Aerco BMK 750, BMK 2500, BMK 1000, BMK 2000, BMK 3000 Operation And Service Manual

...

GF-201

Natural Gas:

• BMK 2000P

APPLIES TO MODELS:

USER MANUAL

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

SEE ALSO: Benchmark Platinum

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

(2 of 2)

OPERATION, SERVICE, and MAINTENANCE GUIDE

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

Installation and Startup Guide,

OMM-0115 (GF-200)

• BMK 750

• BMK 1000

• BMK 1500

• BMK 2000

• BMK 2500

• BMK 3000

Propane:

• BMK 750P

• BMK 1000P

• BMK 1500P

Dual-Fuel (NG/P):

• BMK 1500DF

• BMK 2000DF

• BMK 2500DF

• BMK 3000DF

• BMK 2500P

• BMK 3000P

Applies to Serial Numbers:

Latest Update: 03/15/2017

OMM-0116_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 178 GF-201 Ph.: 800-526-0288 03/15/2017

G-17-0001 and above.

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and 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 CONTROL PANEL DESCRIPTION ...................................................................................................... 14

2.3 CONTROL PANEL 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: AERTRIM OPERATION .................................................................. 39

4.1 AERTRIM INTRODUCTION ................................................................................................................. 39

4.2 AERTRIM ACTI VATION ....................................................................................................................... 39

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

CONTENTS

4.3 OPERATION DETAILS ......................................................................................................................... 40

4.4 AERTRIM AUTO CALIBRATION .......................................................................................................... 42

4.5 AERTRIM MENU ITEMS ...................................................................................................................... 43

4.6 AERTRIM MENU VAL U ES AND DEFAULTS....................................................................................... 44

4.7 AERTRIM MAINTENANCE AND TROUBLESHOOTING ..................................................................... 50

SECTION 5: MAINTENANCE ............................................................................ 53

5.1 MAINTENANCE SCHEDULE ............................................................................................................... 53

5.2 IGNITER-INJECTOR ............................................................................................................................ 54

5.3 FLAME DETECTOR ............................................................................................................................. 59

5.4 O2 SENSOR .......................................................................................................................................... 59

5.5 SAFETY DEVIC E T ESTING ................................................................................................................. 60

5.6 BURNER INSPECTION ........................................................................................................................ 60

5.6.1 BMK 750/1000 BURNER INSPECTION ............................................................................................................. 61

5.6.2 BMK 1500 – 3000 BURNER INSPECTION ......................................................................................................... 63

5.7 CONDENSATE DRAIN TRAP .............................................................................................................. 67

5.8 AIR FILTER CLEANING AND REPLACEMENT .................................................................................. 68

5.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ............................................................... 69

5.9.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................................... 70

5.9.2 Low Water Cutoff (LWCO) - Standard C-More Test ........................................................................................ 71

5.10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD ................................................................... 71

5.11 PLACING THE BO IL E R BACK IN SER VI C E AFTER A PROLONGED SHUTDOWN ....................... 71

5.12 SPARK MONITOR (AC CURRENT TRANSDUCER) ......................................................................... 72

SECTION 6: TROUBLESHOOTING GUIDE ......................................................... 73

6.1 INTRODUCTION ................................................................................................................................... 73

6.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................... 85

APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ............................................. 87

TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS ......................................................................... 87

TABLE A-2: SETUP MENU ITEM DESCRIPTIONS ................................................................................... 89

TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS ................................................................ 90

TABLE A-4: TUNING MENU ITEM DESCRIPTIONS ................................................................................. 93

TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS ............................................. 94

TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS ....................................................................... 95

APPENDIX B: STARTUP, STATUS, & FAULT MESSAGES ...................................... 99

TABLE B-1: STARTUP AND STATUS MESSAGES .................................................................................. 99

TABLE B-2: FAULT MESSAGES ............................................................................................................. 100

APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART ...................................... 103

APPENDIX D: RECOMMENDED PERIODIC TESTING .......................................... 105

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS ................................ 107

APPENDIX F: BENCHMARK 750/1000 PART LISTS ........................................... 111

APPENDIX G: BENCHMARK 1500/2000 PART LISTS .......................................... 121

APPENDIX H: BENCHMARK 2500/3000 PART LISTS .......................................... 137

APPENDIX I: WIRING DIAGRAMS ................................................................... 159

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

CONTENTS

APPENDIX J: C-MORE CONTROL PANEL VIEWS ............................................... 175

APPENDIX K: RECOMMENDED SPARES ........................................................... 177

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

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)

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 for 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 descriptions provided in this document apply to the Benchmark Platinum Series of boiler.

• all measurements apply to both natural gas and propane models, unless otherwise

specified.

BMK PLATINUM BOILER INTAKE and OUTPUT RANGES

BMK

MODEL

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 Category II and IV, positive pressure appliances. Single and/or multiple breeched units are capable of operation in the following vent configurations:

• Room Combustion Ai r :

• Ducted Combustion Air:

emission standards outlined in: South Coast Air Quality Management District

o Vertical Discharg e o Horizontal Discharge

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

MINIMUM MAXIMUM MINIMUM MAXIMUM

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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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

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

A control system developed by AERCO and currently used in all

Carbon Monoxide

COMM (Comm)

Communication

Cal.

Calibration

CNTL

Control

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

Gas Fired (an AERCO document numbering system)

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

A (Amp) Ampere 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 (see below)

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

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

(or Control Box) CFH Cubic Feet per Hour (1 CFH = 0.028 m

Benchmark, Innovation and KC1000 Series product lines.

/hr)

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 Factory Mutual. Used to define boiler gas trains.

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

MBH

1000 BTUs per Hour

duplex data transmission protocol developed by AEG

onAER

P/N

Part Number

POC

Proof of Clos ure

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

GND Ground HDR Header 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 Control Box INTLK (INTL’K) Interlock I/O Input/Output

I/O Box 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® NC (N.C.) Normally Closed

NO (N.O.) Normally Open NOx Nitrogen Oxide NPT National Pipe T hread O2 Oxygen

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

KC1000 Series products

A serial, half-

Modicon

O.D. Outside Diameter OMM & O&M Oper ation and Maintenance Manual

AERCO’s on-line remote monitoring system PCB Printed Circuit Board PMC Board Primary Micro-Contr oller (PMC) board, contained in the C-More

PPM Part s per Million PSI Pounds per Square Inch (1 PSI = 6.89 kPa)

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

duplex (FDX) transmission of data based

cause invalid data in the

VDC

Volts, Direct Current

VFD

Vacuum Fluorescent Display, also Variable Frequency Drive

Watt

W.C.

Water Column, a unit of pressure (1 W.C. = 249 Pa)

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

PTP Point-to-Point (usually over RS232 networks) 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) RS422

(or EIA-422) RS485

(or EIA-485) 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

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

A standard for serial, full-

on the RS232 Standard

A standard for serial, full-

on the RS422 Standard

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

on the RS485 Standard

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

in order to prevent reflections that may

communication

µA Micro amp (1 millionth of an ampere)

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

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 wat er. Call a qualified service technician

to inspect and replace any part that has been under water.

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

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-0115 (GF-200) 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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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS

Boiler Installations within the Commonwealth of Massachusetts must conform to the

(a) For all 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

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):

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 the above requirements; provided, however, that during said thirty (30) day 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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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

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

2. The "special venting systems" 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

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.

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

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

SECTION 2: OPERATION

2.1 INTRODUCTION

The information in this section provides a guide to the operation of the Benchmark Boiler using the Control Panel 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 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-0115 (GF-200) must be completed b efore attempt i ng to start the unit.

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SECTION 2: OPERATION

2.2 CONTROL PANEL DESCRIPTION

All Benchmark boilers utilize the C-More Control 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.

Figure 2-1: Control Panel Front View

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

CONTROL, INDICATOR

or DISPLAY

Segment LED display continuously displays the outlet

blinks when operating in the

of displaying up to 16 alphanumeric characters. The information

trained personnel to monitor

communications, in combination with the RS232 Adaptor

124675

LED indicator lights when a boiler alarm condition

be cleared by simply pressing this key. Troubleshooting

opens the water level probe circuit and

SECTION 2: OPERATION

TABLE 2-1: CONTROLS, INDICATORS, AND DISPLAYS (ref. Figure 2-1)

ITEM

FUNCTION

LED STATUS INDICATORS

Four Status LEDs indicate the current operating status as follows:

COMM =

MANUAL =

REMOTE =

DEMAND =

OUTLET TEMPERATURE

Display

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.

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.

On a BST Manager, display flashes & shows header temperature. Vacuum Fluorescent Display (VFD) consists of 2 lines each capable

displayed includes:

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

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 conditions have been satisfied.

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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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

CONTROL, INDICATOR

or DISPLAY

Six (6) keys which provide the following functions for the Control Panel 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

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

BACK

▲

(UP)

Arrow

▼

(DOWN)

Arrow

CHANGE

FUNCTION

MENU KEYPAD

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 the top of a main menu category.

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.

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

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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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

MENU NAVIGATION and PROCESSING PROCEDURE Instructions

menu and the VFD will display the

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 CONTROL PANEL MENUS

The Control Panel 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-0115 (GF-200)), to perform combustion calibration prior to service use.

2.3.1 Menu Navigation and Processing Procedure

Accessing and initiating each menu and option is ac complished 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 Control Panel will normally be in the Operating

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.

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 k ey. 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. T he menu option choices do not wrap around.

7. To select and store a changed menu item, press the ENTER key.

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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-0115 (GF-200).

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.

Page 18 of 178 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A 03/15/2017 Ph.: 800-526-0288 GF-201

Figure 2-2: Menu Structure

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

AVAILABLE CHOICES OR LIMITS

Minimum

Maximum

30°F (-1.1°C)

240°F (115.6°C)

Ignition Time

SSOV Time to OPN

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 m enu 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

Active Setpoint

Outlet Temp

Inlet Temp

Air Temp

Outdoor Temp

Valve Position In 0% 100%

Valve Position Out 0% 100% Configuration Menu

FFWD Temp

Exhaust Temp Displays current exhaust temperature

Flame Strength 0% 100%

Min Flame Str Not Used

O2 Monitor Enable Disable O2 Monitor = Enabled

Oxygen Level 0% 21%

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)

0.00 10.00

Appears Only If

Enabled in:

Configuration Menu

15 16

Spark Current

Run Cycles 0 999,999,999

Run Hours 0 999,999,999

Fault Log 0 19

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

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0.00 10.00

0 amps 2.5 amps

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

AVAILABLE CHOICES OR LIMITS

Minimum

Maximum

Language

English

Date

01/01/00

12/31/99

01/01/00

Comm Address

127

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 Control Box software version.

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

Table 2-3: SETUP Menu

MENU ITEM DISPLAY

Password 0 9999 0

Time 12:00 am 11:59 pm 12:00

Unit of Temp Fahrenheit or Celsius Fahrenheit

onAER Mode Et hernet or SD Card Ethernet

Min Upload Timer 0 9,999 Sec 0

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

Unit Year 0 99 0

Unit Serial # 0 9999 0

Software Ver 0.00 Ver 9.99

DEFAULT

Current software

version

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-4: CONFIGURATION Menu

AVAILABLE CHOICES OR LIMITS

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.

MENU ITEM DISPLAY

Internal Setpt

Unit Type

Unit Size

(Only displays sizes available for the unit)

Fuel Type

Boiler Mode

Remote Signal (If Mode = Remote

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

Outdoor Sensor * Bldg Ref Temp

(If Mode = Outdoor Reset)

* Reset Ratio

(If Mode = Outdoor Reset)

* System Start Tmp

(If Outdoor Sensor = Enabled)

Setpt Lo Limit

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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)

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

AVAILABLE CHOICES OR LIMITS

Minimum

Maximum

(Do NOT change)

SECTION 2: OPERATION

Table 2-4: CONFIGURATION Menu

MENU ITEM DISPLAY

Setpt Hi Limit

Temp Hi Limit 40°F (4.4°

Max Valve Position

Pump Delay Timer

Aux Start On Dly

Failsafe Mode

17 18

Analog Output Low Fire Timer

Setpt Limiting

Setpt Limit Band

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

Demand Offset

Deadband High

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

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

Slow Shutdown Enabled or Disabled Disabled

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

O2 Warnings Enabled or Disabled Disabled

O2 Trim ID Displays 4 digit AERtrim ID

Fixed ID Displays unit’s fixed 4 dig it ID

O2 Trim Key Displays AERtrim 4 digit licens e key

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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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-5: TUNING Menu

AVAILABLE CHOICES OR LIMITS

Minimum

Maximum

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

Acceptable Range

Default

Minimum

Maximum

Natural gas

Propane

CAL Voltage 18%

0.25

10.00

2.10

CAL Voltage 30%

0.25

10.00

2.55

CAL Voltage 45%

0.25

10.00

3.10

CAL Voltage 60%

0.25

10.00

3.50

CAL Voltage 80%

0.25

10.00

4.60

CAL Voltage 100%

0.25

10.00

5.60

SET Valve Position

100%

Blower Output

Monitor Blower Output Voltage

0.00

Set Stdby Volt

0 V

10.0 V

2.00

Oxygen Level

25%

0.0

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

Prop Band

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

DEFAULT

Integral Gain 0.00 2.00 1.00 Derivative Time 0.0 min 2.00 min 0.0min

Warmup Prop Band

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

1°F (0.55°C) 120°F (66°C) 95 °F (52°C)

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 T able 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-0115 (GF-200).

) and Carbon

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

Menu Item Display

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-7a: COMBUSTION CAL Menu: BMK 1500/2000

SINGLE FUEL – NATURAL GAS

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

DUAL FUEL

0.25

10.00

1.50

–

0.25

10.00

– – 1.20

2.10

0.25

10.00

3.30

4.50

3.00

4.10

0.25

10.00

4.10

4.80

3.50

4.10

100

Variable

Displays current value

10.0

2.00

SECTION 2: OPERATION

2.8.2 BMK 1500/2000 COMBUSTION CAL Menus

Menu Item Display

CAL Voltage 16%

CAL Voltage 18% – 1.40

CAL Voltage 30%

CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100% SET Valve Position 0% 100% Variable Blower Output Displays current value Set Stdby Volt 0 10.00 V 2.00 V 2.00 V Oxygen Level Displays current value

Menu Item Display

Acceptable Range Defaults

Minimum Maximum BMK 1500 BMK 2000

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

Acceptable Range

NATURAL GAS *

1.80 –

Defaults

PROPANE

CAL Voltage: 16%

CAL Voltage: 18%

CAL Voltage 30%

CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100%

SET Valve Position

Blower Output Set Stdby Volt

Oxygen Level

Minimum Maximum

0.25 10.00 2.60 4.50 2.30 3.50

0.25 10.00 3.20 4.50 2.80 3.90

0.25 10.00 8.30 9.80 7.70 8.90

BMK 1500 BMK 2000 BMK 1500 BMK 2000

Displays current value

* 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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2.10

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

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

SINGLE FUEL – NATURAL GAS

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

0.25

10.00

–

0.25

10.00

– – 2.00

2.30

CAL Voltage: 20%

0.25

10.00

2.10 – –

–

0.25

10.00

5.40

3.30

4.40

0.25

10.00

6.60

4.60

5.40

0.25

10.00

6.60

–

5.60

–

0.25

10.00 – – – –

0.25

10.00

8.00

–

7.00

100

Variable

Displays current value

10.0

2.00

Displays current value

SECTION 2: OPERATION

2.8.3 BMK 2500/3000 COMBUSTION CAL Menus

MENU ITEM DISPLAY

CAL Voltage 16%

CAL Voltage 14% – 2.80

CAL Voltage 30%

CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100% SET Valve Position 0% 100% Variable Blower Output Displays current value Set Stdby Volt 0 10.00 V 2.00 V 2.00 V Oxygen Level Displays current value

Menu Item Display

Acceptable range Defaults

Minimum Maximum BMK 2500 BMK 3000

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

Acceptable Range

NATURAL GAS *

Minimum Maximum BMK 2500 BMK 3000 BMK 2500 BMK 3000

2.20 –

Defaults

PROPANE

CAL Voltage: 14% CAL Voltage: 16%

CAL Voltage: 18%

CAL Voltage: 22%

CAL Voltage 30% CAL Voltage 45%

CAL Voltage 65% CAL Voltage 70%

CAL Voltage 75% CAL Voltage 85%

CAL Voltage 100%

SET Valve Position Blower Output Set Stdby Volt

Oxygen Level

0.25 10.00 –

2.15

0.25 10.00

0.25 10.00 – 7.00 – 5.70

0.25 10.00

–

3.90

5.60

–

8.50

2.40 –

– 2.00 –

8.70 7.90 8.60

– –

* 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.

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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-9: BST Menu

BST Mode

*BST SETUP MENU*

Disabled

Enabled

Disabled

Remote

Setpoint

Outdoor

Reset

0-20 mA/0-5

VDC

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

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

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

BST Fire Rate 0 100% Fire rate %

BST Ave Fire Rate 0 100% Avg Fire Rate %

BST Outdoor Temp Read Only – current outdoor temperature in °F N/A Units Available 0 8 Units Present

Units Ignited 0 8 Units firing

BST Valve State 0 (CLOSED) 1 (OPEN) 0 1 BST Comm Errors 8 0 9 0

1 BST Units 8 0 (see table) 0 (see table) 0

AVAILABLE CHOICES OR LIMITS

DEFAULT

Minimum Maximum

Off BST Client BST Manager Off

BST Setpoint Mode

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

Head Temp Source Network FFWD Temp FFWD Temp

Mdbus Temp Units Degrees C or Degrees F Degrees C

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Constant Setpoint

Constant Setpt

Network Network

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-9: BST Menu

Yes

feature.

On-Outlet

Temp

*OPERATE MENU*

*TEMP CTRL MENU*

SECTION 2: OPERATION

MENU ITEM DISPLAY

Header Temp Addr 0 255 240

Header Temp Point 0 255 14

BST Outdoor Sens Disabled Enabled Disabled

Outdr Tmp Source Outdoor Temp Network Outdoor Temp Outdoor Tmp Addr 0 255 240

Outdoor Tmp Pnt 0 255 215

BST Auto Mstr No

BST Auto Timer 10 sec 120 sec 30 sec

Remote Intlk Use Boiler Shutdown System Shutdown System Shutdown

One Boiler Mode Off

1 Blr Threshold 10 35 25

Setpoint Setback Disable Enable Disable

Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130°F (54.4°C) Setback Start 12:00am 11:59pm 12.00am

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)

AVAILABLE CHOICES OR LIMITS

DEFAULT

Minimum Maximum

NOTE! A Modbus temperature transmitter must be installed in conjunction with this

On-Avg Temp Off

35 36 37

39 40 41

44 45

47 48 49

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-0116_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 178

GF-201 Ph.: 800-526-0288 03/15/2017

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-9: BST Menu

*BST COMM MENU*

SECTION 2: OPERATION

MENU ITEM DISPLAY

BST Deadband Hi 0 25 1

BST Deadband Lo 0 25 1

Deadband En Time 0 120 Sec 30 Sec

BST FR Up Rate 1 120 20 BST Bldg Ref Tmp 40°F (4.4°C) 230°F (110°C) 70°F (21.1°C)

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)

Comm Address 0 127 0

BST Min Addr 1 128 1

BST Max Addr 1 128 8

SSD Address 0 250 247 SSD Poll Control 0 1000 0

Err Threshold 1 9 5

SSD Temp Format Degrees Points Degrees

BST Upld Timer 0 9999 sec 0

AVAILABLE CHOICES OR LIMITS

DEFAULT

Minimum Maximum

Disabled Enabled Disabled

Page 28 of 178 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A 03/15/2017 Ph.: 800-526-0288 GF-201

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-10: Calibration Menu

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

Default

Minimum Maximum

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

Purge Timer 5 sec. 60 sec Depends on unit type/size

Post Purge Timer 0 sec. 60 sec. 0 sec.

IGN Position 5% 60% Depends on unit type/size

Ign Pos Hold Tmr 0 sec. 60 sec. 0 sec.

Available Choices or Limits

FFWD Temp Disply Enabled or Disabled

Outlet Tmp Dsply Enabled or Disabled

Inlet Tmp Dsply Enabled or Disabled

Valv Pos Out Dsp Enabled or Disabled

Exhaust Tmp Dsp Enabled or Disabled

Exhaust Safety Enabled or Disabled

Flue Material

Exhst Fault Temp 100 °F 500 °F 200 °F

PVC,CPVC; PolyPro;

Stainless

Disabled Disabled Disabled

Enabled

Disabled

Enabled

PVC,CPVC

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

Exhst Warn Temp 100 °F 500 °F 180 °F

Exhst Tmp VP Adj 0 10 5

Exhst Adj Rate 1 600 30

VP Change Rate 5 600 25

VP Up Rate 0.5 60.0 Depends on unit type/size

VP Down Rate 0.5 60.0 Depends on unit type/size

Purge Blwr Offst -1.0 8.0 Depends on unit type/size

4-20mA Purge Pct 60% 100% 70%

PWM In Adj -5.0% 5.0% 0.0%

Analog In Adj

Flow In Adj

Supply Gas Pressure In Adj -5.0% 5.0% 0.0%

Gas Plate dp In Adj -5.0% 5.0% 0.0%

OMM-0116_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 178 GF-201 Ph.: 800-526-0288 03/15/2017

-5.0% 5.0% 0.0%

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

Table 2-10: Calibration Menu

SECTION 2: OPERATION

Menu Item Display

Available Choices or Limits

Minimum Maximum

mA Out Adj -1.0 m A 1.0 mA 0.0 mA

A/F Sensitivity 1% 5% 2%

Power Reset Automatic or Manual Automatic

Water Temp Reset Automatic or Manual Automatic

Gas Press Reset Automatic or Manual Manual

Min Off Time 0 Min 15 Min 1 Min

Heatr Tuning Dsp Enabled or Disabled Disabled

Heatr Bkpt Dsp Enabled or Disabled Disabled

Stop Level 0% Start Level 16

Start Level Stop Level 40% 22

Skip Range Cntr 10 95 40

Skip Range Span 0 3 0%

Skip Speed 0.5 2.0 0.5%

O2 Gain 0.500 1.500 1.000

Default

O2 Offset -24.0 +2.0 1.0

O2 Sensor Enabled or Disabled Depends on unit type/size

Cal Temp Sensors

FFWD Temp Offset -20 +20 0

Exhst Tmp Offset -20 +20 0

Outdr Air Offset -20 +20 0

Inlet Air Offset -20 +20 0

Inlet Wtr Offset -20 +20 0

Outlet Wtr Offset -20 +20 0

24 hr Max Cycles 0 9999 0

24 hr Max Ovrtemp 0 9999 0

0-10v Out Test 0.0 10.0 0.00

Spark Monitor Enabled or Disabled Depends on unit type/size

Min Spark Amps 0.0 Amps 2.5 Amps 0.10 Amps

Max Spark Amps 0.0 Amps 2.5 Amps 0.40 Amps

Off or Start Off

Page 30 of 178 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A 03/15/2017 Ph.: 800-526-0288 GF-201

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