARTUP, STATUS, AND DISPLAY MESSAGES
Appendix B: Startup, STATUS & DISPLAY MESSAGES
Appendix B1: Startup and Status Messages
TABLE B-1: Startup and Status Messages
MESSAGE
DESCRIPTION
DEMAND DELAY
XX sec
Displayed if Demand Delay is active.
DISABLED
HH:MM pm, pm
MM/DD/YY
Displayed if ON/OFF switch is set to OFF. The display also shows
the 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 during the purge cycle during startup. The duration of
the purge cycle counts up in seconds.
STANDBY
Displayed when ON/OFF switch is in the ON position, but there is
no demand for heat. The time and date are also displayed.
WAIT
Prompts the operator to wait.
WARMUP
XX sec
Displayed for 2 minutes during the initial warm-up only.
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 95 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX B – STARTUP, STATUS, AND DISPLAY MESSAGES
Appendix B2: Fault Messages
TABLE B-2: Fault Messages
Fault Message
AIRFLOW FAULT
DURING PURGE
AIRFLOW FAULT
DURING IGN
AIRFLOW FAULT
DURING RUN
DELAYED
INTERLOCK OPEN
DIRECT DRIVE
SIGNAL FAULT
FFWD TEMP
SENSOR FAULT
FLAME LOSS
DURING IGN
FLAME LOSS
DURING RUN
HEAT DEMAND
FAILURE
HIGH EXHAUST
TEMPERATURE
Fault Description
The Blower Proof switch opened during purge,
or air inlet is blocked.
The Blower Proof switch opened during ignition.
The Blower Proof switch opened during run.
The Delayed Interlock is open. Valve Proving device may have
tripped unit off.
The direct drive signal is not present or is out of range.
The temperature measured by the Feed Forward (FFWD) Sensor
is out of range.
The Flame signal was not seen during ignition or lost within 5
seconds after ignition.
The Flame signal was lost during run.
The Heat Demand Relays on the Ignition board failed to activate
when commanded.
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
The temperature measured by the Outlet Sensor exceeded the
Temp Hi Limit setting.
TEMPERATURE
HIGH WATER TEMP
SWITCH OPEN
Page 96 of 128
1/30/2018
The High Water Temperature Limit switch is open, or the VFD is in
“Local” mode or voltage to the unit dropped below threshold or the
Surface Temp sensor is open.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX B – STARTUP, STATUS, AND DISPLAY MESSAGES
TABLE B-2: Fault Messages
Fault Message
IGN BOARD
COMM FAULT
IGN SWTCH CLOSED
DURING PURGE
IGN SWTCH OPEN
DURING IGNITION
INTERLOCK
OPEN
LINE VOLTAGE
OUT OF PHASE
LOW WATER
LEVEL
NETWORK COMM
FAULT
Fault Description
A communication fault has occurred between the PMC board and
Ignition board.
The Ignition Position Limit switch on the Air/Fuel Valve closed
during purge.
The Ignition Position Limit switch on the Air/Fuel Valve opened
during ignition.
The Remote Interlock is open.
The Line (Hot) and Neutral wires are reversed.
The Low Water Cutoff board is indicating low water level.
The RS-485 network information is not present or is corrupted.
O2 % OUT OF RANGE
The O2 % has gone below 3% or above 8%.
OUTDOOR TEMP
The temperature measured by the Outdoor Air Sensor is out of
range.
SENSOR FAULT
The temperature measured by the Outlet Sensor is out of range:
OUTLET TEMP
SENSOR FAULT
PRG SWTCH CLOSED
DURING IGNITION
PRG SWTCH OPEN
DURING PURGE
REMOTE SETPT
SIGNAL FAULT
OMM-0130_0A
GF-208-I
•
OUTLET TEMPERATURE display = SHt Indicates sensor
is shorted
•
OUTLET TEMPERATURE display = Opn indicates sensor
is open-circuited
The Purge Position Limit switch on the Air/Fuel Valve closed
during ignition.
The Purge Position Limit switch on the Air/Fuel Valve opened
during purge.
The Remote Setpoint signal is not present or is out of range.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 97 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX B – STARTUP, STATUS, AND DISPLAY MESSAGES
TABLE B-2: Fault Messages
Fault Message
RESIDUAL
FLAME
SSOV
SWITCH OPEN
SSOV FAULT
DURING PURGE
SSOV FAULT
DURING IGN
SSOV FAULT
DURING RUN
SSOV RELAY
FAILURE
STEPPER MOTOR
FAILURE
Page 98 of 128
1/30/2018
Fault Description
The Flame signal was seen for more than 60 seconds during
standby.
The SSOV switch opened during standby.
The SSOV switch opened dug purge.
The SSOV switch closed or failed to open during ignition.
The SSOV switch closed for more than 15 seconds during run.
A failure has been detected in one of the relays that control the
SSOV.
The Stepper Motor failed to move the Air/Fuel Valve to the desired
position.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART
Appendix C: SENSOR RESISTANCE/VOLTAGE CHART
Temperature Sensor Resistance Voltage Chart
(BALCO)
TEMPERATURE
°F
°C
-40
-30
-20
-10
0
10
20
30
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
OMM-0130_0A
GF-208-I
RES (OHMS)
VOLTS*
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
1364.2
1391.0
1418.2
1445.7
1.93
1.96
1.99
2.02
2.05
2.07
2.10
2.12
2.15
2.17
2.20
2.23
2.25
2.27
2.30
2.32
2.34
2.36
2.39
2.41
2.43
2.45
2.47
2.50
2.52
2.54
2.56
2.58
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 99 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART
(This page intentionally blank)
Page 100 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX D – RECOMMENDED PERIODIC TESTING
Appendix D: RECOMMENDED PERIODIC TESTING
WARNING!
Periodic testing of all boiler controls and safety devices is required to determine that they are
operating as designed. Precautions shall be taken while tests are being performed to protect
against bodily injury and property damage. The owner or user of an automatic boiler system
should set up a formal system of periodic preventive maintenance and testing. Tests should
be conducted on a regular basis and the results recorded in a log-book.
Recommended Periodic Testing
ITEM
FREQUENCY
ACTION BY
REMARKS
NOTE: Refer to indicated sections and guides for detailed procedures
Gauges, monitors
and indicators
Daily
Operator
Visual inspection and record readings in operator
log.
Instrument and
equipment settings
Daily
Operator
Visual check against factory recommended
specifications.
Weekly
Operator
Verify factory settings.
Semi-Annual
Firing Rate Control
Annually
Service Technician Verify factory settings.
Check with combustion calibration test
equipment. See Section 4.2 of the Benchmark
Service Technician 5000 – 6000 Installation and Startup GuideINTERNATIONAL OMM-0129 (GF-207-I) 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 4.2 of this guide.
Air/Fuel Valve
position
Weekly
Operator
Check position of indicator dial. See Section 3.2
Start Sequence of the Benchmark 5000 – 6000
Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I).
SSOV Leakage test
Annually
Service Technician
Check for leakage in accordance with the SSOV
manufacturer’s (Siemens) recommendations.
Flame failure
Weekly
Operator
Close manual gas shutoff valve and check safety
shutdown. See Section 5.7 Flame Fault Tests of
the Benchmark 5000 – 6000 Installation and
Startup Guide-INTERNATIONAL OMM-0129
(GF-207-I).
Flame signal strength
Weekly
Operator
Check flame strength using the C-More
Controller’s Operating menu. See Section 2.4 of
this guide.
Low water level cut
off and alarm
Weekly
Operator
See Section 5.4 of the Benchmark 5000 – 6000
Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I).
Semi-Annual
Operator
Perform a slow drain test per ASME Boiler and
Pressure Vessel Code, Sect. IV.
Slow drain test
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 101 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX D – RECOMMENDED PERIODIC TESTING
Recommended Periodic Testing
ITEM
FREQUENCY
ACTION BY
REMARKS
See Section 5.5 of the Benchmark 5000 – 6000
Service Technician Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I).
High water temp.
safety control test
Annually
Operating controls
Annually
Operator
See Section 2.2, above.
Low air flow
Monthly
Operator
See Section 5.8 of the Benchmark 5000 – 6000
Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I).
High and low gas
pressure interlocks
Monthly
Operator
See Sections 5.2 and 5.3 of the Benchmark 5000
– 6000 Installation and Startup GuideINTERNATIONAL OMM-0129 (GF-207-I).
Air/Fuel Valve purge
position switch
Annual
See Section 5.10 of the Benchmark 5000 – 6000
Service Technician Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I).
Air/Fuel Valve
ignition position
switch
Annual
See Section 5.11 of the Benchmark 5000 – 6000
Service Technician Installation and Startup Guide-INTERNATIONAL
OMM-0129 (GF-207-I).
Operator
Check per A.S.M.E. Boiler and Pressure Vessel
Code, Section IV
Safety valves
As required
Inspect burner
components
Semi-Annual
Condensate Trap
Semi-Annual
Operator
See Section 4.9 of this guide.
Oxygen (O2) Level
Monthly
Operator
Verify oxygen level is between 3% and 8% during
boiler operation.
Page 102 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Service Technician See Section 4.7 of this guide.
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS
Appendix E: INDOOR/OUTDOOR RESET RATIO CHARTS
Header Temperature for a Building Reference Temperature = 50°F (10.0°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
50
53
56
59
62
65
68
71
74
77
80
83
86
89
92
50
54
58
62
66
70
74
78
82
86
90
94
98
102
106
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
50
56
62
68
74
80
86
92
98
104
110
116
122
128
134
50
57
64
71
78
85
92
99
106
113
120
127
134
141
148
50
58
66
74
82
90
98
106
114
122
130
138
146
154
162
50
59
68
77
86
95
104
113
122
131
140
149
158
167
176
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
50
60
72
83
94
105
116
127
138
149
160
171
182
193
204
50
62
74
86
98
110
122
134
146
158
170
182
194
206
218
Header Temperature for a Building Reference Temperature = 60°F (15.6°C)
AIR TEMP
°F
°C
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
OMM-0130_0A
GF-208-I
RESET RATIO
0.6
60
63
66
69
72
75
78
81
84
87
90
93
96
99
102
105
108
0.8
60
64
68
72
76
80
84
88
92
96
100
104
108
112
116
120
124
1.0
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
1.2
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
150
156
1.4
60
67
74
81
88
95
102
109
116
123
130
137
144
151
158
165
172
1.6
60
68
76
84
92
100
108
116
124
132
140
148
156
164
172
180
188
1.8
60
69
78
87
96
105
114
123
132
141
150
159
168
177
186
195
204
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
2.0
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
2.2
60
71
82
93
104
115
126
137
148
159
170
181
192
203
214
2.4
60
72
84
96
108
120
132
144
156
168
180
192
204
216
Page 103 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS
Header Temperature for a Building Reference Temperature = 65°F (18.3°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
65
68
71
74
77
80
83
86
89
92
95
98
101
104
107
110
113
116
65
69
73
77
81
85
89
93
97
101
105
109
113
117
121
125
129
133
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
65
71
77
83
89
95
101
107
113
119
125
131
137
143
149
155
161
167
65
72
79
86
93
100
107
114
121
128
135
142
149
156
163
170
177
201
65
73
81
89
97
105
113
121
129
137
145
153
161
169
177
185
193
218
65
74
83
92
101
110
119
128
137
146
155
164
173
182
191
200
209
65
75
85
95
105
115
125
135
145
155
165
175
185
195
205
215
65
76
87
98
109
120
131
142
153
164
175
186
197
208
219
65
77
89
101
113
125
137
149
161
173
185
197
209
Header Temperature for a Building Reference Temperature = 70°F (21.1°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
70
73
76
79
82
85
88
91
94
97
100
103
106
109
112
115
118
121
124
70
74
78
82
86
90
94
98
102
106
110
114
118
122
126
130
134
138
142
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
70
76
82
88
94
100
106
112
118
124
130
136
142
148
154
160
166
172
178
70
77
84
91
98
105
112
119
126
133
140
147
154
161
168
175
182
189
196
70
78
86
94
102
110
118
126
134
142
150
158
166
174
182
190
198
206
214
70
79
88
97
106
115
124
133
142
151
160
169
178
187
196
205
214
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
70
81
92
103
114
125
136
147
158
169
180
191
202
213
70
82
94
106
118
130
142
154
166
178
190
202
214
Page 104 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS
Header Temperature for a Building Reference Temperature = 75°F (23.9°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
23.9
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
75
78
81
84
87
90
93
96
99
102
105
108
111
114
117
120
123
126
129
75
79
83
87
91
95
99
103
107
111
115
119
123
127
131
135
139
143
147
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
75
81
87
93
99
105
111
117
123
129
135
141
147
153
159
165
171
177
183
75
82
89
96
103
110
117
124
131
138
145
152
159
166
173
180
187
194
201
75
83
91
99
107
115
123
131
139
147
155
163
171
179
187
195
203
211
219
75
84
93
102
111
120
129
138
147
156
165
174
183
192
201
210
219
75
85
95
105
115
125
135
145
155
165
175
185
195
205
215
75
86
97
108
119
130
141
152
163
174
185
196
207
218
75
87
99
111
123
135
17
159
171
183
195
207
219
Header Temperature for a Building Reference Temperature = 80°F (26.7°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
26.7
23.9
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
80
83
86
89
92
95
98
101
104
107
110
113
116
119
122
125
128
131
134
80
84
88
92
96
100
104
108
112
116
120
124
128
132
136
140
144
148
152
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
80
86
92
98
104
110
116
122
128
134
140
146
152
158
164
170
176
182
188
80
87
94
101
108
115
122
129
136
143
150
157
164
171
178
185
192
199
206
80
88
96
104
112
120
128
136
144
152
160
168
176
184
192
200
208
216
80
89
98
107
116
125
134
143
152
161
170
174
188
197
206
215
80
90
100
110
120
130
140
150
160
170
180
190
200
210
80
91
102
113
124
135
146
157
168
179
190
201
212
80
92
104
116
128
140
152
164
176
188
200
212
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 105 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS
Header Temperature for a Building Reference Temperature = 90°F (32.2°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
32.2
29.4
26.7
23.9
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
90
93
96
99
102
105
108
111
114
117
120
123
126
129
132
135
138
141
144
90
94
98
102
106
110
114
118
122
126
130
134
138
142
146
150
154
158
162
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
90
96
102
108
114
120
126
132
138
144
150
156
162
168
174
180
186
192
198
90
97
104
111
118
125
132
139
146
153
160
167
174
181
188
195
202
209
216
90
98
106
114
122
130
138
146
154
162
170
178
186
194
202
210
218
90
99
108
117
126
135
144
153
162
171
180
189
198
207
216
90
100
110
120
130
140
150
160
170
180
190
200
210
90
101
112
123
134
145
156
167
178
189
200
90
102
114
126
138
150
162
174
186
198
210
Page 106 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
Appendix F: PART LISTS AND DRAWINGS
Benchmark 5000 & 6000 Part List
Item #
Qty
Part #
Description
EXHAUST MANIFOLD
1
2
3
1
3
1
39131
9-22
84042
GAS TRAIN ASSEMBLY
6
7
1
1
22222
24629
EXHAUST MANIFOLD
PIPE PLUG: 1/4" NPT: STEEL
SEAL: MANIFOLD
STANDARD GAS TRAIN
VALVE PROVING ASSEMBLY
BLOWER ASSEMBLY
19
21
23
27
1
1
1
1
65218
65182
29700
59198
380V BLOWER
FLAME DETECTOR Replacement Kit
IGNITOR ASSEMBLY
TURNBUCKLE
BURNER, AIR/FUEL VALVE & HEAT EXCHANGER
30
1
31
33
34
37
38
39
40
1
2
2
1
1
1
1
CONTROLS
46
49
50
51
52
54
61
62
63
64
66
67
68
69
1
1
1
1
2
1
1
1
2
2
2
2
1
1
24328-4
24495-4
58066
81159
88014
83028
83027
96017
39170
BMK 6000 BURNER ASSEMBLY, 380V
BMK 5000 BURNER ASSEMBLY, 380V
AIR/FUEL VALVE Replacement Kit
BURNER GASKET
FILTER: AIR 6" X 12 LG
FRONT REFRACTORY
REAR REFRACTORY
WYE-DUCT: 8" X 6" X 6"
SHIELD ASSY.
65104
69102-3
64153
65162
69141
69172
69186‐4
65085
65135
65134
61032
123449
61026
61030
CABLE: H.V. IGNITION
PUMP RELAY
VFD 380V (Parameters 69323)
24V POWER SUPPLY (Sequencing Valve)
DIN RAIL MOUNT END STOP
I/O ASSEMBLY
C-MORE CONTROLLER
IGNITION TRANSFORMER
OMRON RELAY BASE
OMRON RELAY 120V
SURFACE TEMP SENSOR
INLET WATER TEMP. SENSOR 1-1/2"
LEAN OXYGEN SENSOR
OUTLET TEMPERATURE SENSOR
70
71
72
73
74
75
77
78
79
80
81
82
83 
1
1
1
1
1
1
2
2
3
2
1
1
2
87
1
89
91
92
93
96
98
99
100
1
1
1
1
1
1
2
1
58132
64081
65011
65109
123552
123966
65120
65121
65122
65118
64088
65137
124512
65155
61034
38035
38036
65200
61024
24508-1
92094
69126
THERMOWELL Replacement Kit
ECU
TRANSFORMER 115V/24V 100VA
12V POWER SUPPLY
OVER TEMP-MANUAL RESET SWITCH
ADJUSTABLE TEMP LIMIT SWITCH
TERMINAL BLOCK: DIN MOUNTED: BLK
TERMINAL BLOCK: DIN MOUNTED: WHT
TERMINAL GROUND BLOCK: DIN Mount
FUSE TERMINAL: DIN MOUNTED
LIMIT CONTROL TEMPERATURE
3 POLE 30A BREAKER
FUSE: 4 AMP
TRANSFORMER STEPDOWN: 380V to
115V
SPARK MONITOR
PANEL COVER: I/O BOX
POWER PANEL COVER
FUSE, 4 AMP, 500V
AIR INLET TEMPERATURE SENSOR
AIR EDUCTOR ASSY
DRAIN VALVE 3/4 NPT
LOW WATER CAPACITY CUTOFF ASSY
SHEET METAL / PANEL ASSEMBLY
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
4
2
1
1
1
1
1
1
8
1
2
1
1
2
1
30155
35049
30162
30163
30164
30166
30165
39216
59133
25085-4
35048
30167
74044
33148
25088
SIDE PANEL
SIDE PILLAR
TOP PANEL: FRONT
TOP PANEL: MIDDLE
TOP PANEL: REAR
BACK PANEL: RIGHT
BACK PANEL LEFT
AIR INLET ADAPTER
LATCH: COMPRESSION
FRONT PANEL ASSEMBLY
TOP RAIL
INLET/OUTLET BACK PANEL
BENCHMARK LABEL
BRACE: DIAGONAL
FRONT FRAME ASSEMBLY
HOSE & INSULATION
119
120
1
2
80084
80098
INSULATION: UPPER
INSULATION: LOWER
 Not shown on drawing
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0130_0A
GF-208-I
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 1 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 107 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
Optional Accessories / Parts
Part #
Description
58067
92084-6
SAMPLING TUBE KIT
MOTORIZED SEQUENCING VALVE
Wiring Harnesses (not shown in figures below)
Part #
Description
63083
63090
63104
63105
63111
63113-1
63115
63125-1
63135
63162
63223
63224
HARNESS: O2 SENSOR
HARNESS: TEMPERATURE LIMIT CONTROL
HARNESS: I/O INTERLOCK
HARNESS: I/O SENSOR COMM
HARNESS: CONTROL
HARNESS: SHELL
HARNESS: AIR INLET SENSOR
HARNESS: GAS TRAIN, 7 SEC. IGNITION
VFD/BLOWER POWER WIRE #10 AWG
HARNESS: DOUBLE OPTICAL SENSOR
HARNESS: VFD INTERLOCK
HARNESS: VALVE PROVING SYSTEM
Benchmark 5000/6000 Spare Parts Kit P/N 58053-CHI
Part #
Description
123675-5
123540
24441
9-126
124416
TRIDICATOR
2” BALL VALVE
CONDENSATE VALVE ASSEMBLY
6” SLIP ON FLANGE
HEAD GASKET, 6” FLANGE
Additional Benchmark 5000/6000 Kits Available
Part #
Description
27086-2
24383
58084
58089
ACTUATOR W/ POC SWITCH Replacement Kit
SSOV W/ REGULATOR Replacement Kit
IGNITER ROD Replacement Kit
SOLENOID VALVE Replacement Kit
AERCO
International, Inc.
Blauvelt, NY 10913
Page 108 of 128
1/30/2018
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 2 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
FRONT
REAR
CROSS-SECTION
RIGHT-SIDE VIEW
LEFT-SIDE VIEW
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0130_0A
GF-208-I
REAR VIEW
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 3 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 109 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
NOTE
A complete Air/Fuel Valve,
Blower and Burner part list is
shown on pages below
AERCO
International, Inc.
Blauvelt, NY 10913
Page 110 of 128
1/30/2018
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 4 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0130_0A
GF-208-I
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 5 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 111 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
92
91
REAR
FRONT
OVERHEAD VIEW
AERCO
International, Inc.
Blauvelt, NY 10913
Page 112 of 128
1/30/2018
FRONT VIEW
(Front Frame removed)
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 6 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
TRANSFORMER
RELAY ASSEMBLY
(P/N 24358-1)
83
POWER I/O BOX
P/N 24353-3
POWER / I/O BOX HARNESSES (not shown)
QTY PART #
DESCRIPTION
1
63004
HARNESS: 460V TRANSFORMER
1
63090
HARNESS ASSY: TEMP LIM CONT PWR
1
63104
I/O INTERLOCK HARNESS
1
63105
I/O SENSOR/COMM HARNESS
1
63111
HARNESS: CONTROL
1
63112
HARNESS: O2 SENSOR (Power Box)
1
63121
HARNESS: 12V POWER SOURCE
1
63122
GROUND CABLE: #12
1
63126
BLOWER CONTROL HARNESS
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0130_0A
GF-208-I
Benchmark 5000 & 6000 Part List
10/12/2017
Whole Boiler P/N 28500-CHI (BMK 6000)
28657-CHI (BMK 5000)
Sheet 7 of 7
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 113 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
Benchmark 5000 & 6000 FM Gas Train – P/N 22222-CHI rev F
Item Qty
1
3
4
7
10
12
14
18
1
1
1
4
4
1
2
1
Part #
123542
123540
99015
12951-2
9-22
124142
58089
24383
Description
FLANGE 2" 125# 2" NPT
VALVE: BALL 2" FULL PORT
DAMPING ORIFICE: SSOV
BUSHING: CONTROL BOX
PIPE PLUG: 1/4" NPT: STEEL
VALVE: SSOV: DOUBLE BODY: 2" NPT
SOLENOID VALVE: 1/4" NPT
ACTUATOR: SSOV W/ REGULATOR
Item
19
20
21
25
26
33
34
35
Qty Part #
1
2
1
1
1
1
1
2
24384
95030
60020
27086-2
99017
97087-20
60032
92143
Description
MAXITROL REGULATOR W/ 2-6" SPRING
FLANGE: SSOV 2" NPT
GAS PRESSURE SWITCH: 2-20" W.C.
ACTUATOR: SSOV w POC SWITCH
SNUBBER: PRESSURE: 1/4"
FLEX HOSE, 20"
GAS PRESSURE SWITCH: 1-20" W.C.
1/4" BALL VALVE: WATTS
 Part number of Replacement Kit
Item
VP1
VP2
VP3
AERCO
International, Inc.
Blauvelt, NY 10913
Page 114 of 128
1/30/2018
Qty
1
1
1
Part #
24629-2
92087-16
92087-20
Description
VALVE PROVING ASSY.
FLEX HOSE, 16"
FLEX HOSE, 20"
Benchmark 5000 & 6000 FM Gas Train
10/19/2017
P/N 22222-CHI rev F
Sheet 1 of 2
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
The Benchmark 5000 and 6000 gas trains (P/N 22222) are connected to a Valve Proving
assembly (P/N 24629-2):
This device monitors the gas pressure on both sides of the Actuator. If the pressure difference
falls below a fixed value, indicating the failure of the Actuator or leakage in the gas line, it
triggers the shutdown of the boiler. When this occurs, the C-More Controller will display
DELAYED INTERLOCK OPEN.
Once the problem has been diagnosed and corrected, the Valve Proving device must be reset
by pressing the red Reset switch before the unit is restarted and the C-More Controller must be
reset.
RED ALARM LIGHT & RESET SWITCH
YELLOW RUN LIGHT
• OFF during normal operation
• ON indicates a leak or Actuator failure
• OFF during normal operation
• ON during valve proving operation
• ON when unit is not running
OVERHEAD VIEW – LOOKING DOWN FROM ABOVE
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0130_0A
GF-208-I
Benchmark 5000 & 6000 FM Gas Train
10/19/2017
P/N 22222-CHI rev F
Sheet 2 of 2
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 115 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX F – PART LIST DRAWINGS
BMK 6000 Burner Assy. (P/N 24328-4), BMK 5000 Burner Assy. (P/N 24495-4)
Item
Qty Part #
Description
Item Qty
Part #
Description
1
2
3
4
5
6
1
1
2
1
2
1
10
11
14
1
1
1
15
1
7
1
8
13
FRONT PLATE ASSY
BURNER
GASKET: BURNER
380V BLOWER
OBSERVATION PORT
SIGHT GLASS 1"
BMK 6000 A/F VALVE ASSY
BMK 5000 A/F VALVE ASSY
3/8-16 NUT: FLANGED
16
19
20
22
1
1
3
1
29700
88016
60011-4
61002-5
61002-23
65150
93367
9-21
61024
IGNITOR: PILOT
O-RING #2-378
SWITCH ASSY: BLOWER PROOF
BMK 6000 BLOCKED INLET SWITCH -8.0" W.C.
BMK 5000 BLOCKED INLET SWITCH -3.9" W.C.
FLAME ROD ASSY
SNUBBER: FAN PROVING SWITCH
PLUG, HEX HEAD 1/8” NPT
AIR INLET TEMPERATURE SENSOR
24371
46025
81159
65218
59192
59140
24352
24496
56004
AERCO
International, Inc.
Blauvelt, NY 10913
Page 116 of 128
1/30/2018
Benchmark 5000 & 6000 Burner Assembly
10/09/2017
BMK 5000: 24495-4 rev C, BMK 6000: 24328-4 rev H
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX G – WIRING DIAGRAMS
Appendix G: WIRING DIAGRAMS
Wiring Diagram 68093 rev A Sheet 1 of 2
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 117 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX G – WIRING DIAGRAMS
Wiring Diagram 68093 rev A Sheet 2 of 2
Page 118 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX G – WIRING DIAGRAMS
BMK 5000/6000 WIRING DIAGRAMS
Standard BMK 5000/6000 Drawing Number: 22222 rev B Gas Train Wiring Diagram Sheet 1 of 1
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 119 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX G – WIRING DIAGRAMS
(This page intentionally blank)
Page 120 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX H – C-MORE CONTROLLER VIEWS
Appendix H: C-MORE CONTROLLER VIEWS
CONNECTOR BOARD
P/N 124366
LOW WATER CUTOFF BOARD
P/N 124363
PMC BOARD
P/N 124364
DISPLAY BOARD
P/N 124365
GREEN LED
P/N 124948
ENCLOSURE
P/N 124951
POWER SUPPLY BOARD
P/N 124362
ROCKER
SWITCH
P/N 124947
V.F.D DISPLAY
MODULE
P/N 124527
IGNITION STEPPER BOARD
P/N 124361
FISH PAPER INSULATOR
P/N 124960
PUSH BUTTON
SWITCHES
P/N 124954
FRONT FACE PLATE, BENCHMARK
P/N 124949
VERTICAL OVERLAY, BENCHMARK
P/N 124718
Figure H-1 – Benchmark Series C-More Controller - Exploded View
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 121 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX H – C-MORE CONTROLLER VIEWS
INTERLOCK HARNESS CONNECTOR
(16 PIN)
TO INPUT/OUTPUT (I/O) BOX
SHELL HARNESS CONNECTOR
(19 PIN)
GAS TRAIN HARNESS CONNECTOR
(9 PIN)
A/F VALVE HARNESS CONNECTOR
(16 PIN)
EXT. SENSOR/COMM HARNESS
CONNECTOR (24 PIN)
TO INPUT/OUTPUT (I/O) BOX
SENSOR HARNESS CONNECTOR
(7 PIN)
Figure H-2: Benchmark C-More Contoller Rear View
Page 122 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX I – RECOMMENDED SPARE PARTS
Appendix I: RECOMMENDED SPARES
NOTE:
Refer to the Parts List Illustrations in Appendix F for the locations of the recommended and
optional spare parts listed below.
TABLE I-1: Recommended Emergency Spare Parts
DESCRIPTION
PART NUMBER
Actuator Replacement Kit: SSOV with P.O.C. Switch Kit
27086‐2
Actuator Replacement Kit: SSOV with Regulator, POC
Switch & Damping Orifice
64106
Pilot Regulator w/ 2‐6" Spring
24384
Pilot Solenoid Valve, 1/4" NPT Replacement Kit
58089
Temperature Switch - Manual Reset
123552
TABLE I-2: Recommended Spare Parts For Maintenance
DESCRIPTION
PART NUMBER
Annual Maintenance Kit
58025-11
24-month Waterside/Fireside Inspection Kit
(See Section 4.1 for kit descriptions)
58025-12
58025-14
58025-15
58025-16
TABLE I-3: Optional Spare Parts
DESCRIPTION
PART NUMBER
C-More Controller
69186‐4
Temperature Sensor, 1‐1/2"
123449
Lean Oxygen Sensor
61026
Over Temp‐Auto Reset Switch
123966
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 123 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX I – RECOMMENDED SPARE PARTS
(This page intentionally blank)
Page 124 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX J – LONG TERM STORAGE
Appendix J: LONG TERM STORAGE
CAUTION!
Failure to adhere to the instructions below voids all warranties in their entirety.
Appendix J-I: Long Term Boiler Storage
If the temperature in the storage location will ever get below freezing, for even a short time,
you must drain all water from the unit before the temperature falls below freezing. This includes
using a suction pump inserted through the inspection ports to remove all water from the bottoms
of both heat exchanges, and fully draining all water from the base assembly.
Appendix J-2: Long Term Blower Storage
Damage can result if the Blower is left in long term storage (exceeding 30 days after receipt of
equipment). If the Blower is kept in storage for more than 30 days, you must you must complete
the instructions below.
Long Term Blower Storage 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, timbers, or railroad ties) should be placed diagonally under each corner.
3. If the equipment is to be stored for more than three (3) months, the entire blower assembly
must be loosely covered with plastic, but not tightly wrapped.
4. Storage Maintenance:
NOTE:
A periodic inspection and maintenance log, by date and action taken, must be developed and
maintained for each blower. See example below. Each item must be checked monthly.
Example Storage / Maintenance Schedule Log
Item
Action
Dates Checked
1
Re-inspect units to insure any protective devices used
are functioning properly. Check for scratches in the
finish which will allow corrosion or rust to form
2
Rotate wheel a minimum of 10 full revolutions to keep
the motor bearing grease from separating and drying
out.
(THIS STEP IS CRITICAL!)
(Continued)
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 125 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
APPENDIX J – LONG TERM STORAGE
Long Term Blower Storage Instructions
5. General Motor Procedure:
If the motor is not put into service immediately, the motor must be stored in a clean, dry, warm
location. Minimum temperature of 50°F. (10°C,). Several precautionary steps must be
performed to avoid motor damage during storage.
a) Use a “Megger” each month to ensure that integrity of the winding insulation has been
maintained. Record the Megger readings. Immediately investigate any significant drop
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 humid location will, very quickly, cause internal corrosion and
motor failure which is not warranted.
NOTE:
For specific storage instructions, for the actual motor and any accessory parts that were
supplied, refer to the manufacturer’s instructions.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
INLET FLANGE
INLET-SIDE PLATE
INLET-SIDE HOUSING
BLOWER WHEEL
DRIVE-SIDE HOUSING
DRIVE-SIDE PLATE
BASE, FAN
MOTOR
RISER BLOCKS *
RISER BASE *
* IF REQUIRED
Figure J-1: Benchmark 6000 Blower Exploded View
Page 126 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
NOTES:
OMM-0130_0A
GF-208-I
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 127 of 128
1/30/2018
Benchmark 5000-6000 Operation-Service-Maintenance Guide-INTERNATIONAL
Change Log:
Date
01/30/2018
Description
Changed by
Rev A:
Initial release
© AERCO International, Inc., 2018
Page 128 of 128
1/30/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0130_0A
GF-208-I
Download PDF
Similar pages