Aerco BMK 750P, BMK 750, BMK 1500DF, BMK 1000P, BMK 1500P User Manual

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

GF-206

Natural Gas:

APPLIES TO MODELS:

Applies to Serial Numbers:

G-17-2400 and above.

USER MANUAL

SEE ALSO: Benchmark

750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers

Propane:

BMK 2000P

(2 of 2)

OPERATION, SERVICE and MAINTENANCE GUIDE

Natural Gas, Propane Gas, or Dual Fuel Fired Modulating, Condensing Boilers

Installation and Startup Guide,

Dual-Fuel (NG/P):

• BMK 750

• BMK 1000

• BMK 1500

• BMK 2000

• BMK 2500

• BMK 3000

• BMK 750P

• BMK 1000P

• BMK 1500P

•

• BMK 1500DF

• BMK 2000DF

• BMK 2500DF

• BMK 3000DF

• BMK 2500P

• BMK 3000P

Latest Update: 11/29/2017

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

CONTENTS

TABLE OF CONTENTS

FOREWORD ...................................................................................................... 5

SECTION 1: SAFETY PRECAUTIONS ................................................................... 9

1.1 WARNINGS & CAUTIONS ..................................................................................................................... 9

1.2 EMERGENC Y SHUT D OWN ................................................................................................................. 10

1.3 PROLONGED SHUTDOWN ................................................................................................................. 10

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ............................................................... 11

SECTION 2: OPERATION ................................................................................. 13

2.1 INTRODUCTION ................................................................................................................................... 13

2.2 C-MORE CONTROLLER DESCRIPTION ............................................................................................ 14

2.3 C-MORE CONTROLLER MENUS ........................................................................................................ 17

2.3.1 Menu Navigation and Processing Procedure .................................................................................................. 17

2.4 OPERATING MENU ............................................................................................................................. 19

2.5 SETUP MENU ....................................................................................................................................... 20

2.6 CONFIGURATION MENU .................................................................................................................... 21

2.7 TUNING MENU ..................................................................................................................................... 23

2.8 COMBUSTION CAL MENU .................................................................................................................. 23

2.8.1 BMK 750/1000 COMBUSTION CAL Menu ....................................................................................................... 23

2.8.2 BMK 1500/2000 COMBUSTION CAL Menus ................................................................................................... 24

2.8.3 BMK 2500/3000 COMBUSTION CAL Menus ................................................................................................... 25

2.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU ....................................................................... 26

2.10 CALIBRATION MENU......................................................................................................................... 29

SECTION 3: MODES OF OPERATION ............................................................... 31

3.1 INTRODUCTION ................................................................................................................................... 31

3.2 INDOOR/OUTDOOR RESET MODE ................................................................................................... 31

3.2.1 Reset Ratio ...................................................................................................................................................... 31

3.2.2 Building Reference Temperature .................................................................................................................... 31

3.2.3 Outdoor Air Temperature Sensor Installation ................................................................................................ 31

3.2.4 Indoor/Outdoor Startup ................................................................................................................................. 32

3.3 CONSTANT SETPOINT MODE ........................................................................................................... 32

3.3.1 Setting the Setpoint ........................................................................................................................................ 33

3.4 REMOTE SETPOINT MODES ............................................................................................................. 33

3.4.1 Remote Setpoint Field Wiring ......................................................................................................................... 34

3.4.2 Remote Setpoint Startup ................................................................................................................................ 34

3.5 DIRECT DRIVE MODES....................................................................................................................... 34

3.5.1 Direct Drive Field Wiring ................................................................................................................................. 35

3.5.2 Direct Drive Startup ........................................................................................................................................ 35

3.6 AERCO CONTROL SYSTEM (ACS) .................................................................................................... 36

3.6.1 ACS External Field Wiring................................................................................................................................ 36

3.6.2 ACS Setup and Startup .................................................................................................................................... 36

3.7 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 37

3.7.1 Combination Control System Field Wiring ...................................................................................................... 38

3.7.2 Combination Control System Setup and Startup ............................................................................................ 38

SECTION 4: MAINTENANCE ............................................................................ 39

4.1 MAINTENANCE SCHEDULE ............................................................................................................... 39

4.2 IGNITER-INJECTOR ............................................................................................................................ 40

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CONTENTS

4.3 FLAME DETECTOR ............................................................................................................................. 45

4.4 O2 SENSOR .......................................................................................................................................... 45

4.5 SAFETY DEVICE TESTING ................................................................................................................. 46

4.6 BURNER INSPECTION ........................................................................................................................ 46

4.6.1 BMK 750/1000 BURNER INSPECTION ............................................................................................................. 47

4.6.2 BMK 1500 – 3000 BURNER INSPECTION ......................................................................................................... 49

4.7 CONDENSATE DRAIN TRAP .............................................................................................................. 53

4.8 AIR FILTER CLEANING AND REPLACEMENT .................................................................................. 54

4.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ............................................................... 55

4.9.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................................... 56

4.9.2 Low Water Cutoff (LWCO) - Standard C-More Test ........................................................................................ 57

4.10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD ................................................................... 57

4.11 PLACING THE BO IL E R BACK IN SER VI C E AF TER A PRO LO N G ED SHUTDOWN ....................... 57

4.12 SPARK MONITOR (AC CURRENT TRANSDUCER) ......................................................................... 58

SECTION 5: TROUBLESHOOTING GUIDE ......................................................... 59

5.1 INTRODUCTION ................................................................................................................................... 59

5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................... 71

APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ............................................. 73

TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS ......................................................................... 73

TABLE A-2: SETUP MENU ITEM DESCRIPTIONS ................................................................................... 75

TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS ................................................................ 76

TABLE A-4: TUNING MENU ITEM DESCRIPTIONS ................................................................................. 79

TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS ............................................. 80

TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS ....................................................................... 81

APPENDIX B: STARTUP, STATUS, & FAULT MESSAGES ...................................... 85

TABLE B-1: STARTUP AND STATUS MESSAGES .................................................................................. 85

TABLE B-2: FAULT MESSAGES ............................................................................................................... 86

APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART ........................................ 89

APPENDIX D: RECOMMENDED PERIODIC TESTING ............................................ 91

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS .................................. 93

APPENDIX F: BENCHMARK 750/1000 PART LIST ............................................... 97

APPENDIX G: BENCHMARK 1500/2000 PART LIST ........................................... 107

APPENDIX H: BENCHMARK 2500/3000 PART LIST ........................................... 123

APPENDIX I: WIRING DIAGRAMS ................................................................... 145

APPENDIX J: C-MORE CONTROLLER VIEWS .................................................... 161

APPENDIX K: RECOMMENDED SPARES ........................................................... 163

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CONTENTS

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

FORWARD

FOREWORD

The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas and
propane 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, the Benchmark's modulating capability relates
energy input directly to fluctuating system loads. These BMK models provide extremely high
efficiency operation and are ideally suited f or modern low temperature, as well as, conventional
heating systems.

The Benchmark models operate within the following input and output ranges:

IMPORTANT!

Unless otherwise specified, all measurements apply to both natural gas and propane models.

Benchmark Boiler Intake and Output Ranges

INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.)

MODEL

MINIMUM MAXIMUM MINIMUM MAXIMUM

BMK 750 50,000 (14.6 kW) 750,000 (220 kW) 47,750 (14 kW) 716,250 (210 kW)

BMK 1000 50,000 (14.6 kW) 1,000,000 (293 kW) 48,300 (14.15 kW) 968,000 (284 kW)

BMK 1500 75,000 (22 kW) 1,500,000 (440 kW) 64,500 (18.9 kW) 1,395,000 (409 kW)

BMK 2000 100,000 (29.3 kW) 2,000,000 (586 kW) 86,000 (25.2 kW) 1,860,000 (545 kW)

BMK 2500 167,000 (48.9 kW) 2,500,000 (732 kW) 144,000 (42.2 kW) 2,395,000 (702 kW)

BMK 3000 200,000 (58.6 kW) 3,000,000 (879 kW) 174,000 (51.0 kW) 2,874,000 (842 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 NO

(SCAQMD), Rule 1146.2. In addition, the BMK 750 & 1000 comply with the Bay Area Air
Quality Management District regulation 9, Rule 7.

Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting
flexibility with minimum installation space requirements. These boilers are Categ ory II and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:

• Room Combustion Air:

• Ducted Combustion Air:

emission standards outlined in: South Coast Air Quality Management District

x

o Vertical Discharge
o Horizontal Discharge

o Vertical Discharge
o 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.

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A (Amp)

Ampere

(see below)

British Thermal Unit. A unit of energy approximately equal to the
BTU/HR

BTUs p er Hour

CCP

Combination Control Panel

CCS

Combination Control System

system developed by AERCO and currently used in all

3

Double Block and Bleed, a gas trains containing 2 Safety Shutoff

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

ACS AERCO Control System, AERCO’s boiler management systems
ADDR Address
AGND Anal og 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

Symbol rate, or simply the number of distinct symbol changes

Baud Rate

(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

C-More Controller
CFH Cubic Feet per Hour (1 CFH = 0.028 m

heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)

(1 BTU/hr = 0.29 W)

A control

Benchmark, Innovation and KC1000 Series product lines.

/hr)

CO Carbon Monoxide
COMM (Comm) Communication
Cal. Calibration
CNTL Control
CPU Central Processing Unit

DBB

Valves (SSOVs) and a solenoid operated vent valve.
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 Factor y Mutual. Used to define boiler gas trains.
GF-xxxx Gas Fired (an AERCO document numbering system)
GND Ground

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

HDR

Header

MBH

1000 BTUs per Hour

duplex data transmission protocol developed by AEG

POC

Proof of Clos ure

PPM

Parts per Million

PSI

Pounds per Square Inch (1 PSI = 6.89 kPa)

PTP

Point-to-Point (usually over RS232 networks)

FORWARD

AERCO Technical Terminology Meanings

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 the C-More Controller
INTLK (INTL’K) Interlock
I/O Input/Output

I/O Box

Input/Output (I/O) Box currently used on Benchmark, Innovation and

KC1000 Series products
IP Internet Protocol
ISO International Organization for Standardization
Lbs. Pounds (1 lb = 0.45 kg)
LED Light Emitting Diode
LN Low Nitrogen Oxide
MA (mA) Milliampere (1 thousandth of an ampere)
MAX (Max) Maximum

MIN (Min) Minimum
Modbus®

A serial, half-

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 Oper ation 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

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P&T

Pressure and Temperature

(or EIA-232)

duplex (FDX) transmission of data based

on the RS232 Standard

duplex (FDX) transmission of data based

(or EIA-485)

on the RS485 Standard

data in the

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

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

RS422
(or EIA-422)

RS485

A standard for serial, full-

A standard for serial, full-

on the RS422 Standard

A standard for serial, half-duplex (HDX) transmission of data based

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

A resistor placed at each end of a daisy-chain or multi-drop network
Terminating Resistor

in order to prevent reflections that may cause invalid

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 Fluor escent 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)

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

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.

See section 1.4 for important information regarding installation of units within the
Commonwealth of Massachusetts.

IMPORTANT!

This Instruction Manual 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 operates under a positive pressure and therefore must be

completely sealed to prevent leakage of combustion products into living spaces.

• Electrical voltages up to 120 VAC 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.

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VALVE

CLOSED

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

Figure 1-1: Manual Gas Shutoff Valve

1.3 PROLONGED SHUTDOWN

After prolonged shutdown, it is recommended that the startup procedures and safety device test
procedures, described in Section 4 and 5, respectively of the Benchmark 750 – 3000 Installation
and Startup Guide, OMM-0121 (GF-205) be performed to verify all system-operating
parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler
and close the manual gas valve located upstream the unit. The installer must identify the
emergency shut-off device.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Requirements For Massachusetts Installations

Boiler Installations within the Commonwealth of Massachusetts must conform to the

l side wall horizontally vented gas fueled equipment installed in every dwelling,

monoxide detector with an alarm is installed on each additional level of the dwelling,

be the responsibility of the property owner to secure the services of qualified licensed

the above requirements; provided, however, that during said thirty (30) day period, a

Each carbon monoxide detector as

accordance with the above provisions shall comply with NFPA 720 and be

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)

SECTION 1: SAFETY PRECAUTIONS

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS

following requirements:

• Boiler must be installed by a plumber or a gas fitter who is licensed within the

Commonwealth of Massachusetts.

• Prior to unit operation, the complete gas train and all connections must be leak

tested using a non-corrosive soap.

• The vent termination must be located a minimum of 4 feet above grade level. If

side-wall venting is used, the installation must conform to the following
requirements extracted from 248 CMR 5.08 (2):

(a) For al
building or structure used in whole or in part for residential purposes, including those owned or
operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon

building or structure served by the side wall horizontal vented gas fueled equipment. It shall

professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a
crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with

battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS:
required in

ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the
exterior of the building at a minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS

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Requirements For Massachusetts Installations

observes carbon monoxide detectors and signage installed in accordance with the

venting system design or venting system components with the equipment, the instructions

When the manufacturer of a Product Approved side wall horizontally vented gas fueled

stems" shall be Product Approved by the Board, and the

SECTION 1: SAFETY PRECAUTIONS

4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas
fueled equipment shall not approve the installation unless, upon inspection, the inspector

provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in
the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a
room or structure separate from the dwelling, building or structure used in whole or in
part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When
the manufacturer of Product Approved side wall horizontally vented gas equipment provides a

provided by the manufacturer for installation of the equipment and the venting system shall
include:

1. Detailed instructions for the installation of the venting system design or the venting
system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

equipment does not provide the parts for venting the flue gases, but identifies "special venting
systems", the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and

2. The "special venting sy
instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of
the installation.

……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

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 W AR NINGS and
CAUTIONS must be observed at all times.

WARNING!

• ELECTRICAL VO LTAGES IN THIS SYSTEM INCLUDE 120 VAC (BMK 750 – 2000) and

208 or 460 VAC (BMK 2500/3000) 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 the Benchmark 750 – 3000 Installation and Startup Guide,
OMM-0121 (GF-205) must b e completed before attempti ng to start the unit.

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SECTION 2: OPERATION

2.2 C-MORE CONTROLLER DESCRIPTION

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

2

1

3

12

11

10

9

4

5

6

7

8

Figure 2-1: C-More Controller Front View

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Segment LED display continuously displays the outlet

blinks when operating in the

On a BST Manager, display flashes & shows header temperature.

of displaying up to 16 alphanumeric characters. The information

trained personnel to monitor

communications, in combination with the RS232 Adaptor

LED indicator lights when a boiler alarm condition

be cleared by simply pressing this key. Troubleshooting

conditions have been satisfied.

8

opens the water level probe circuit and

SECTION 2: OPERATION

TABLE 2-1: Controls, Indicators, And Displays (ref. Figure 2-1)

ITEM

1

2

CONTROL, INDICATOR

or DISPLAY

COMM =

MANUAL =

REMOTE =

DEMAND =

OUTLET
TEMPERATURE

Display

Four Status LEDs indicate the current operating status as follows:

Lights when RS232 communication is occurring – see Item 4.
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.
Lights when the unit is being controlled by an external signal from an Energy

Management System.
Lights when there is a demand for heat.

FUNCTION

LED STATUS INDICATORS

3–Digit, 7–
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
DEADBAND mode.

Vacuum Fluorescent Display (VFD) consists of 2 lines each capable
displayed includes:

3

4

5

6

7

9

VFD Display

RS232 Port

FAULT Indicator

CLEAR Key

READY Indicator
ON/OFF switch

LOW WAT ER
LEVEL

TEST/RESET

switches

• Startup Messages

• Fault Messages

• Operating Status Messages

• Menu Selection

• BST Messages

This port is used only by factory­onAER
Cable (P/N 124675).

Red FAULT
occurs. An alarm message will appear in the VFD.

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
may be required to clear these types of alarms.

Lights when ON/OFF switch is set to ON and when all Pre-Purge

Enables and disables boiler operation.

• Allows operator to test operation of the water level monitor.

• Pressing TEST

simulates a Low Water Level alarm.

• Pressing RESET resets the water level monitor circuit.

• Pressing the CLEAR key (item 6) resets the display.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Six (6) keys which provide the following functions for the C-More Controller menus:

Allows you to go back to the previous menu level without changing any
information. Continuously pressing this key will bring you back to the

the top of a main menu category.

arrow key will

key is

ement the

Saves the modified menu settings in memory. The display will stop

SECTION 2: OPERATION

TABLE 2-1: Controls, Indicators, And Displays (ref. Figure 2-1)

ITEM

10

CONTROL, INDICATOR

or DISPLAY

MENU

BACK

▲

(UP)

Arrow

▼

(DOWN)

Arrow

Steps through the main menu categories shown in Figure 2-2. T he menu
categories wrap around in the order shown.

default status display in the VFD. Also, this key allows you to go back to

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 ▲
increment the selected setting.

When in one of the main menu categories (Figure 2-2), pressing this key
will select the displayed menu category. If the CHANGE k ey was pressed
and the menu item is flashing, pressing the ▼ arrow key will decrement the
selected setting.

FUNCTION

MENU KEYPAD

Permits a setting to be changed (edited). When the CHANGE

CHANGE

pressed, the displayed menu item will begin to flash. Pressing the ▲ or ▼
arrow key when the item is flashing will increment or decr
displayed setting.

ENTER

11

12

AUTO/MAN switch

VALVE POSITION

Bargraph

flashing.

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.

20 segment red LED bargraph continuously shows the Air/Fuel
Valve position in 5% increments from 0 to 100%

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Menu Navigation and Processing Proce dure Instructions

menu, which is the next menu

in the

Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.

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. 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), which is used in initial startup (see Section 4: Initial
Startup of the Benchmark 750 – 3000 I nstallation and Startup Guide, OMM-0121 (GF-205)), to
perform combustion calibration prior to service use.

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:

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

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

selected menu will be displayed.

5.

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.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 2: OPERATION

* Only if BST is enabled. BST is described in detail in Section 6 of the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121 (GF-205).

NOTE:

The following sections provide brief descriptions of the options contained in each menu.
Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B
for a list and descriptions of startup, status and error messages.

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Figure 2-2: Menu Structure

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-2: OPERATING Menu

Minimum

Maximum

30°F (-1.1°C)

240°F (115.6°C)

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. T his menu can be
accessed without entering a password.

A full description of each item appears in Appendix A-1.

MENU ITEM DISPLAY

1

Active Setpoint

2

Outlet Temp

3

Inlet Temp

4

Air Temp

5

Outdoor Temp

6

Valve Position In 0% 100%

7

Valve Position Out 0% 100% Configuration Menu

8

FFWD Temp

9

Exhaust Temp Displays current exhaust temperature

10

Flame Strength 0% 100%

11

Min Flame Str Not Used

12

O2 Monitor Enable Disable O2 Monitor = Enabled

13

Oxygen Level 0% 21%

14

Ignition Time 0.00 10.00

AVAILABLE CHOICES OR LIMIT

40°F (4.4°C) 240°F (116°C)
30°F (-1.1°C) 240°F (116°C)
30°F (-1.1°C) 240°F (116°C)

-70°F (-56.7°C) 245°F (118°C)

-70°F (-56.7°C) 130°F (54.4°C)

Appears Only If

Enabled in:

Configuration Menu

Configuration Menu

15

SSOV Time to OPN 0.00 10.00

16

Spark Current

17

Run Cycles 0 999,999,999

18

Run Hours 0 999,999,999

19

Fault Log 0 19

An additional parameter associated with the Operating menu, (Min = 0, Max = 100) does not
appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More
Controller’s front face.

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0 amps 2.5 amps

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-3: SETUP Menu

2

Language

English

English

3

Time

12:00 am

11:59 pm

12:00

4

5

Unit of Temp

Fahrenheit or Celsius

Fahrenheit

6

7

Baud Rate

2400, 4800, 9600, 19.2K

9600

SECTION 2: OPERATION

2.5 SETUP Menu

The Setup menu 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 C­More Controller software version.

A full description of each item appears in Appendix A-2.

MENU ITEM DISPLAY

AVAILABLE CHOICES OR LIMIT

Minimum Maximum

1

Password 0 9999 0

Date 01/01/00 12/31/99 01/01/00

Comm Address 0 127 0

8

onAER Mode Et hernet or SD Card Ethernet

9

Min Upload Timer 0 9,999 Sec 0

10

Unit Alpha E, G, H, R, N or A A

11

Unit Year 0 99 0

12

Unit Serial # 0 9999 0

13

Software Ver 0.00 Ver 9.99

Current software

DEFAULT

version

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

AVAILABLE CHOICES OR LIMIT

Minimum

Maximum

SECTION 2: OPERATION

2.6 CONFIGURATION Menu

The Configuration menu 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.

A full description of each item appears in Appendix A-3.

NOTE:

The Configuration menu set tings are Factory-Set in accordance with the requirements specified
for each individual order. Under normal operating conditions, no changes will be required.

TABLE 2-4: CONFIGURATION Menu

MENU ITEM DISPLAY

Internal Setpt

1

2

Unit Type

Unit Size

3

(Only displays sizes
available for the unit)

4

Fuel Type

5

Boiler Mode

Remote Signal
(If Mode = Remote

6

Setpoint, Direct Drive
or Combination)

40°F (4.4°C) 240°F (115.6°C)

BMK Blr Std, BMK Blr Std Dual,

BMK Blr LN, BMK Blr LN Dual

750 MBH (220 kW), 1000 MBH (293

kW), 1500 MBH (439.6 kW), 2000 MBH

(586.1 kW), 2500 MBH (732.6 kW), 3000

MBH (879.2 kW)

Natural Gas or Propane

Constant Setpoint, Remote Setpoint,

Direct Drive, Combination,

Outdoor Reset

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (Legacy BMS), Network

DEFAULT

130°F (54.4°

BMK Boiler LN

750 MBH (220 kW),

Natural Gas in

standard and dual fuel

models, Propane in

propane only models

Constant Setpoint

4 – 20 mA,

1-5V

C)

7

Outdoor Sensor
* Bldg Ref Temp

8

(If Mode = Outdoor
Reset)

* Reset Ratio

9

(If Mode = Outdoor
Reset)

* System Start Tmp

10

(If Outdoor Sensor =
Enabled)

Setpt Lo Limit

11

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Enabled or Disabled Disabled

40°F

(4.4°C)

0.1 9.9 1.2

30°F

(-1.1°C)

40°F (4.4°C) Setpt Hi Limit 60°F (15.6°C)

230°F

(110°C)

100°F

(37.8°C)

70°F

(21.1°C)

60°F

(15.6°C)

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

AVAILABLE CHOICES OR LIMIT

Minimum

Maximum

(Do NOT change)

22

SECTION 2: OPERATION

TABLE 2-4: CONFIGURATION Menu

MENU ITEM DISPLAY

Setpt Hi Limit

12

Temp Hi Limit 40°F (4.4°

13

Max Valve Position

14

Pump Delay Timer

15

Aux Start On Dly

16

Failsafe Mode

17
18

Analog Output
Low Fire Timer

19

Setpt Limiting

20

Setpt Limit Band

21

Network Timeout
Shutoff Dly Temp 0°F (0°C) 25°F (13.75°C) 10°F (5.5°C)

23

Demand Offset

24

Deadband High

25

Setpt Lo Limit 210°F (98.9°C) 180°F (82.2°C)

C) 210°F (98.9°C) 195°F (90.6°C)

40% 100% 100%
0 min. 30 min. 0 min.
0 sec. 120 sec. 0 sec.

Shutdown or Constant Setpt Constant Setpt

Off, Setpoint, Outlet Temp, Valve Pos 4-

Valve Pos 0-10v

20mA, valve Pos 0-10v

2 sec. 600 sec. 2 sec.

Enabled or Disabled Disabled

0°F (0°C) 10°F (5.5°C) 5°F (2.75°C)

5 sec. 999 sec. 30 sec.

0°F (0°C) 25°F (13.75°C) 10°F (5.5°C)
0°F (0°C) 25°F (13.75°C) 5°F (2.75°C)

DEFAULT

Deadband Low

26
27

IGST Version

28

IGN Time Setting Displays 4 sec. or 7 sec. depending on wiring harness installed

29

Slow Shutdown Enabled or Disabled Disabled

30

Slow Sht Duration 0 sec. 9,999 sec. 60 sec.
Slow Sht Threshold 40% 100% 60

31

O2 Warnings Enabled or Disabled Disabled

32

O2 Trim ID Displays 4 digit AERtrim ID

33

Fixed ID Displays unit’s fixed 4 dig it ID

34

O2 Trim Key Displays AERtrim 4 digit licens e key

35

O2 Trim Menu Enabled or Disabled Disabled

36
37

BST Menu Enabled or Disabled Disabled

0°F (0°C) 25°F (13.75°C) 5°F (2.75°C)

Displays current IGST version

V2.02

*NOTE

The Bldg Ref Temp and Reset Ratio menu Items are only displayed when the Outdoor Sensor,
item # 7 is set to Enabled.

CAUTION!

DO NOT change the Analog Output menu item from its default setting (Valve Position 0-10V).

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-5: TUNING Menu

1

Prop Band

5

6

7

TABLE 2-6: COMBUSTION CAL Menu: BMK 750/1000

Natural gas

Propane

1

0.25

10.00

2

0.25

10.00

3

0.25

10.00

4

0.25

10.00

5

0.25

10.00

6

0.25

10.00

7

8

9

10

SECTION 2: OPERATION

2.7 TUNING Menu

The Tuning menu items are Factory set for each individual unit. Do not change these menu
entries unless specifically requested to do so by factory-trained personnel.

A full description of each item appears in Appendix A-4.

MENU ITEM DISPLAY MINIMUM MAXIMUM DEFAULT

1°F (0.55°C) 120°F (66°C) 70°F (38.5°C)

2

Integral Gain 0.00 2.00 1.00

3

Derivative Time 0.0 min 2.00 min 0.0min

4

Warmup Prop Band

1°F (0.55°C) 120°F (66°C) 95 °F (52°C)
Warmup Int Gain 0.00 2.00 0.50
Warmup PID timer 0 sec. 240 sec. 20 sec.
Reset Defaults? Yes, No, Are You Sure? No

2.8 COMBUSTION CAL Menu

The Com bustion 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, 2-7 and 2-8. 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 (NO
Monoxide (CO) emissions specified in the combustion calibration instructions in Section 4.4 of
the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

CAL Voltage values are factory adjusted for each unit prior to shipping, and so may differ from
the defaults shown in the tables below. A full description of each item appears in Appendix A-5.

2.8.1 BMK 750/1000 COMBUSTION CAL Menu

) and Carbon

x

MENU ITEM DISPLAY

CAL Voltage 18%
CAL Voltage 30%
CAL Voltage 45%
CAL Voltage 60%
CAL Voltage 80%
CAL Voltage 100%
SET Valve Position 0% 100% 0% 0%
Blower Output Monitor Blower Output Voltage 0.00 0.00
Set Stdby Volt 0 V 10.0 V 2.00 2.00
Oxygen Level 0% 25% 0.0 0.0

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MINIMUM MAXIMUM

DEFAULT

2.10 2.10

2.55 2.55

3.10 3.10

3.50 3.50

4.60 4.60

5.60 5.60

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

7

SET Valve Position

0%

100%

Variable

TABLE 2-7b: COMBUSTION CAL Menu: BMK 1500/2000

0.25

10.00

– – 1.20

2.10

0.25

10.00

2.60

4.50

2.30

3.50

3

0.25

10.00

3.20

4.50

2.80

3.90

0.25

10.00

4.10

4.80

3.50

4.10

0.25

10.00

8.30

9.80

7.70

8.90

0

10.0

2.00

2.00

2.00

2.00

10

Displays current value

SECTION 2: OPERATION

2.8.2 BMK 1500/2000 COMBUSTION CAL Menus

TABLE 2-7a: COMBUSTION CAL Menu: BMK 1500/2000
SINGLE FUEL – NATURAL GAS

MENU ITEM DISPLAY MINIMUM MAXIMUM

CAL Voltage 16%

1

CAL Voltage 18% – 1.40

2

CAL Voltage 30%

3

CAL Voltage 40%

4

CAL Voltage 50%

5

CAL Voltage 70%

6

CAL Voltage 100%

8

Blower Output Displays current value

9

Set Stdby Volt 0 10.00 V 2.00 V 2.00 V

10

Oxygen Level Displays current value

0.25 10.00

0.25 10.00 2.30 3.80

0.25 10.00 2.50 4.30

0.25 10.00 2.90 5.40

0.25 10.00 3.80 6.40

0.25 10.00 7.90 9.50

DUAL FUEL

DEFAULT

BMK 1500 BMK 2000

1.80 –

DEFAULT

MENU ITEM DISPLAY

CAL Voltage: 16%

1

CAL Voltage: 18%

2

CAL Voltage 30%
CAL Voltage 40%

4

CAL Voltage 50%

5

CAL Voltage 70%

6

CAL Voltage 100%

7

SET Valve Position

8

Blower Output

9

Set Stdby Volt
Oxygen Level

MINIMUM MAXIMUM

0.25 10.00 1.50

0.25 10.00 3.30 4.50 3.00 4.10

0 100 Variable

NATURAL GAS *

BMK 1500 BMK 2000 BMK 1500 BMK 2000

2.10

Displays current value

PROPANE

– –

* The default values for Natural Gas on Dual Fuel units are different than the default values for

Natural Gas on Single Fuel units. These values do NOT apply to single fuel units.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-8a: COMBUSTION CAL Menu: BMK 2500/3000

SINGLE FUEL – NATURAL GAS

DEFAULT

BMK 2500

BMK 3000

TABLE 2-8b: COMBUSTION CAL Menu: BMK 2500/3000 DUAL FUEL

*

0.25

10.00

–

–

–

16%

0.25

10.00

–

–

0.25

10.00

2.10 – –

–

0.25

10.00 – –

2.00

–

2

0.25

10.00

5.40

3.30

4.40

0.25

10.00

–

7.00

–

5.70

0.25

10.00

6.60

–

5.60

–

0.25

10.00

8.00

–

7.00

0.25

10.00

8.70

7.90

8.60

7

0

100

Variable

0

10.0

2.00

2.00

2.00

2.00

Displays current value

SECTION 2: OPERATION

2.8.3 BMK 2500/3000 COMBUSTION CAL Menus

MENU ITEM DISPLAY MINIMUM MAXIMUM

CAL Voltage 16%

1

CAL Voltage 14% – 2.80

2

CAL Voltage 30%

3

CAL Voltage 40%

4

CAL Voltage 50%

5

CAL Voltage 70%

6

CAL Voltage 100%

7

SET Valve Position 0% 100% Variable

8

Blower Output Displays current value

9

Set Stdby Volt 0 10.00 V 2.00 V 2.00 V

10

Oxygen Level Displays current value

0.25 10.00

0.25 10.00 4.10 4.60

0.25 10.00 4.80 5.00

0.25 10.00 5.30 5.50

0.25 10.00 6.80 6.90

0.25 10.00 8.50 9.10

2.20 –

DEFAULT

MENU ITEM DISPLAY

CAL Voltage: 14%
CAL Voltage:

1

CAL Voltage: 18%
CAL Voltage: 20%
CAL Voltage: 22%

CAL Voltage 30%

3

CAL Voltage 45%

4

CAL Voltage 65%
CAL Voltage 70%

5

CAL Voltage 75%
CAL Voltage 85%

6

CAL Voltage 100%
SET Valve Position

8

Blower Output

9

Set Stdby Volt

10

Oxygen Level

MINIMUM MAXIMUM

0.25 10.00 –

0.25 10.00

0.25 10.00

NATURAL GAS

BMK 2500 BMK 3000 BMK 2500 BMK 3000

2.40

2.15

3.90

5.60

–
–

8.50

Displays current value

–
–

6.60 4.60 5.40

– – –

* The default values for Natural Gas on Dual Fuel units are different than the default values for

Natural Gas on Single Fuel units. These values shown DO NOT APPLY to single fuel units.

PROPANE

2.00 2.30

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-9: BST Menu

AVAILABLE CHOICES OR LIMIT

1

BST Mode

9

12

*BST SETUP MENU*

Disabled

Enabled

Disabled

Remote

Setpoint

Outdoor

Reset

0-20 mA/0-5

VDC

16

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 set 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. BST Monitor Items

2. *BST SETUP MENU*

3. *OPERATE MENU*

4. * TEMP CTRL MENU*

5. * 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 g roup has been
enabled from the C-More keypad.

MENU ITEM DISPLAY

2

BST Setpoint BST Setpt Lo Limit BST Setpt Hi Limit 130°F (54.4°C)

3

Header Temp Read Only – current Header temperature in °F N/A

4

BST Fire Rate 0 100% Fire rate %

5

BST Ave Fire Rate 0 100% Avg Fire Rate %

6

BST Outdoor Temp Read Only – current outdoor temperature in °F N/A

7

Units Available 0 8 Units Present

8

Units Ignited 0 8 Units firing
BST Valve State 0 (CLOSED) 1 (OPEN) 0

10

1 BST Comm Errors 8 0 9 0

11

1 BST Units 8 0 – 8 (see * NOTE below) 0

Minimum Maximum

Off BST Client BST Manager Off

DEFAULT

13

BST Setpoint Mode

14

BST Remote Signl 4-20 mA/1-5 VDC

15

Head Temp Source Network FFWD Temp FFWD Temp

Mdbus Temp Units Degrees C or Degrees F Degrees C

Page 26 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C

11/29/2017 Ph.: 800-526-0288 GF-206

Constant Setpoint

Constant Setpt

Network Network

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-9: BST Menu

AVAILABLE CHOICES OR LIMIT

19

Yes

feature.

25

On-Outlet

Temp

28

32

*OPERATE MENU*

36

40

44

*TEMP CTRL MENU*

48

SECTION 2: OPERATION

MENU ITEM DISPLAY

DEFAULT

Minimum Maximum

17

Header Temp Addr 0 255 240

18

Header Temp Point 0 255 14
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

NOTE! A Modbus

23

BST Auto Mstr No

24

BST Auto Timer 10 sec 120 sec 30 sec

temperature transmitter
must be installed in
conjunction with this

Remote Intlk Use Boiler Shutdown System Shutdown System Shutdown

26

One Boiler Mode Off

27

1 Blr Threshold 10 35 25

On-Avg Temp Off

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
Rate Threshold 1°F (0.55°C) 30°F (16.5°C) 15°F (8.25°C)

No

33
34
35

37
38
39

41
42
43

45
46
47

49
50

Disabled Enabled Disabled
BST Next On VP 16% 100% 50%
BST Max Boilers 1 8 8
BST On Delay 30 sec 300 sec 60 sec
BST On Timeout 15 sec 300 sec 60 Sec
Valve Override Off Closed Open Off
Valve Off Delay 0 15 min 1 min
BST Sequencing Run Hours Unit Size Select Lead Run Hours
Select Lead Unit 0 127 0
Select Lag Unit 0 127 0
Lead/Lag Hours 25 hours 225 hours 72 hours

Disabled Enabled Disabled
BST Temp Hi Limit 40°F (4.4°C) 210°F (98.9°C) 210°F (98.9°C)
BST Setpt Lo Limit 40°F (4.4°C) BST Setpt HI Limit 60°F (15.5°C)
BST Setpt HI Limit BST Setpt Lo Limit 220°F (104.4°C) 195°F (90.6°C)
BST Prop Band 1°F (-17.2°C) 120°F (48.9°C) 100°F (37.8°C)
BST Intgral Gain 0.00 2.00 0.50
BST Deriv Time 0.00 Min 2.00 Min 0.10 Min

OMM-0122_0C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 164

GF-206 Ph.: 800-526-0288 11/29/2017

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-9: BST Menu

AVAILABLE CHOICES OR LIMIT

53

57

*BST COMM MENU*

61

65

SECTION 2: OPERATION

MENU ITEM DISPLAY

51

BST Deadband Hi 0 25 1

52

BST Deadband Lo 0 25 1
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
System Start Tmp 30°F (-1.1°C) 120°F (48.9°C) 60°F (15.6°C)

58
59

Comm Address 0 127 0

60

BST Min Addr 1 128 1
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
SSD Temp Format Degrees Points Degrees

66

BST Upld Timer 0 9999 sec 0

Minimum Maximum

Disabled Enabled Disabled

DEFAULT

* 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 0 1 * A b

Page 28 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C
11/29/2017 Ph.: 800-526-0288 GF-206

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-10: CALIBRATION Menu

Minimum

Maximum

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 Appendix A-6.

MENU ITEM DISPLAY

1

Stepper Fbk Cal 0%, Verify 50%, Cal 100% Cal 0 %

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

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 PVC,CPVC; PolyPro; Stainless PVC,CPVC

13

Exhst Fault Temp 100 °F 500 °F 200 °F

14

Exhst Module Temp 100 °F 500 °F 190 °F

DEFAULT

Disabled
Disabled
Disabled

Enabled

Disabled

Enabled

AVAILABLE CHOICES OR LIMIT

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%

23

PWM In Adj -5.0% 5.0% 0.0%

24

Analog In Adj

25

Flow In Adj

26

Supply Gas Pressure In Adj

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

OMM-0122_0C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 164
GF-206 Ph.: 800-526-0288 11/29/2017

-5.0% 5.0% 0.0%

-5.0% 5.0% 0.0%

-5.0% 5.0% 0.0%

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-10: CALIBRATION Menu

AVAILABLE CHOICES OR LIMIT

Minimum

Maximum

SECTION 2: OPERATION

MENU ITEM DISPLAY

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 0 Min 15 Min 1 Min

34

Heatr Tuning Dsp Enabled or Disabled Disabled

35

Heatr Bkpt Dsp Enabled or Disabled Disabled

36

Stop Level 0% Start Level 16

37

Start Level Stop Level 40% 22

38

Skip Range Cntr 10 95 40

39

Skip Range Span 0 3 0%

40

Skip Speed 0.5 2.0 0.5%

41

O2 Gain 0.500 1.500 1.000

42

O2 Offset -24.0 +2.0 1.0

DEFAULT

43

O2 Sensor Enabled or Disabled Depends on unit type/size

44

Cal Temp Sensors

45

FFWD Temp Offset -20 +20 0

46

Exhst Tmp Offset -20 +20 0

47

Outdr Air Offset -20 +20 0

48

Inlet Air Offset -20 +20 0

49

Inlet Wtr Offset -20 +20 0

50

Outlet Wtr Offset -20 +20 0

51

24 hr Max Cycles 0 9999 0

52

24 hr Max Ovrtemp 0 9999 0

53

0-10v Out Test 0.0 10.0 0.00

54

Spark Monitor Enabled or Disabled Depends on unit type/size

55

Min Spark Amps 0.0 Amps 2.5 Amps 0.10 Amps

56

Max Spark Amps 0.0 Amps 2.5 Amps 0.40 Amps

Off or Start Off

Page 30 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C
11/29/2017 Ph.: 800-526-0288 GF-206