AER Benchmark BMK 5000 Installation and user guide

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
OMM-0124_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1of 136
GF-208 Ph.: 800-526-0288 05/03/2017
GF-208
OPERATION, SERVICE, and MAINTENANCE GUIDE
®
Natural Gas, Propane Gas and Dual Fuel Fired Modulating, Condensing Boilers
Latest Update: 05/03/ 2017
This Guide Applies to Models:
Single Fuel Dual Fuel
Natural Gas
•BMK 5000
•BMK 6000
Propane
•BMK 5000 P
•BMK 6000 P
Natural Gas & Propane
•BMK 5000 DF
•BMK 6000 DF
See also:
Benchmark 5000 – 6000 INSTALLATION
and STARTUP Guide
OMM-0123 (GF-207)
Applies to Serial Numbers:
N-17-0100 and above
5000 and 6000 MBH Boilers
USER MANUAL
(2 of 2)

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
CONTENTS
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TABLE OF CONTENTS
SECTION 1: SAFETY PRECAUTIONS ...................................................................9
1.1 WARNINGS & CAUTIONS .....................................................................................................................9
1.2 EMERGENCY SHUTDOWN.................................................................................................................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
2.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU .......................................................................24
2.10 CALIBRATION MENU.........................................................................................................................26
SECTION 3: MODES OF OPERATION ...............................................................29
3.1 INDOOR/OUTDOOR RESET MODE ...................................................................................................29
3.1.1 Reset Ratio......................................................................................................................................................29
3.1.2 Building Reference Temperature....................................................................................................................29
3.1.3 Outdoor Air Temperature Sensor Installation ................................................................................................29
3.1.4 Indoor/Outdoor Startup .................................................................................................................................30
3.2 CONSTANT SETPOINT MODE ...........................................................................................................30
3.2.1 Setting the Setpoint ........................................................................................................................................31
3.3 REMOTE SETPOINT MODES .............................................................................................................31
3.3.1 Remote Setpoint Field Wiring.........................................................................................................................32
3.3.2 Remote Setpoint Startup ................................................................................................................................32
3.4 DIRECT DRIVE MODES.......................................................................................................................32
3.4.1 Direct Drive Field Wiring.................................................................................................................................33
3.4.2 Direct Drive Startup ........................................................................................................................................33
3.5 AERCO CONTROL SYSTEM (ACS)....................................................................................................34
3.5.1 ACS External Field Wiring................................................................................................................................34
3.5.2 ACS Setup and Startup....................................................................................................................................34
3.6 COMBINATION CONTROL SYSTEM (CCS).......................................................................................35
3.6.1 Combination Control System Field Wiring......................................................................................................36
3.6.2 Combination Control System Setup and Startup............................................................................................36
SECTION 4: MAINTENANCE ............................................................................37
4.1 MAINTENANCE SCHEDULE ...............................................................................................................37
4.2 PILOT BURNER....................................................................................................................................38
4.3 MAIN FLAME DETECTOR ...................................................................................................................40
4.4 O2SENSOR..........................................................................................................................................40
4.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT.............................................42
4.5.1 Pilot Regulator Pressure Testing.....................................................................................................................42

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
CONTENTS
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4.5.2 Pilot Regulator Pressure Calibration...............................................................................................................44
4.6 SAFETY DEVICE TESTING.................................................................................................................45
4.7 BURNER INSPECTION........................................................................................................................45
4.8 REFRACTORY REMOVAL & REPLACEMENT...................................................................................49
4.8.1 Rear Refractory Removal and Replacement...................................................................................................49
4.8.2 Front Refractory Replacement .......................................................................................................................52
4.9 CONDENSATE DRAIN TRAP ..............................................................................................................53
4.10 AIR FILTER CLEANING AND REPLACEMENT ................................................................................54
4.11 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST.............................................................55
4.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test .........................................................................56
4.11.2 Low Water Cutoff (LWCO) - Standard C-More Controller Test.....................................................................57
4.12 SHUTTING BOILER DOWN FOR EXTENDED PERIOD...................................................................57
4.13 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN.......................58
4.14 GAS VALVE ACTUATOR REPLACEMENT.......................................................................................59
SECTION 5: TROUBLESHOOTING GUIDE .........................................................61
5.1 INTRODUCTION...................................................................................................................................61
5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ....................................................74
APPENDIX A: BOILER MENU ITEM DESCRIPTIONS .............................................79
TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS .........................................................................79
TABLE A-2: SETUP MENU ITEM DESCRIPTIONS...................................................................................81
TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS ................................................................82
TABLE A-4: TUNING MENU ITEM DESCRIPTIONS.................................................................................85
TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS.............................................86
TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS.......................................................................87
APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES ....................................91
TABLE B-1: STARTUP AND STATUS MESSAGES..................................................................................91
TABLE B-2: FAULT MESSAGES ...............................................................................................................92
APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART........................................95
APPENDIX D: RECOMMENDED PERIODIC TESTING ............................................97
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS ..................................99
APPENDIX F: PART LISTS AND DRAWINGS ......................................................103
APPENDIX G: WIRING DIAGRAMS ...................................................................115
BMK 5000/6000 STANDARD FUEL MODEL WIRING DIAGRAMS.........................................................127
APPENDIX H: C-MORE CONTROLLER VIEWS ....................................................131
APPENDIX I: RECOMMENDED SPARES ...........................................................133
APPENDIX J: LONG TERM STORAGE ...............................................................134
J-I: LONG TERM BOILER STORAGE......................................................................................................134
J-2: LONG TERM BLOWER STORAGE ..................................................................................................134

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
CONTENTS
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FOREWORD
The AERCO Benchmark (BMK) 5000 MBH (1465 kW) and 6000 MBH (1758 kW) natural gas
and dual fuel propane/natural gas fueled boilers are modulating and condensing units. They
represent a true industry advance that meets the needs of today's energy and environmental
concerns. Designed for application in any closed loop hydronic system, their modulating
capability relates energy input directly to fluctuating system loads. The maximum turn down ratio
for the BMK 5000 and 6000 is 15:1. These Benchmark models provide extremely high
efficiency, which makes them ideally suited for modern low temperature, as well as conventional
heating systems.
The Benchmark platinum 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
INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.)
MINIMUM MAXIMUM MINIMUM MAXIMUM
5000 400,000 (117 kW)
5,000,000 (1465 kW) 348,000 (102 kW) 4,750,000 (1392 kW)
6000 400,000 (117 kW)
6,000,000 (1758 kW) 348,000 (102 kW) 5,700,000 (1670 kW)
The output of the boiler is a function of the unit’s firing rate (valve position) and return water
temperature.
When installed and operated in accordance with this Instruction Manual, these boilers comply
with the NOx emission standards outlined in: South Coast Air Quality Management District
(SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the BMK 1500 and BMK 2000 boilers offer
the maximum venting flexibility with minimum installation space requirements. These boilers are
Category II and IV, positive pressure appliances. Single and/or multiple breeched units are
capable of operation in the following vent configurations:
•Room Combustion Air:
oVertical Discharge
oHorizontal Discharge
•Ducted Combustion Air:
oVertical Discharge
oHorizontal 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.

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
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AERCO Technical Terminology
TERMINOLOGY MEANING
A (Amp) Ampere
ACS AERCO Control System, AERCO’s boiler management systems
ADDR Address
AGND Analog Ground
ALRM Alarm
ANSI American National Standards Institute,
ASME American Society of Mechanical Engineers
AUX
Auxiliary
BAS Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate Symbol
rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BMK (Benchmark) AERCO’s Benchmark series boilers
BMS or BMS II AERCO Boiler Management Systems
BLDG (Bldg) Building
BST AERCO on-board Boiler Sequencing Technology
BTU
British Thermal Unit. A unit of energy approximately equal to the
heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)
BTU/HR BTUs per Hour (1 BTU/hr = 0.29 W)
CCP Combination Control Panel
CCS Combination Control System
C-More Controller
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CFH Cubic Feet per Hour (1 CFH = 0.028 m3/hr)
CO Carbon Monoxide
COMM (Comm) Communication
Cal. Calibration
CNTL Control
CPU Central Processing Unit
DBB
Double Block and Bleed, a gas trains containing 2 Safety Shutoff
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.
GF-xxxx Gas Fired (an AERCO document numbering system)
GND Ground

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AERCO Technical Terminology
TERMINOLOGY MEANING
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 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 thousand
th
of an ampere)
MAX (Max) Maximum
MBH
1000 BTUs per Hour
MIN (Min) Minimum
Modbus® A serial, half-
duplex data transmission protocol developed by AEG
Modicon
NC (N.C.) Normally Closed
NO (N.O.) Normally Open
NOx Nitrogen Oxide
NPT National Pipe Thread
O
2
Oxygen
O.D. Outside Diameter
OMM & O&M Operation and Maintenance Manual
onAER
AERCO’s on-line remote monitoring system
PCB Printed Circuit Board
PMC Board Primary Micro-Controller (PMC) board, contained in the C-More
P/N
Part Number
POC
Proof of Closure
PPM Parts per Million
PSI Pounds per Square Inch (1 PSI = 6.89 kPa)

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AERCO Technical Terminology
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) A standard for serial, full-duplex (FDX)
transmission of data based
on the RS232 Standard
RS422
(or EIA-422) A standard for serial, full-
duplex (FDX) transmission of data based
on the RS422 Standard
RS485
(or EIA-485) A standard for serial, half-duplex (HDX) transmission of data based on the RS485 Standard
RTN (Rtn) Return
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield
SPDT
Single Pole Double Throw, a type of switch
SSOV
Safety Shut Off Valve
TEMP (Temp)
Temperature
Terminating Resistor A resistor placed at each end of a daisy-chain or multi-drop network
in order to prevent reflections that may cause invalid data in the
communication
Tip-N-Tell A device that indicates if a package was tipped during shipping
UL A business that tests and validates products
VAC Volts, Alternating Current
VDC Volts, Direct Current
VFD Vacuum Fluorescent Display, also Variable Frequency Drive
W Watt
W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa)
µA Micro amp (1 million
th
of an ampere)

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 1: SAFETY PRECAUTIONS
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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 Guide is an integral part of the product and must be maintained in legible condition. It
must be given to the user by the installer and kept in a safe place for future reference.
WARNING!
•Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.
•Fluids under pressure may cause injury to personnel or damage to equipment when
released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully
decrease all trapped pressures to zero before performing maintenance.
•Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
•The exhaust vent pipe of the unit may operate under a positive pressure and therefore
must be completely sealed to prevent leakage of combustion products into living spaces.
•Electrical voltages of 120, 208, 460, 575 and 24 may be used in this equipment. Therefore
the cover on the unit’s power box (located behind the front panel door) must be installed
at all times, except during maintenance and servicing.
•A three-pole switch must be installed on the electrical supply line of the unit. The switch
must be installed in an easily accessible position to quickly and safely disconnect
electrical service. Do not affix switch to unit sheet metal enclosures.
CAUTION!
•Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
•DO NOT use this boiler if any part has been under water. Call a qualified service
technician to inspect and replace any part that has been under water.

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 1: SAFETY PRECAUTIONS
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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.
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
If there is an emergency, turn off the electrical power supply to the boiler and close the manual
gas valve located upstream the unit. The installer must identify the emergency shut-off device.
If the boiler needs to be shut down for a prolonged period, follow the instructions in Section
4.12: Shutting Boiler Down For Extended Period of this manual, and review the procedures in
Appendix J at the end of this manual.
After prolonged shutdown, it is recommended that the procedures in Section 4: Initial Startup
and Section 5: Safety Device Testing of the Benchmark 5000 – 6000 Installation and Startup
Guide OMM-0123 (GF-207) be performed to verify that all system-operating parameters are
correct.
VALVE
OPEN
VALVE
CLOSED
MANUAL GAS SHUT-OFF VALVE

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
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1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS
Boiler Installations within the Commonwealth of Massachusetts must conform to the
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 all side wall horizontally vented gas fueled equipment installed in every dwelling,
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
monoxide det
ector with an alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure the services of qualified licensed
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 period, a
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS:
Each carbon monoxide detector as
required in
accordance with the above provisions shall comply with NFPA 720 and be
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
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)

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REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS
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
observes carbon monoxide detectors and signage installed in accordance with the
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
venting system design or venting system components with the equipment, the instructions
provided by the manufacturer for installation of the equipment and the venting system shall
include:
1. Detailed instructions for the installation of the venting system design or the venting
system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled
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 systems" shall be Product Approved by the Board, and the
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)]…………………

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 2: OPERATION
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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 VOLTAGES IN THIS SYSTEM INCLUDE 120, 208, 460, 575 AND 24
VOLTS AC. IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE
TECHNICIANS.
•DO NOT ATTEMPT TO DRY FIRE THE UNIT. STARTING THE UNIT WITHOUT A
FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN
INJURY TO PERSONNEL OR PROPERTY DAMAGE. THIS SITUATION WILL VOID
ANY WARRANTY.
CAUTION!
All of the installation procedures in Section 2 of the Benchmark 5000 – 6000 Installation and
Startup Guide OMM-0123 (GF-207) must have been completed before attempting to start the
unit.

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 2: OPERATION
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2.2 CONTROL PANEL 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.
Figure 2-1: Control Panel Front View
1
12
11
10
9
8
7
5
4
3
6
2

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 2: OPERATION
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TABLE 2-1: CONTROLS, INDICATORS, AND DISPLAYS (ref. Figure 2-1)
ITEM CONTROL, INDICATOR
or DISPLAY FUNCTION
1
LED STATUS INDICATORS
Four Status LEDs indicate the current operating status as follows:
COMM = Lights when RS232 communication is occurring – see Item 4.
MANUAL = Lights when the valve position (fire rate) is being controlled using the front
panel keypad. This mode of operation is for service technician use only.
REMOTE = Lights when the unit is being controlled by an external signal from an Energy
Management System.
DEMAND = Lights when there is a demand for heat.
2 OUTLET
TEMPERATURE
Display
3–Digit, 7–
Segment LED display continuously displays the outlet
water temperature. The °F or °C LED next to the display lights to
indicate whether the displayed temperature is in degrees Fahrenheit
or degrees Celsius. The °F or °C blinks when operating in the
DEADBAND mode.
On a BST Manager, display flashes & shows header temperature.
3 VFD Display
Vacuum Fluorescent Display (VFD) consists of 2 lines each capable
of displaying up to 16 alphanumeric characters. The information
displayed includes:
•Startup Messages
•Fault Messages
•Operating Status Messages
•Menu Selection
•BST Messages
4 RS232 Port This port is used only by factory-
trained personnel to monitor
onAER communications, in combination with the RS232 Adaptor
Cable (P/N
124675
).
5 FAULT Indicator Red FAULT
LED indicator lights when a boiler alarm condition
occurs. An alarm message will appear in the VFD.
6 CLEAR Key Turns off the FAULT indicator and clears the alarm message if the
alarm is no longer valid. Lockout type alarms will be latched and
cannot be cleared by simply pressing this key. Troubleshooting
may be required to clear these types of alarms.
7 READY Indicator Lights when ON/OFF switch is set to ON and when all Pre-Purge
conditions have been satisfied.
8
ON/OFF switch Enables and disables boiler operation.
9
LOW WATER
LEVEL
TEST/RESET
switches
•Allows operator to test operation of the water level monitor.
•Pressing TEST
opens the water level probe circuit and
simulates a Low Water Level alarm.
•Pressing RESET resets the water level monitor circuit.
•Pressing the CLEAR key (item 6) resets the display.

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Page 16 of 136 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0124_0A
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TABLE 2-1: CONTROLS, INDICATORS, AND DISPLAYS (ref. Figure 2-1)
ITEM CONTROL, INDICATOR
or DISPLAY FUNCTION
10
MENU KEYPAD
Six (6) keys which provide the following functions for the Control Panel menus:
MENU Steps through the main menu categories, shown in Figure 2-2, below. The
menu categories wrap around in the order shown.
BACK
Allows you to go back to the previous menu level without changing any
information. Continuously pressing this key will bring you back to the
default status display in the VFD. Also, this key allows you to go back to
the top of a main menu category.
▲
(UP)
Arrow
When in one of the main menu categories (Figure 2-2), pressing the ▲
arrow key will select the displayed menu category. If the CHANGE key was
pressed and the menu item is flashing, pressing the ▲ arrow key will
increment the selected setting.
▼
(DOWN)
Arrow
When in one of the main menu categories (Figure 2-2), pressing this key
will select the displayed menu category. If the CHANGE key was pressed
and the menu item is flashing, pressing the ▼ arrow key will decrement the
selected setting.
CHANGE
Permits a setting to be changed (edited). When the CHANGE
key is
pressed, the displayed menu item will begin to flash. Pressing the ▲or ▼
arrow key when the item is flashing will increment or decrement the
displayed setting.
ENTER
Saves the modified menu settings in memory. The display will stop
flashing.
11 AUTO/MAN switch
This switch toggles the boiler between the AUTOMATIC and
MANUAL modes of operation. When in the MANUAL (MAN) mode,
the front panel controls are enabled and the MANUAL status LED
lights. Manual operation is for service only.
When in the AUTOMATIC (AUTO) mode, the MANUAL status LED
will be off and the front panel controls disabled.
12 VALVE POSITION
Bargraph 20 segment red LED bargraph continuously shows the Air/Fuel
Valve position in 5% increments from 0 to 100%

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 2: OPERATION
OMM-0124_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 17 of 136
GF-208 Ph.: 800-526-0288 05/02/2017
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, below. Each of the menus
shown, contain options which permit operating parameters to be viewed or changed. The
menus are protected by password levels to prevent unauthorized use.
Prior to entering the correct password, the options contained in the Operation, Setup,
Configuration and Tuning menu categories can be viewed. However, with the exception of
Internal Setpoint Temperature (Configuration menu), none of the viewable menu options can be
changed.
Once the valid level 1 password (159) is entered, the options listed in the Setup, Configuration
and Tuning menus can be viewed and changed, if desired. The Combustion Cal menu is
protected by the level 2 password (6817), which is used in Section 4.5, below, 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:
MENU NAVIGATION and PROCESSING PROCEDURE Instructions
1. The Control Panel will normally be in the Operating
menu and the VFD will display the
current unit status. Pressing the ▲ or ▼ arrow key will display the other available data
items in the Operating menu.
2. Press the MENU key. The display will show the Setup
menu, which is the next menu
category shown in Figure 2-2. This menu contains the Password option which must be
entered if other menu options will be changed.
3. Continue pressing the MENU key until the desired menu is displayed.
4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option
in the
selected menu will be displayed.
5.
Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.
Pressing the ▲ arrow key will display the available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence.
The menu options will wrap-around after the first or last available option is reached.
6. To change the value or setting of a displayed menu option, press the CHANGE key. The
displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the
available menu option choices for the option to be changed. The menu option choices do
not wrap around.
7. To select and store a changed menu item, press the ENTER key.

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
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Page 18 of 136 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0124_0A
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* Boiler Sequencing Technology (BST) appears only if enabled. See Section 6 in the
Benchmark 5000 – 6000 Installation and Startup Guide, OMM-0123 (GF-207) for
instructions.
Figure 2-2: Menu Structure
NOTE:
The following sections provide brief descriptions of the options contained in each menu.
Refer to Appendix A in this guide for detailed descriptions of each menu option. Refer to
Appendix B for listings and descriptions of displayed startup, status and error messages.
* Boiler Sequencing
Technology

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 2: OPERATION
OMM-0124_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 19 of 136
GF-208 Ph.: 800-526-0288 05/02/2017
2.4 OPERATING Menu
The Operating menu displays a number of key operating parameters for the unit. All items in this
menu except O2 Monitor (item 15) are “Read-Only” and cannot be changed. This menu can be
accessed without entering a password.
A full description of each item appears in Appendix A-1.
Table 2-2: OPERATING Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMITS
Appears Only If
Enabled in:
Minimum
Maximum
1 Active Setpoint 40°F (4.4°C) 240°F (116°C)
2 Outlet Temp 30°F (-1.1°C) 240°F (116°C) Configuration Menu
3 Inlet Temp 30°F (-1.1°C) 240°F (116°C)
4 Air Temp -70°F (-56.7°C) 245°F (118°C)
5 Outdoor Temp -70°F (-56.7°C) 130°F (54.4°C) Configuration Menu
6 Valve Position In 0% 100%
7 Valve Position Out 0% 100% Configuration Menu
8 FFWD Temp
30°F (-1.1°C)
240°F (115.6°C)
9 Exhaust Temp Displays current exhaust temperature
10 Flame Strength 0% 100%
11 Min Flame Str Not Used
12 O2 Monitor Enable Disable O2 Monitor = Enabled
13 Oxygen Level 0% 21%
14 Ignition Time 0.00 10.00
15 SSOV Time to OPN 0.00 10.00
16 Spark Current 0 amps 2.5 amps
17 Run Cycles 0 999,999,999
18 Run Hours 0 999,999,999
19 Fault Log 0 19
*NOTE
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
button on the C-More Controller’s front face.

BMK 5000-6000 Boiler OPERATION-SERVICE-MAINTENANCE GUIDE
SECTION 2: OPERATION
Page 20 of 136 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0124_0A
05/03/2017 Ph.: 800-526-0288 GF-208
2.5 SETUP Menu
The Setup menu (Table 2-3) permits the operator to enter the unit password (159) which is
required to change the menu options. To prevent unauthorized use, the password will time-out
after 1 hour. Therefore, the correct password must be reentered when required. In addition to
permitting password entries, the Setup menu is also used to enter date and time, and units of
temperature measurements. A view-only software version display is also provided to indicate
the current C-More Controller software version.
Table 2-3: SETUP Menu
MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMITS DEFAULT
Minimum Maximum
1 Password 0 9999 0
2
Language
English
English
3
Time
12:00 am
11:59 pm
4
Date
01/01/00
12/31/99
5
Unit of Temp Fahrenheit or Celsius Fahrenheit
6
Comm Address
0
127
0
7
Baud Rate
2400, 4800, 9600, 19.2K
9600
8 onAER Mode Ethernet 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
version