AERCO BMK 1000 User Manual
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
BENCHMARK Series
USER MANUAL
Installation, Operation and Maintenance
Natural Gas & Propane
Modulating &
Condensing Hot Water Boiler
Models:
Gas-Fired Boilers
• BMK 750
• BMK 1000
Applicable to Serial Numbers :
• G-14-0752 and above
Latest Update: 05/21/2014
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Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
Disclaimer
The information contained in this manual is subject to change without notice from AERCO
International, Inc. AERCO makes no warranty of any kind with respect to t his mater ial, including
but not limited to implied warranties of merchantability and fitness for a particular application.
AERCO International is not liable for errors appearing in this manual. Nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of this
material.
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TABLE OF CONTENTS
FOREWORD ................................................................................................................. 7
CHAPTER 1. SAFETY PRECAUTIONS ..................................................................... 11
1.1 WARNINGS & CAUTIONS ................................................................................................................... 11
1.2 EMERGENCY SHUTDOWN ................................................................................................................. 12
1.3 PROLONGED SHUTDOWN ................................................................................................................. 13
CHAPTER 2. INSTALLATION .................................................................................... 15
2.1 INTRODUCTION ................................................................................................................................. 15
2.2 RECEIVING THE UNIT ......................................................................................................................... 15
2.3 UNPACKING ....................................................................................................................................... 15
2.4 SITE PREPARATION ............................................................................................................................ 16
2.4.1 Installation Clearances ................................................................................................................ 16
2.4.2 Setting the Unit ........................................................................................................................... 17
2.5 SUPPLY AND RETURN PIPING ............................................................................................................ 19
2.6 PRESSURE RELIEF VALVE INSTALLATION ........................................................................................... 19
2.7 CONDENSATE DRAIN & PIPING ......................................................................................................... 20
2.8 GAS SUPPLY PIPING ........................................................................................................................... 22
2.8.1 Gas Supply Specifications ........................................................................................................... 22
2.8.2 Manual Gas Shutoff Valve .......................................................................................................... 23
2.8.3 External Gas Supply Regulator .................................................................................................... 23
2.8.3.1 Massachusetts Installations Only ......................................................................................... 23
2.8.3.2 All Installations (Except Massachusetts) .............................................................................. 23
2.9 AC ELECTRICAL POWER WIRING ........................................................................................................ 24
2.9.1 Electrical Power Requirements ................................................................................................... 25
2.10 FIELD CONTROL WIRING .................................................................................................................. 26
2.10.1 OUTDOOR AIR IN Terminals...................................................................................................... 28
2.10.2 COMBUSTION AIR Terminal ...................................................................................................... 29
2.10.3 O
2.10.4 SPARK SIGNAL Terminals .......................................................................................................... 29
2.10.5 ANALOG IN Terminals ............................................................................................................... 29
2.10.6 B.M.S. (PWM) IN Terminals ...................................................................................................... 29
2.10.7 SHIELD Terminals ...................................................................................................................... 29
2.10.8 ANALOG OUT Terminals ........................................................................................................... 30
2.10.9 RS-485 Comm Terminals ........................................................................................................... 30
2.10.10 RS-232 Comm Terminals ......................................................................................................... 30
2.10.11 VFD/Blower (0-10 & AGND) .................................................................................................... 30
2.10.12 Interlocks ................................................................................................................................ 30
2.10.12.1 REMOTE INTL’K Terminals................................................................................................ 30
2.10.12.2 DELAYED INTL’K Terminals (OUT & IN) ............................................................................ 30
2.10.13 FAULT RELAY (NC, COM, & NO) Terminals ............................................................................. 31
2.10.14 AUX RELAY CONTACTS (NC, COM, & NO) Terminals .............................................................. 31
2.11 FLUE GAS VENT INSTALLATION ....................................................................................................... 31
2.12 COMBUSTION AIR ............................................................................................................................ 32
2.12.1 Combustion From Outside the Building ................................................................................... 32
SENSOR Terminals ................................................................................................................ 29
2
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2.12.2 Combustion Air from Inside the Building ................................................................................. 32
2.13 DUCTED COMBUSTION AIR ............................................................................................................. 33
2.14 BENCHMARK PUMP RELAY OPTION ................................................................................................ 33
2.15 SEQUENCING ISOLATION VALVE INSTALLATION ............................................................................. 34
CHAPTER 3. OPERATION ......................................................................................... 37
3.1 INTRODUCTION ................................................................................................................................. 37
3.2 CONTROL PANEL DESCRIPTION ......................................................................................................... 37
3.3 CONTROL PANEL MENUS .................................................................................................................. 41
3.3.1 Menu Processing Procedure ....................................................................................................... 41
3.4 OPERATING MENU ............................................................................................................................ 43
3.5 SETUP MENU ..................................................................................................................................... 43
3.6 CONFIGURATION MENU .................................................................................................................... 44
3.7 TUNING MENU .................................................................................................................................. 46
3.8 COMBUSTION CAL MENU .................................................................................................................. 47
3.9 BST (Boiler Sequencing Technology ) Menu ...................................................................................... 47
3.10 START SEQUENCE ............................................................................................................................ 50
3.11 START/STOP LEVELS ........................................................................................................................ 53
CHAPTER 4. INITIAL STAR T-UP ............................................................................... 55
4.1 INITIAL START-UP REQUIREMENTS ................................................................................................... 55
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION ................................................ 55
4.2.1 Required Tools & Instrumentation ............................................................................................. 56
4.2.2 Installing Gas Supply Manometer ............................................................................................... 56
4.2.3 Accessing the Analyzer Probe Port ............................................................................................. 57
4.3 NATURAL GAS COMBUSTION CALIBRATION ..................................................................................... 58
4.4 PROPANE COMBUSTION CALIBRATION............................................................................................. 61
4.5 REASSEMBLY AFTER COMBUSTION CALIBRATION ............................................................................ 64
4.6 OVER-TEMPERATURE LIMIT SWITCHES ............................................................................................. 65
4.6.1 Digital Alarm Switch Checks and Adjustments ........................................................................... 66
CHAPTER 5. MODE OF OPERATION ........................................................................ 69
5.1 INTRODUCTION ................................................................................................................................. 69
5.2 INDOOR/OUTDOOR RESET MODE ..................................................................................................... 69
5.2.1 Reset Ratio .................................................................................................................................. 69
5.2.2 Building Reference Temperature ................................................................................................ 69
5.2.3 Outdoor Air Temperature Sensor Installation ............................................................................ 69
5.2.4 Indoor/Outdoor Startup ............................................................................................................. 70
5.3 CONSTANT SETPOINT MODE ............................................................................................................. 70
5.3.1 Setting the Setpoint .................................................................................................................... 70
5.4 REMOTE SETPOINT MODES ............................................................................................................... 71
5.4.1 Remote Setpoint Field Wiring ..................................................................................................... 72
5.4.2 Remote Setpoint Startup ............................................................................................................ 72
5.5 DIRECT DRIVE MODES ....................................................................................................................... 72
5.5.1 Direct Drive Field Wiring ............................................................................................................. 73
5.5.2 Direct Drive Startup .................................................................................................................... 73
5.6 AERCO CONTROL SYSTEM (ACS) ........................................................................................................ 73
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5.6.1 ACS External Field Wiring ........................................................................................................... 74
5.6.2 ACS Setup and Startup ................................................................................................................ 74
5.7 COMBINATION CONTROL SYSTEM (CCS) ........................................................................................... 74
5.7.1 Combination Control System Field Wiring.................................................................................. 75
5.7.2 Combination Control System Setup and Startup ........................................................................ 75
CHAPTER 6. SAFETY DEVICE TESTING .................................................................. 77
6.1 TESTING OF SAFETY DEVICES ............................................................................................................. 77
6.2 LOW GAS PRESSURE FAULT TEST ...................................................................................................... 78
6.3 HIGH GAS PRESSURE TEST ................................................................................................................. 79
6.4 LOW WATER LEVEL FAULT TEST ........................................................................................................ 80
6.5 WATER TEMPERATURE FAULT TEST .................................................................................................. 81
6.6 INTERLOCK TESTS .............................................................................................................................. 82
6.6.1 Remote Interlock Test ................................................................................................................ 82
6.6.2 Delayed Interlock Test ................................................................................................................ 82
6.7 FLAME FAULT TESTs .......................................................................................................................... 83
6.8 AIR FLOW FAULT TESTS ..................................................................................................................... 84
6.8.1 Blower Proof Switch Test ............................................................................................................ 84
6.8.2 Blocked Inlet Switch Test ............................................................................................................ 84
6.9 SSOV PROOF OF CLOSURE SWITCH ................................................................................................... 86
6.10 PURGE SWITCH OPEN DURING PURGE ........................................................................................... 87
6.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................................... 87
6.12 SAFETY PRESSURE RELIEF VALVE TEST ............................................................................................ 88
CHAPTER 7. MAINTENANCE .................................................................................... 89
7.1 MAINTENANCE SCHEDULE ................................................................................................................ 89
7.2 IGNITER-INJECTOR REPLACEMENT .................................................................................................... 90
7.3 FLAME DETECTOR REPLACEMENT ..................................................................................................... 92
7.4 O
SENSOR REPLACEMENT ................................................................................................................ 93
2
7.5 COMBUSTION CALIBRATION ............................................................................................................. 93
7.6 SAFETY DEVICE TESTING .................................................................................................................... 93
7.7 BURNER ASSEMBLY INSPECTION ....................................................................................................... 93
7.8 CONDENSATE DRAIN TRAP MAINTENANCE ...................................................................................... 96
7.9 AIR FILTER CLEANING & REPLACEMENT ............................................................................................ 98
7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................................. 99
7.11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN .................................. 99
CHAPTER 8. TROUBLESHOOTING GUIDE ............................................................ 101
8.1 INTRODUCTION ............................................................................................................................... 101
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .......................................................... 113
CHAPTER 9. RS-232 COMMUNICATION ................................................................ 117
9.1 INTRODUCTION ............................................................................................................................... 117
9.1.1 Aquiring the PuTTY Application ................................................................................................ 117
9.1.2 Logging on to a Remote Machine Using PuTTY ........................................................................ 117
9.1.3 Running a Command on a Remote Machine Using PuTTY ....................................................... 118
9.2 RS-232 COMMUNICATION SETUP ................................................................................................... 119
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9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ............................................................ 119
9.4 DATA LOGGING................................................................................................................................ 120
9.4.1 Fault Log .................................................................................................................................... 120
9.4.2 Operation Time Log .................................................................................................................. 121
9.4.3 Sensor Log ................................................................................................................................. 122
CHAPTER 10. BOILER SEQUENCING TECHNOLOGY ........................................ 123
10.1 INTRODUCTION ............................................................................................................................. 123
10.2 AERCO BST Quick Start Chart ........................................................................................................ 124
10.3 BST Implementation Instruction ................................................................................................... 125
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor .......................................... 125
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor ...................................... 126
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor
Sensor ................................................................................................................................................ 127
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor .... 129
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive
........................................................................................................................................................... 131
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive
........................................................................................................................................................... 133
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive...... 134
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive ... 136
APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ...................................................................... 139
APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES ............................................................. 145
APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART ................................................................ 149
APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ......................................................... 151
APPENDIX E – BOILER DEFAULT SETTINGS ................................................................................. 155
APPENDIX F – DIMENSIONAL DRAWINGS .................................................................................. 157
APPENDIX G – PART LIST DRAWINGS ......................................................................................... 161
APPENDIX H – PIPING DRAWINGS .............................................................................................. 171
APPENDIX I – C-MORE WIRING DIAGRAMS ................................................................................ 175
APPENDIX J – RECOMMENDED PERIODIC TESTING.................................................................... 179
APPENDIX K – C-MORE CONTROL PANEL VIEWS ........................................................................ 181
APPENDIX L: RECOMMENDED SPARES ...................................................................................... 183
APPENDIX M – ULTRA-LOW NOx CALIBRATION ......................................................................... 185
LIMITED WARRANTY ................................................................................................................... 189
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Input Range (BTU/hr.)
Output Range (BTU/hr.)
Benchmark Model
Minimum
Maximum
Minimum
Maximum
BMK 750
50,000
750,000
47750
716,250
BMK 1000
50,000
1,000,000
48300
968,000
FOREWORD
The AERCO Benchmark (BMK) 750 and 1000 MBH Boilers are modulating and condensing
units. They are a true industry advancement 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. The
maximum turn down ratios for the BMK 1000 and BMK 750 are 20:1 and 15:1, respectively.
Both BMK models provide extremely high efficiencies and make them ideally suited for modern
low temperature, as well as, conventional heating systems.
The Benchmark Models BMK 750 and BMK 1000 operate within the following input and output
ranges:
The output of each boiler model 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, the BMK 750 and BMK
1000 MBH 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 750 and BMK 1000 offer the
maximum venting flexibility with minimum installation space requirements. These Boilers are
Category II, II I and IV, positive pressure appliances. Single and/or multiple breeched units are
capable of operation in the following vent configurations:
• Conventional, Vertical
• Conventional, Sidewall
• Conventional, Direct Vent, Vertical
• Sealed, Direct Vent, Horizontal
These boilers are capable of being vented utilizing PVC, CPVC, 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.
IMPORTANT
Unless otherwise specified, all descriptions and procedures provided in this
Installation, Operation & Maintenance Manual apply to both Benchmark
750 MBH and Benchmark 1000 MBH boilers.
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Phrase, Abbreviation
or Acronym
A (Amp)
Ampere
ACS
AERCO Control System, AERCO’s boiler management systems
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ASME
American Society of Mechanical Engineers
AUX
Auxiliary
(see below)
Symbol rate, or simply the number of distinct symbol changes
second, unless each symbol is 1 bit long.
BMK
Benchmark series boilers
BLDG (Bldg)
Building
CCP
Combustion Control Panel
(or Control Box)
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CO
Carbon Monoxide
COMM (Comm)
Communication
required to raise 1 pound of water 1° F.
Cal.
Calibration
CNTL
Control
DIP
Dual In-Line Package
EMS
Energy Management System; often used interchangeably with BAS
FM
Factory Mutual. Used to define boiler gas trains.
GND
Ground
HDR
Header
Hex
Hexadecimal Number (0 – 9, A – F)
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
Phrases, Abbreviations and Acronyms
Meaning
BAS
Baud Rate
Building Automation System, often used interchangeably with EMS
(signaling events) transmitted per second. It is not equal to bits per
BMS or BMS II AERCO Boiler Management Systems
BST AERCO on-board Boiler Management Technology
BTU
British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound of water 1° F.
C-More Controller
BTU
British Thermal Unit. A unit of energy approximately equal to the heat
Double Block and Bleed. Used to define boiler gas trains containing 2
DBB
Safety Shutoff Valves (SSOVs) and a solenoid operated vent valve.
Also known as IRI gas trains (see below)
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Phrase, Abbreviation
or Acronym
INTLK (INTL’K)
Interlock
I/O
Input/Output
KC1000 Series products
IP
Internet Protocol
trains containing two SSOVs and a solenoid operated vent valve.
ISO
Isolated
LED
Light Emitting Diode
LN
Low NOx
MA (mA)
Milliampere (1 thousandth of an ampere)
MAX (Max)
Maximum
MIN (Min)
Minimum
duplex data transmission protocol developed by AEG
Modicon
NC (N.C.)
Normally Closed
NO (N.O.)
Normally Open
NOx
Nitrogen Oxide
NPT
National Pipe Thread
O2
Oxygen
O.D.
Outside Diameter
Control Box used on all Benchmark units.
PPM
Parts Per Million
PTP
Point-to-Point (usually over RS-232 networks)
PWM
Pulse Width Modulation
REF (Ref)
Reference
RES.
Resistive
(or EIA-232)
the RS-232 Standard
(or EIA-422)
the RS-422 Standard
(or EIA-485)
the RS-485 Standard
RTN (Rtn)
Return
SETPT (Setpt)
Setpoint Temperature
SHLD (Shld)
Shield
SSOV
Safety Shut Off Valve
TEMP (Temp)
Temperature
Phrases, Abbreviations and Acronyms - Continued
Meaning
I/O Box
IRI
Modbus®
PMC Board
Input/Output (I/O) Box currently used on Benchmark, Innovation and
Industrial Risk Insurers. A now discontinued code used to define gas
A serial, half-
A Primary Micro-Controller (PMC) board is contained in the C-More
RS-232
RS-422
RS-485
A standard for serial, full-duplex (FDX) transmission of data based on
A standard for serial, full-duplex (FDX) transmission of data based on
A standard for serial, half-duplex (HDX) transmission of data based on
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Phrase,
Acronym
s that may cause invalid data in the
communication
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, or Variable Frequency Drive
W
Watt
W.C.
Water Column
Phrases, Abbreviations and Acronyms – Continued
Abbreviation or
Meaning
A resistor placed at each end of a daisy-chain or multi-drop network in
Terminating Resistor
order to prevent reflection
µA Micro amp (1 millionth of an ampere)
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WARNING
WARNING
WARNING
WARNING
CHAPTER 1 – SAFETY PRECAUTIONS
CHAPTER 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 pages 13 and 14 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.
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 THERE-FORE MUST BE COMPLETELY
SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCT S INTO
LIVING SPACES.
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WARNING
WARNING
CAUTION
CAUTION
CHAPTER 1 – SAFETY PRECAUTIONS
ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFO RE THE COVER ON THE UNI T’S POWER BOX
(LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
A DOUBLE-POLE SWITCH MUST BE INSTAL LED ON T HE ELECTRICAL
SUPPLY LINE OF THE UNIT. T HE SWIT CH MUST BE INSTALLED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY
DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO
UNIT SHEET METAL ENCLOSURES.
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 t his boiler if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
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
Figure 1-1: Manual Gas Shutoff Valve
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VALVE CLOSED
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of this manual be performed to verify all systemoperating parameters. If there is an emergency, turn off the electrical power supply to the
AERCO boiler and close the manual gas valve located upstream of the unit. The inst aller must
identify the emergency shut-off device.
IMPORTANT – 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 f eet above grade
level. If side-wall venting is used, the installation must conform to the
following requirem ent s extract ed 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 CARBO N 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 detector with an alarm is installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented gas fueled equipment. It shall be the
responsibility of the 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 batter y
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 com ply 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
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CHAPTER 1 – SAFETY PRECAUTIONS
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 OBSTRUC TIONS".
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 Chapter 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)]
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
AERCO Benchmark Boiler Models BMK 750 and BMK 1000.
2.2 RECEIVING THE UNIT
Each Benchmark Boiler System is shipped as a single crated unit. T he shipping weights for the
BMK 750 and BMK 1000 Models are approximately 1100 and 1200 pounds , respectively. The
unit must be moved with the proper rigging equipment for safety and to avoid equipment
damage. The unit should be completely inspected for evidence of shipping damage and
shipment completeness at the time of receipt from the carrier and before the bill of lading is
signed.
NOTE
AERCO is not responsible for lost or damaged freight. Each unit has a TipN-Tell indicator on the outside of the crate. This indicates if the unit has
been turned on its side during shipment. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either packed separately within
the unit’s shipping container or are factory installed on the unit:
• Pressure/Temperature Gauge
• ASME Pressure Relief Valve
• Condensate Drain Trap (part no. 24060)
• 1” Gas Supply Shutoff Valve
• Lifting Bar (with attaching hardware)
When optional accessories are ordered, they may be packed within the unit’s shipping
container, factory installed on the unit, or packed and shipped in a separate container. Any
standard or optional accessories shipped loose should be identified and stored in a safe place
until ready for installation or use.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
Housekeeping pad should not extend under the condensate assembly
CHAPTER 2 – INSTALLATION
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark Boiler includes:
• Access to AC Input Power at 1 20 VAC, S i ngle-Phase, 60 Hz @ 20 Amps.
• Access to one of the following with the unit operating at maximum capacity:
o For Benchmark 750 & 1000, a NATURAL GAS line at a minimum pressure of 4” W.C.
o For Benchmark 750, a PROPANE gas line at a minimum pressure of 7” W.C.
o For Benchmark 1000, a PROPANE gas line at a minimum pressure of 11” W.C.
2.4.1 Installation Clearances
Benchmark Models 750 and 1000 are packaged in enclosures having identical exterior
dimensions. The unit must be installed with the prescribed clearances for service as shown in
Figure 2-1a. The minimum clearance dimensions, required by AERCO, are listed below.
However, if Local Building Codes require additional clearances, these codes shall supersede
AERCO’s requirements. Minimum acceptable clearances required are as follows:
• Sides: 24 inches
• Front : 24 inches
• Rear: 24 inches
• Top: 18 inches
All gas piping, water piping and electrical conduit or cable must be arranged so that t hey do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
Figure 2-1a: BMK 750 & 1000 Clearances
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
WARNING
CAUTION
CHAPTER 2 – INSTALLATION
Figure 2-1b: BMK 750 & 1000 Anchor Bolt Locations
KEEP THE UNIT AREA CLEAR AND FREE FR OM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS
.
While packaged in the shipping container, the unit must be moved by pallet
jack or forklift from the FRONT ONLY.
FOR MASSACHUSSETTS ONLY:
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter licensed within the Commonwealth of Massachusetts. In addition,
the installation must comply with all requirements specified in Chapter 1
(Safety Precautions), pages 11 and 12.
2.4.2 Setting the Unit
The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate
drainage (see NOTE below). If anchoring the unit, refer to the dimensional drawings in Figure 21b for anchor locations.
NOTE
When using the AERCO Condensate Neutralizer Tank for proper
condensate drainage, the Neutralizer Tank must be stored in a pit, OR the
boiler and AERCO Condensate Trap must be elevated higher than 4”
above the floor. See Condensate Tank instructions in TID-0074 for details.
After unpacking and inspecting the boiler, remove the four (4) lag screws securing the boiler to
the shipping pallet. The boiler can be lifted and moved by inserting forklift tines in the front slots
provided in the base of the unit, or it can be lifted by attaching a lifting bar to the unit’s heat
exchanger. A lifting bar (59174), with attaching hardware, is supplied with each unit. When
shipped, this bar is attached to the rear of the unit as shown in Figure 2-2, View A. One (1)
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
VIEW B - LIFTING POSITION
CHAPTER 2 – INSTALLATION
lifting tab is provided at the top of the unit’s heat exchanger as shown. This tab is used to attach
the lifting bar to the unit as follows:
WARNING
WHEN LIFTING OR MOVING THE BOILER:
• DO NOT ATTEMPT TO MANIPULATE THE BOILER USING THE
GAS TRAIN OR BLOWER
• WHEN USING THE LIFTING TAB AND BAR, ENSURE THERE IS
NO LOAD PLACED ON THE GAS TRAIN OR BLOWER
Attachment of Lifting Bar
1. Remove the lifting bar from its shipping location at the r ear of the unit (Figure 2-2, Vi ew
A). Retain the attaching hardware consisting of two (2) hex head cap scr ews, hex nuts
and flat washers.
2. Remove the top shroud from the boiler by grasping the handle on the top of the unit and
lifting straight up. Locate the lifting tab at the top-rear of the heat exchanger.
3. Refer to Figure 2-2, View B and attach the lifting bar to the heat exchanger lifting tab
using the hardware removed in step 1. The upper end of the lifting bar containing the oval
cutout should be positioned over the top of the heat exchanger as shown.
4. Using proper rigging equipment, capable of supporting 1000 to 1200 lbs., lift the boiler
and position it on the housekeeping pad.
5. After the boiler is properly set on the pad, detach the lifting bar and replace the shroud on
the top of the unit.
6. Retain the lifting bar for possible reuse at the installation site.
LIFTING TAB
LIFTING
BAR IN
SHIPPING
POSITION
VIEW A - SHIPPING POSITION
LIFTING BAR IN
LIFTING
POSITION
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Figure 2-2: Boiler Lifting Provisions
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
PRIMARY INTLET
DRAIN VALVE
EXHAUST MANIFOLD
CHAPTER 2 – INSTALLATION
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient
space for piping connections and future service/maintenance requirements must also be taken
into consideration. All piping must include ample provisions for expansion.
If installing a Combination Control Panel (CCP) system, it is important to identify the
Combination Mode Boilers in advance and place them in the proper physical location. Refer to
Chapter 5 for information on Combination Mode Boilers.
2.5 SUPPLY AND RETURN PIPING
The Benchmark Boiler utilizes 3” 150# flanges for the water system supply and return piping
connections. The physical location of the supply and return piping connections are on the rear of
the unit as shown in Figure 2-3. Refer to Appendix F, Drawing AP-A-891 for additional
dimensional data.
BOILER HOT
WATER OUTLET
1” NATURAL GAS
OR PROPANE
INLET
SECONDARY INLET
AIR INLET
Figure2-3: Supply and Return Locations
2.6 PRESSURE RELIEF VALVE INSTALLATION
An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler. The pressure
rating for the relief valve must be specified on the sales order. Available pressure ratings range
from 30 psi to 160 psi. The relief valve is installed on the hot water outlet of the boiler as shown
in Figure 2-4. A suitable pipe joint compound should be used on the threaded connections. Any
excess should be wiped off to avoid getting any joint compound into the valve body. T he relief
valve must be piped to within 12 inches of the floor to prevent injury in the event of a discharge.
The relief piping must be full size, without reduct ion. No valves, restrictions, or other block ages
are allowed in the discharge line. In multiple unit installations t he discharge lines must not be
manifolded together. Each must be individually run to a suitable discharge location.
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PRIMARY INTLET
EXHAUST
MANIFOLD
PAR TI AL REAR VIE W
CHAPTER 2 – INSTALLATION
PRESSURE
RELIEF VALVE
3” HOT BOILER
WATER OUTLET
P&T GAUGE
COUPLING
Figure2-4: Pressure Relief Valve Location
2.7 CONDENSATE DRAIN & PIPING
The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore,
the installation must have provisions for suitable condensate drainage or collection.
The condensate drain port located on the exhaust manifold (Figure 2-5) must be connected to
the condensate trap (part no. 24060) which is packed separately within the unit’s shipping
container. The condensate trap inlet and outlet connections contain tapped 3/4” NPT ports.
DRAIN VALVE
CONDENSATE DRAIN
ANALYZER
PROBE PORT
Figure2-5: Condensate Drain Connection Location
A sample condensate trap installation is shown in Figure 2-6. However, the actual installation
details for the trap will vary depending on the available clearances, housekeeping pad height/
dimensions and other prevailing conditions at the site. The following general guidelines must be
observed to ensure proper condensate drainage:
• The condensate trap inlet (Figure 2-6) must be level with, or lower than the exhaust
• The base of the condensate trap must be supported to ensure that it is level (horizontal).
• The trap must be removable for routine maintenance. AERCO recommends that a union
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manifold drain port.
be utilized between the exhaust manifold condensate drain port and the trap inlet port.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
CAUTION
COMBUTION
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLE
HOSE
CLAMP
T O
DRAIN
(P/N 24060)
TRAP INLET
TOP COVER
(4 each)
1” DIAM.
HOSE
4” MINIMUM
(6” MAXIMUM)
4”
3/4” NPT
NIPPLES
UNION
CHAPTER 2 – INSTALLATION
While observing the above guidelines, install the condensate trap as follows:
Condensate Trap Installation
1. Connect the condensate trap inlet to the exhaust manifold drain connection using the
appropriate piping components (nipples, reducers, elb ows, etc.) for the boiler installation
site.
2. At the condensate trap outlet, install a 3/4” NPT nipple.
3. Connect a length of 1” I.D polypropylene hose to the trap outlet and secure with a hose
clamp.
4. Route the hose on the trap outlet to a nearby floor drain.
If a floor drain is not available, a condensate pump can be used to remove the condensate to an
appropriate drain. The maximum condensate flow rate is 10 GPH. The condensat e drain trap,
associated fittings and drain line must be removable for routine maintenance.
Use PVC, stainless steel, aluminum or polypropylene for condensate drain
piping (Figure 2-6). DO NOT use carbon or copper components.
ANALYZER
NOTE
HOUSKEEPING
PAD MUST NOT
EXTEND
UNDER THE
CONDENSATE
ASSEMBLY.
INTEGRAL ADAPTOR AND
THUMBSCREW
THUMB SREWS
CONDENSATE
TRAP
FLOOR
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Figure2-6: Sample Condensate Trap Installation
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
Natural Gas
Propane
Benchmark 750
Benchmark 1000
Natural Gas
Propane
Benchmark 750
728 CFH, maintaining 4” W.C.
300 CFH, maintaining 7” W.C.
Benchmark 1000
976 CFH, maintaining 4” W.C.
400 CFH, maintaining 11” W.C.
WARNING
CAUTION
CHAPTER 2 – INSTALLATION
2.8 GAS SUPPLY PIPING
The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be
consulted prior to designing or installing any gas supply piping.
NEVER USE MATCHES, CANDLES, FLAMES OR OTHER
SOURCES OF IGNITION TO CHECK FOR GAS LEAKS
Many soaps used for gas pipe leak testing are corros ive to met als.
Therefore, piping must be rinsed thoroughly with clean water after
soap leak checks have been completed.
NOTE
All gas piping must be arranged so that it does not interfere with
removal of any covers, inhibit service/maintenance, or restrict
access between the unit and walls, or another unit.
.
Benchmark 750 and 1000 MBH units contain either a 1 inch NATURAL GAS or a 1 inch
PROPANE gas inlet connection on the rear of the unit, as shown in Figure 2-3.
Prior to installation, all pipes should be de-burred and internally cleared of any scale, metal
chips or other foreign particles. Do not install any flexible connectors or unapproved gas
fittings. Piping must be supported from the floor, ceiling or walls only and must not be supported
by the unit.
A suitable piping compound, approved for use with natural gas, should be used. Any excess
must be wiped off to prevent clogging of components.
To avoid unit damage when pressure testing gas piping, isolate the unit from the g as supply
piping. At no time should the gas pressure applied to the unit exceed 14” W.C. Leak test all
external piping thoroughly using a soap and water solution or suitable equivalent. The gas
piping used must meet all applicable codes.
2.8.1 Gas Supply Specifications
The gas supply input specifications to the unit are as follows:
• The maximum static pressure to the unit must not exceed the following:
14” W.C. 14” W.C.
14” W.C. 16” W.C.
• Supply piping and pressure to the unit must be sufficient to provide the volume of gas
while maintaining gas pressure listed below while operating at maximum capacity:
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CHAPTER 2 – INSTALLATION
2.8.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply line upstream of the boiler as shown
in Figure 2-7. Maximum allowable gas pressure to the boiler is 14” W.C.
2.8.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions
(see sections 2.8.3.1 and 2.8.3.2, below). Regulators must conform to the following
specifications:
• NATURAL GAS: The external natural gas regulator must be capable of regulating
49,000 – 1,020,000 BTU/HR while maintaining a minimum g as pr essu re of 4.0” W.C. to
the unit.
• PROPANE: The external natural gas regulator must be capable of regulating 49,000 –
1,020,000 BTU/HR while maintaining a minimum gas pressure of 11.0 ” W . C . to the unit.
• A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C.
2.8.3.1
For Massachusetts installations, a mandatory external gas supply regulator must be
positioned as shown in Figure 2-7. The gas supply regulator must be properly vented to
outdoors. Consult the local gas utility for detailed requirements concerning venting of the
supply gas regulator.
2.8.3.2
For multi-unit installations (other than Massachusetts) that EXCEED 7” W.C. gas pressure, a
separate external g as supply regulator, as shown in Figure 2-7, is highly recomm ended. No
regulator is required for gas pressures below 7” W.C. of pressure. Consult the local gas
utility for detailed requirements concerning venting of the supply gas regulator.
Massachusetts Installations Only
All Installations (Except Massachusetts)
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POWER BOX
FRONT COVER
FRONT UPPER-RIGHT CORNER OF UNIT
1” MANUAL
VALVE
GAS PRESSURE
DIRT TRAP
It is the responsibility of the customer to
source and purchase the appropriate gas
e. However,
AERCO offers for sale an appropriate
of unit purchase or separately. Contact
CHAPTER 2 – INSTALLATION
SHUTOFF
GAS INLET
REGULATOR
NOTE
regulator as described abov
regulator, which may be ordered at the time
AERCO for more information.
Figure2-7: Manual Gas Shut-Off Valve and Gas Regulator Locations
2.9 AC ELECTRICAL POWER WIRING
The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to
connecting any AC power wiring to the unit. External AC power connections are made to the
unit inside the Power Box. Remove the front panel to access the Power Box, which is mounted
in the upper right corner of the unit as shown in Figure 2-8. Open the hinged cover of the Power
Box to access the AC terminal block connections, and other internal components shown in
Error! Reference source not found. 2-9.
WITH HINGED
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Figure2-8: Power Box With Closed Cover
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
WARNING
12V POWER
FUSE BLOCKS
(2)
FUSIBLE
DISCONNECT
FLAME ROD SIGNAL
AMPLIFIER
TRANSFORMER
CHAPTER 2 – INSTALLATION
THE AC POWER OUTLETS SHOWN IN ERROR! REFERENCE
SOURCE NOT FOUND. 2-9 ARE LIMITED TO 600 WATTS (5
AMP) SERVICE. DO NOT OVER-LOAD THESE OUTLETS.
ALSO, THE FUSIBLE LINK SHOWN IN FIGURE 2-9 DOES NOT
REMOVE POWER FROM THE TERMINAL BLOCKS OR AC
OUTLETS.
AC POWER
OUTLETS (2)
TERMINAL BLOCKS
115V/24V
24 V POWER SUPPLY
(SEQUENCING VALVE)
Figure2-9: Power Box Internal Components
With the exception of the transformer shown in Err or! Reference source not found. 2-9, all of
the components in the Power Box are mounted on a DIN rail.
NOTE
All electrical conduit and hardware must be installed so that it
does not interfere with the removal of any unit covers, inhibit
service/maintenance, or prevent access between the unit and
walls or another unit.
2.9.1 Electrical Power Requirements
The Benchmark Boiler accepts 120 VAC, single-phase, 60 Hz @ 20A. The Power Box contains
terminal blocks as shown in Figure 2-10. In addition, a label showing the required AC power
connections is provided on the front cover of the Power Box as shown in Figure 2-8.
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CHAPTER 2 – INSTALLATION
Figure 2-10: Power Box Cover Label
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD
BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.
A double-pole switch must be installed on the electrical supply line in an easily accessible
location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet
metal enclosures of the unit.
After placing the unit in service, the ignition safety shutoff device must be tested. If an external
electrical power source is used, the installed boiler must be electrically bonded to ground in
accordance with the requirements of the authority having jurisdiction. In the absence of such
requirements, the installation shall conform to National Electrical Code (NEC), ANSI/ NFPA 70
and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.
For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF-
2060).
2.10 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an internal operating control system. No field control
wiring is required for normal operation. However, the C-More Control system used with all
Benchmark units does allow for some additional control and monitoring features. Wiring
connections for these features are made on the Input/Output (I/O) board located behind the
removable front panel assembly of the unit. The I/O board is located in the center-right portion
on the front of the unit directly below the C-More Control Panel as shown in Figure 2-11.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
ECU FOR O2
SENSOR
C-MORE CONTROL
BOX
TERMINAL
STRIPS
CHAPTER 2 – INSTALLATION
I/O BOARD
Figure2-11: Input/Output (I/O) Box Location
The I/O board terminal strip connections are shown in Figure 2-12. All field wir ing is installed
from the rear of the panel by routing the wires through one of the four bushings provided on the
sides of the I/O board.
NOTE
Use Figure 2-12 to determine the functions of the I/O PCB
connections. Do not use the silkscreened labels on the PCB itself,
as these may not match.
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CAUTION
CHAPTER 2 – INSTALLATION
DO NOT make any connections to the I/O Box terminals labeled
“NOT USED”. Attempting to do so may cause equipment
damage.
Figure2-12: I/O Box Terminal Strips
2.10.1 OUTDOOR AIR IN Terminals
The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO
Part No. GM-123525), as required primarily for the Indoor/Outdoor r eset mode of operation. It
can also be used with another mode if it is desired to use the outdoor sensor enable/disable
feature. This feature allows the boiler to be enabled or disabled based on the outdoor air
temperature.
The factory default for the outdoor sensor is DI SABLED. T o enable the sensor and/or select an
enable/disable outdoor temperature, see the Configuration menu in Chapter 3.
The outdoor sensor may be wired up to 200 feet from the boiler. It is connected to the
OUTDOOR AIR IN and AIR SENSOR COMMON terminals in the I/O Box (see Figure 2-12).
Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG. There is no polarity to
observe when terminating these wires. The shield is to be connected only to the terminals
labeled SHIELD in the I/O Box. The sensor end of the shield must be left free and ungrounded.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
When mounting the sensor, it must be located on the North side of the building where an
average outside air temperature is expected. The sensor must be shielded from direct sunlight
as well as impingement by the elements. If a shield is used, it must allow for free air circulation.
2.10.2 COMBUSTION AIR Terminal
The COMBUSTION AIR terminal is used to monitor the combustion air temperature sensor.
This input is always enabled and is a “to view only” input that can be seen in the operating
menu. The sensor is an AERCO BALCO wire sensor P/N 12449. A resistance chart for this
sensor is provided in APPENDIX C. This sensor is an active part of the combustion control
system and must be operational for accurate air/fuel mixing control.
2.10.3 O2 SENSOR Terminals
The O2 SENSOR (+) and O2 SENSOR (–) terminals are used to connect an external oxygen
sensor to the I/O Box. The O
Control system after a 60 second warm-up period.
2.10.4 SPAR K SIGNAL Terminals
The two SPARK SIGNAL terminals (+ & -) permit an external current sensor to be connected for
ignition spark monitoring purposes. If no spark is present during the ignition sequence, the
controller will shut down and display a fault message.
concentration is displayed in the operating menu of the C-More
2
2.10.5 ANALOG IN Terminals
The two ANALOG IN terminals (+ and –) are used when an external signal is used to change
the setpoint (Remote Setpoint Mode) of the boiler.
Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA/ 0 to 5 VDC signal may be used to vary the setpoint or air/fuel valve position. The factory default setting is for 4 to 20 mA / 1 to 5 VDC,
however this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu
described in Chapter 3.
If voltage rather than current is selected as the drive signal, a DIP switch must be set on the
PMC Board located inside the C-More Control Box. Contact the AERCO factory for information
on setting DIP switches.
All supplied signals must be floating (ungrounded) signals. Connections between the source
and the boiler’s I/O Box (see Figur e 2-12) must be made using twisted shielded pair of 18–22
AWG wire such as Belden 9841. Polarity must be maintained and the shield must be connected
only at the source end and must be left floating (not connected) at the Boiler’s I/O Box.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to
240°F setpoint or a 0% to 100% air/fuel valve position. No scaling for these signals is provided
2.10.6 B.M.S. (PWM) IN Terminals
These terminals are only used to connect TO the legacy AERCO Boiler Management System
(BMS), wh i ch utilize a 12 millisecond, ON/OFF duty cycle and is Pulse Width Modulated (PWM)
to control valve position. A 0% valve position = a 5% ON pulse and a 100% valve position = a
95% ON pulse. Note that thes e connections cannot be used with the AERCO Control System
(ACS).
2.10.7 SHIELD Terminals
The two SHIELD terminals are used to terminate any shields used on sensor wires connected to
the unit. Shields must only be connected to these terminals.
OMM-0082_0J AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 192
GF-130 Ph.: 800-526-0288 05/21/2014
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
2.10.8 ANALOG OUT Terminals
The ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor
Setpoint, Outlet Temperature, Valve Pos ition 4-20 mA, Valve Position 0-10v or be set to OFF.
Default sett ing in th e C-More controller is Valve Position 0-10v and settings behave as follows:
• When 0-10VDC is selected, the voltage output is used by the c ontroller to modulate the
combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.10.11).
• If On Board Boiler Sequencing Technology (BST) is enabled, the Analog Output
terminals are used to drive the isolation valve, open and closed.
• When the 4-20mA is selected for the Analog Output, the 0-10VDC is disabled at the
VFD/Blower terminals, and the selected output is available at the terminals labeled
Analog Output +/-.
2.10.9 RS-485 Comm Terminals
The RS-485 communication terminals (+, GND, & -) are used when the boiler plant is being
controlled by an Energy Management System (EMS) or AERCO Control System (ACS) using
Modbus (RS-485) communication.
2.10.10 RS-232 Comm Terminals
The RS-232 communication terminals (TxD and RxD) permit a laptop computer or other suitable
terminal to be connected to the boiler. The RS-232 communication feature permits viewing or
changing of Control Panel menu options and also provides access to data logs showing fault
and sensor log displays.
2.10.11 VFD/Blower (0-10 & AGND)
These terminals (0-10 & AGND) send an analog signal to control the blower speed. When any
of the 4-20mA opt ions is selected for the Analog Outputs (Section 2.10.8), the output from the
VFD/Blower terminals is disabled.
2.10.12 Interlocks
The unit offers two interlock circuits for interfacing with Energy Management Systems and
auxiliary equipment such as pumps or louvers or other accessories. These interlocks are called
the Remote Interlock and Delayed Interlock (REMOTE INTL’K IN an d DELAYED INTL’K IN in
Figure 2-12). Both interlocks, described below, are fact ory wired in the closed position (using
jumpers).
NOTE
Both the Delayed Interlock and Remote Interlock must be in the
closed position for the unit to fire.
2.10.12.1
The remote interlock circuit is provided to remotely star t (enable) and stop (disable) t he unit
if desired. The is 24 VAC and comes factory pre-wired closed (jumped).
2.10.12.2
The unit offers two interlock circuits for interfacing with Energy Management Systems and
auxiliary equipment such as pumps or louvers or other accessories. These interlocks are
called the Remote Interlock and Delayed Interlock ((REMOTE INTL’K IN and DELAYED
INTL’K IN in Fig ure 2-12). Both interlocks, described below, are factory wired in the closed
position (using jumpers).
REMOTE INTL’K Terminals
DELAYED INTL’K Terminals (OUT & IN)
Page 30 of 192 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J
05/21/2014 Ph.: 800-526-0288 GF-130
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