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AERCO BMK 1.5 LN User Manual October 2012

Benchmark 1.5LN Low NOx Boiler
OMM-0041_0E
GF-120
Revised: 10/18/2012
Benchmark 1.5LN Low NOx Boiler
Installation, Operation, and Maintenance
Benchmark 1.5LN
Low NOx Boiler
Modulating, Condensing, Forced Draft, Hot Water Boiler 1,500,000 BTU/H Input
Applicable for Serial N umb er s: G-12-1953 and above.
USER MANUAL
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 1 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
Technical Support:
1-800-526-0288
www.aerco.com
Installation, Operation and Maintenance Manual
(Mon–Fri, 8am-5pm EST)
Disclaimer
The information containe d in this manual is subject to c hange without notice from AERCO Inter national, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness f or 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.
Page 2 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
Benchmark 1.5LN Low NOx Boiler
OMM-0041_0E
GF-120
Table of Contents
CHAPTER 1. SAFETY PRECAUTIONS ............................................................................... 9
1.1 WARNINGS & CAUTIONS ..................................................................................................................... 9
1.2 EMERGENC Y SHUTDOWN ................................................................................................................. 10
1.3 PROLONGED SHUTDOWN ................................................................................................................. 10
CHAPTER 2. INSTALLATION .............................................................................................13
2.1 INTRODUCTION ................................................................................................................................... 13
2.2 RECEIVING THE UNIT ......................................................................................................................... 13
2.3 UNPACKING ......................................................................................................................................... 13
2.4 SITE PREPARATION. .......................................................................................................................... 14
2.4.1 Installation Clearances .................................................................................................................. 14
2.4.2 Setting the Unit .............................................................................................................................. 15
2.5 SUPPLY AND RETURN PIPING .......................................................................................................... 16
2.6 CONDENSATE DRAIN ......................................................................................................................... 16
2.6.1 Exhaust Manifold Condensate Drain ............................................................................................. 17
2.7 GAS SUPPLY PIPIN G .......................................................................................................................... 18
2.7.1 Gas Supply Specifications. ............................................................................................................ 19
2.7.2 Manual Gas Shutoff Valve ............................................................................................................. 19
2.7.3 External Gas Supply Regulator ..................................................................................................... 19
2.7.4 IRI Gas Train Kit ............................................................................................................................ 20
2.8 AC ELECTRICAL POWER WIRING ..................................................................................................... 20
2.8.1 Electrical Power Requirements ..................................................................................................... 21
2.9 MODES OF OPERATION AND FIELD CONTROL WIRING ................................................................ 22
2.9.1 Constant Setpoint Mode ................................................................................................................ 22
2.9.2 Indoor/Outdoor Reset Mode .......................................................................................................... 22
2.9.3 Boiler Management System Mode ................................................................................................ 23
2.9.4 Remote Setpoint and Direct Drive Modes ..................................................................................... 23
2.9.5 Combination Mode ......................................................................................................................... 23
2.10 I/O BOX CONNECTIONS ................................................................................................................... 24
2.10.1 OUTDOOR SENSOR IN (1) ...................................................................................................... 24
2.10.2 AIR TEMP. SENSOR (2) ........................................................................................................... 25
2.10.3 ANALOG IN (3) .......................................................................................................................... 25
2.10.4 B.M.S. (PWM) IN (4) .................................................................................................................. 25
2.10.5 SHIELD (5) ................................................................................................................................. 26
2.10.6 mA OUT (6) ................................................................................................................................ 26
2.10.7 RS-485 COMM (7) ..................................................................................................................... 26
2.10.8 TxD, RxD (8) .............................................................................................................................. 26
2.10.9 VFD/BLOWER (9) ....................................................................................................................... 26
2.10.10 EXHAUST SWITCH IN (11) .................................................................................................... 26
2.10.11 INTERLOCKS (10, 12) ........................................................................................................... 26
2.10.12 FAULT RELAY (13) .................................................................................................................. 27
2.10.13 AUXILIARY RELAY CONTACTS (14) ..................................................................................... 27
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 3 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
Installation, Operation and Maintenance Manual
2.12 FLUE GAS VENT INSTALLATION ..................................................................................................... 27
2.13 COMBUSTION AIR ............................................................................................................................. 28
2.13.1 Combustion Air From Outside the Building ................................................................................. 28
2.13.2 Combustion Air From Inside The Building ................................................................................... 28
2.13.3 Sealed Combustion ..................................................................................................................... 28
2.13.4 Temporary Combustion Air Filtering During Construction ........................................................... 28
2.14 BENCHMAR K PUM P R EL A Y OPTION .............................................................................................. 29
CHAPTER 3. CONTROL PANEL OPERATION ..................................................................31
3.1 INTRODUCTION ................................................................................................................................... 31
3.2 CONTROL PANEL DESCRIPTION ...................................................................................................... 31
3.3 CONTROL PANEL MENUS .................................................................................................................. 35
3.3.1 Menu Processing Procedure ......................................................................................................... 35
3.4 OPERATING MENU ............................................................................................................................. 36
3.5 SETUP MENU ....................................................................................................................................... 37
3.6 CONFIGURATION MENU .................................................................................................................... 38
3.7 TUNING MENU ..................................................................................................................................... 40
3.8 COMBUSTION CAL MENU .................................................................................................................. 40
3.9 START SEQUENCE ............................................................................................................................. 41
3.10 START/STOP LEVELS ....................................................................................................................... 45
CHAPTER 4. INITIAL START-UP .......................................................................................47
4.1 INITIAL START-UP REQUIREMENTS ................................................................................................. 47
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION .......................................... 47
4.2.1 Tools & Instrumentation ................................................................................................................. 48
4.2.2 Installing Gas Supply Manometer .................................................................................................. 48
4.1.1Accessing the Vent Probe Port ....................................................................................................... 49
4.3 RSI REGULATOR SAFE TEST ............................................................................................................ 49
4.4 NATURAL GAS COMBUSTION CALIBRATION .................................................................................. 51
4.5 UNIT REASSEMBLY ............................................................................................................................ 56
4.6 OVER-TEMPERATURE LIMIT SWITCHES ......................................................................................... 56
4.6.1 Digital Alarm Switch Checks and Adjustments .............................................................................. 57
CHAPTER 5. MODE OF OPERATION ................................................................................61
5.1 INTRODUCTION ................................................................................................................................... 61
5.2 INDOOR/OUTDOOR RESET MODE ................................................................................................... 61
5.2.1 Reset Ratio .................................................................................................................................... 61
5.2.2 Building Reference Temperature ................................................................................................... 61
5.2.3 Outdoor Air Temperature Sensor Installation ................................................................................ 61
5.2.4 Indoor/ Outdoor Startup ................................................................................................................. 61
5.3 CONSTANT SETPOINT MODE ........................................................................................................... 62
5.3.1 Setting the Setpoint ....................................................................................................................... 62
5.4 REMOTE SETPOINT MODES ............................................................................................................. 63
5.4.1 Remote Setpoint Field Wiring ........................................................................................................ 63
5.4.2 Remote Setpoint Startup ............................................................................................................... 64
Page 4 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
Benchmark 1.5LN Low NOx Boiler
OMM-0041_0E
GF-120
5.5 DIRECT DRIVE MODES....................................................................................................................... 64
5.5.1 Direct Drive Field Wiring ................................................................................................................ 65
5.5.2 Direct Drive Startup ....................................................................................................................... 65
5.6 BOILER MANAGEMENT SYSTEM (BMS) ........................................................................................... 65
5.6.1 BMS External Field Wiring ............................................................................................................. 66
5.6.2 BMS Setup and Startup ................................................................................................................. 66
5.7 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 66
5.7.1 Combination Control System Field Wiring ..................................................................................... 67
5.7.2 Combination Control System Setup and Startup ........................................................................... 67
CHAPTER 6. SAFETY DEVICE TESTING ..........................................................................69
6.1 TESTING OF SAFETY DEVICES ......................................................................................................... 69
6.2 LOW GAS PRESSURE FAULT TEST .................................................................................................. 69
6.3 HIGH GAS PRESSURE TEST ............................................................................................................. 70
6.4 LOW WATER LEVEL FAULT TEST ..................................................................................................... 71
6.5 WATER TEMPERATURE FAULT TEST .............................................................................................. 71
6.6 INTERLOCK TESTS ............................................................................................................................. 73
6.6.1 REMOTE INTERLOCK .................................................................................................................. 73
6.6.2 DELAYED INTERLOCK ................................................................................................................ 73
6.7 FLAME FAULT TESTS ......................................................................................................................... 73
6.8 AIR FLOW FAULT TESTS .................................................................................................................... 75
6.9 SSOV PROOF OF CLOSURE SWITCH ............................................................................................... 76
6.10 PURGE SWITCH OPEN DURING PURGE ........................................................................................ 76
6.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................................. 77
6.12 SAFETY PRESSURE RELIEF VALV E TEST ..................................................................................... 78
CHAPTER 7. MAINTENANCE ............................................................................................79
7.1 MAINTENANCE SCHEDULE ............................................................................................................... 79
7.2 IGNITER-INJECTOR ............................................................................................................................ 80
7.3 FLAME DETECTOR ............................................................................................................................. 82
7.4 COMBUSTION CALIBRATION & RSI REGULATOR ADJUSTMENT ................................................. 82
7.4.1 RSI Regulator Pressure ................................................................................................................. 82
7.5 SAFETY DEVIC E TESTING ................................................................................................................. 85
7.6 BURNER ASSEMB LY INSPECTION ................................................................................................... 85
7.7 CONDENSATE DRAIN TRAP .............................................................................................................. 88
7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ....................................... 89
7.9 PLACING THE BOI LE R BAC K IN SERVICE AFTER A PROL ON G ED SH UTDOWN ......................... 90
CHAPTER 8. TROUBLE SHOOTING GUIDE .......................................................................91
8.1 INTRODUCTION ................................................................................................................................... 91
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................. 101
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 5 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
Installation, Operation and Maintenance Manual
CHAPTER 9. RS232 COMMUNICATION .......................................................................... 105
9.1 INTRODUCTION ................................................................................................................................. 105
9.1.1 Aquiring the PuTTY Applic ation ................................................................................................... 105
9.1.2 Logging on to a Remote Machine Using PuTTY ......................................................................... 105
9.1.3 Running a Command on a Remote Machine Using PuTTY ........................................................ 106
9.2 RS232 COMMUNICATION SETUP .................................................................................................... 107
9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION .......................................................... 107
9.4 DATA LOGGING ................................................................................................................................. 108
9.4.1 Fault Log ...................................................................................................................................... 108
9.4.2 Operation Time Log ..................................................................................................................... 108
9.4.3 Sensor Log .................................................................................................................................. 109
APPENDIX A: MENU ITEM DESCRIPTIONS 111 APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES 118 APPENDIX C: SENSOR TEMPERATURE RESISTANCE 121 APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHART S 122 APPENDIX E: BOILER DEFAULT SETTINGS 126 APPENDIX F: PART AND DIMENSIONAL DRAWINGS 129 APPENDIX G: PIPING DRAWINGS 145 APPENDIX H: WIRING SCHEMATICS 151 APPENDIX I: RECOMMENDED PERIODI C T ESTI NG CHECK L IST 157 APPENDIX J: BENCHMARK CONTROL PANEL FEATURES 159 APPENDIX K: RECOMMENDED SPARE PARTS LISTS 161 LIMITED WARRANTY: Benchmark Gas-Fired Boiler 163
Page 6 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
GF-120
Foreword
Installation, Operation and Maintenance Manual
Foreword
The AERCO Benchmark 1.5LN Boiler is a modulating unit. It represents a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads. The Benchmark 1.5, with its 20:1 turn down ratio and condensing capability, provides extremely high efficiencies and makes it ideally suited for modern low temperature, as well as, conventional heating systems.
The Benchmark 1.5 operates at inputs ranging from 75,000 BTU/hr. to 1,500,000 BTU/hr. The output of the boiler is a function of the unit’s firing rate and return water temperature. Output ranges from 74,250 BTU/hr. to 1,450,000 BTU/hr., depending on operating conditions.
When installed and operated in accordance with this Instruction Manual, the Benchmark 1.5 Boiler complies with the NOx emission standards outlined in:
South Coast Air Quality Management Distr ic t (SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the Benchmark 1.5 offers the maximum flexibility in venting with minimum installation space requirements. The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration.
For service or parts, contact your local sales representative or AERCO INTERNATIONAL.
NAME: ORGANIZATION: ADDRESS: TELEPHONE: INSTALLATION DATE: _____________________________________________
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 7 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
Installation, Operation and Maintenance Manual
(This page left intentionally blank)
Page 8 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 1
SAFETY PRECAUTIONS
Installation, Operation and Maintenance Manual

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). Where ASME CSD-1 is required by local jurisdiction, the installation must conform to CSD-1.
Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
IMPORTANT
This Instruction Manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.
WARNING
MUST BE OBSERVED TO PREVENT SERIOUS INJURY.
WARNING
BEFORE ATTEMPTING TO PER-FORM ANY MAINTENANCE ON THE UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.
WARNING
THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A POSITIVE PRESSURE AND THERE-FORE MUST BE COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES.
WARNING
A DOUBLE-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.
WARNING
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.
WARNING
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.
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 9 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
MANUAL GAS SHUTOFF VALVE
VALVE OPEN
VALVE CLOSED
CHAPTER 1 SAFETY PRECAUTIONS
ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS EQUIPMENT. THEREFORE T HE COVER ON THE UNIT’S POWER BOX (LOCAT ED BEHIND THE FRONT PANEL DOO R) MUST BE INSTALLED AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
Must be observed to prevent equipment damage or loss of operating effectiveness.
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.
WARNING
CAUTIONS
CAUTION
CAUTION!

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.
IMPORTANT
The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

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 the unit. The installer must identify the emergency shut-off device.
Figure 1-1: Manual Gas Shutoff Valve
Page 10 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 1
SAFETY PRECAUTIONS
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY
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-corros ive s oap .
• If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed upstream of the Fill/Makeup Valve.
• 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:
Installation, Operation and Maintenance Manual
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 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 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,
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 11 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
CHAPTER 1 SAFETY PRECAUTIONS
"GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
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 EQUI PMENT 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 identification of each "special venting system" shall include the listing of either the website, phone number or manufacturer’s address where the venting system installation instructions can be obtained, 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 the Product Approved side wall horizontally vented gas fueled equipment and all the venting instructions, parts lists and/or design instructions for the venting system shall remain with the appliance or equipment at the completion of the installation.
_______________ [End of Extracted Information From 248 CMR 5.08 (2)__________________
Page 12 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION

CHAPTER 2. INSTALLATION

2.1 INTRODUCTION

This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark 1.5 Boiler. Brief descriptions are also provided for each available mode of operation. Detailed procedures for implementing these modes are provided in Chapter 5.

2.2 RECEIVING THE UNIT

Each Benchmark 1.5 System is shipped as a single crated unit. The shipping weight is approximately 1551 pounds. 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 fr om the carrier and before the bill of lading is signed.
NOTE
AERCO is not responsible for lost or damaged freight.
Each unit has a Tip-N-Tell indicator on the outside of the crate. This indicates if t he 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 damag e 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
A close inspection of the unit should be made to ensure that there is no evidence of damage not indicated by the Tip-N-Tell indicator. The freight carrier should be notified immediately if any damage is detected.
IMPORTANT
After unpacking, take off the unit top panel and remove the strap and packing material at the top of the heat exchanger. The packing material is located in the area of the ignitor-injector and staged ignition solenoid on the burner assembly.
The following accessories come standard with each unit and are either packed separately within the unit’s packing container or are factory installed on the boiler:
• Pressure/Temperature Gauge
• Spare Spark Ignitor-Injector
• Spare Flame Detector
• ASME Pressure Relief Valve
• Condensate Drain Trap
• 1-1/2” Gas Supply Shutoff Valve
When ordered, optional accessories may be packed separately, packed within the boiler shipping container, or may be installed on the boiler. Any standard or optional accessories shipped loose should be identified and stored in a safe place until ready for installation or use.
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 13 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
24"
4" HIGH PAD*
REAR
FRONT
44.5"
18"
101"
79"
30" 24"
24"
*(SEE NOTE IN PARAGRAPH 2.4.2)
CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual

2.4 SITE PREPARATION.

Ensure that the site selected for installation of the Benchmark 1.5 Boiler includes:
• Access to AC Input Power at 120 VAC, 1-Phase, 60 Hz @ 20
• Access to Natural Gas line at a minimum pressure of 4 inches W.C.
2.4.1

Installation Clearances

The unit must be installed with the prescribed clearances for service as shown in Figure 2-1. 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:
• Sides: 24 inches
• Front : 24 inches
• Rear: 30 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 2-1: Benchmark 1.5 Boiler Clearances
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.
Page 14 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
While packaged in the shipping container, the boiler must be moved by pallet jack or forklift from the FRONT ONLY.
FOR MASSACHUSSETTS ONLY:
For Massachusetts installations, the boiler must be installed by a plumber or gas fitter who is 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.
WARNING
CAUTION
GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION

2.4.2 Setting the Unit

The unit must be installed on a 4 inch to 6 inch housekeeping pad (see NOTE below) to ensure proper condensate drainage. If anchoring the unit, refer to the dimensional drawings in Appendix F for anchor locations. Two lifting tabs are provided at the top of the heat exchanger. Figure 2-2 shows the location of the tab on the top-left side. The second tab is locat ed on the top-right side of the heat exchanger. USE THESE TW O TABS TO LIFT AND MOVE THE UNIT . Remove the top panel from the unit to provide access to the lifting tabs. Remove the four (4) lag screws securing the unit to the shipping skid. Lift the unit of f the shipping skid and positi on it on the 4 inch to 6 inch housekeeping concrete pad (required) in the desired location.
NOTE:
When using the AERCO Condensate Neutralizer Tank for proper condensate drainage, the Neutralizer Tank must be stored in a pit, O R the boiler and AERCO Condensate Trap must be elevated higher than 4” above the floor. See Condensate Tank instructions in TID-0074 for details.
WARNING
WHEN LIFTING OR MOVING THE BOILER:
• DO NOT MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER
• WHEN USING THE LIFTING TABS, ENSURE THERE IS NO LOAD PLACED ON THE GAS TRAIN OR BLOWER
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.
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Figure 2-2: Partial Top View Showing Lifting Tab Location
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
BOILER SUPPLY
3" – 150# FLANGED
CONNECTION
BOILER RETURN 3" – 150# FLANGED CONNECTION
1-1/2”
GAS INLET
CONNECTION
SHELL DRAIN
VALVE
EXHAUST
MANIFOLD
REAR VIEW
CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual
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 1.5 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-832 for additional dimensional data.
Figure 2-3: Supply and Return Locations

2.6 CONDENSATE DRAIN

The Benchmark 1.5 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 pipe located on the exhaust manifold (Figure 2-4) must be connected t o a condensate trap which is packed separately within the unit’s shipping container.
The procedure to install and connect the condensate drain is provided in paragraph 2.6.1.
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GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
EXHAUST
MANIFOLD
PARTIAL REAR VIEW
CONDENSATE DRAIN CONNECTION
BOILER RETURN
CHAPTER 2
INSTALLATION
Figure 2-4: Condensate Drain Connection Location

2.6.1 Exhaust Manifold Condensate Drain

The exhaust manifold drain pipe connection shown in Figure 2-4, must be connected to a condensate drain trap external to the unit.
NOTE
There are two different types of condensate traps that may be used in; an older style without built-in adapter, and a newer style with a built-in adapter (see Figure 2-5). Installation is the same (1/4” threads are inside built-in adapter on newer style).
Refer to Figure 2-5 and install the trap as follows:
Install 3/4” NPT nipples in the tapped inlet and outlet of the condensate trap (part no. 1.
24060). Install a third 3/4” NPT nipple in the tapped condensate outlet of the exhaust manifold. 2. Connect the exhaust manifold nipple to the condensate trap inlet using a female union. 3. install a suitable support under the condensate trap and ensure that the trap is level. 4. Connect a length of 1” I.D. polypropylene hose (part no. 91030) to the nipple on the 5.
outlet side of the condensate trap and secure it with a hose clamp.
Route the hose on the trap outlet to a nearby floor drain. 6.
If a floor drain is not available, a condensate pump can be used to remove the condensate to drain. The maximum condensate flow rate is 20 GPH. The condensate drain trap, associated fittings and drain lines must be removable for routine maintenance.
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CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual
Figure 2-5: Condensate Trap Installation: Older (l eft) and Newer (right) Style

2.7 GAS SUPPLY PIPING

The AERCO Benchmark 1.5 Gas Components and Supply Design Guide, GF-4030 must be consulted prior to designing or installing any gas supply piping.
WARNING
NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.
Many soaps used for gas pipe leak testing are corrosive to metals. There-fore, piping must be rinsed thor oughly with clean water after 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.
A 1-1/2 inch gas inlet connection is located 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 gas 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.
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Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION
2.7.1
The gas supply input specifications to the unit for Natural Gas are as follows:
2.7.2
A manual shut-off valve must be installed in the gas supply line upstream of the Boiler as shown in Figure 2-6. Maximum allowable gas pressure to the Boiler is 14” W.C.
2.7.3
For Massachusetts installations, a mandatory external gas supply regulator must be positioned as shown in Figure 2-6. The gas supply regulator must be properly vented to outdoors. Consult the local gas utility for detailed requirements concerning venting of the the supply gas regulator.

Gas Supply Specifications.

• The maximum static pressure to the unit must not exceed 14” W.C.
• The gas supply pressure to the unit must be of sufficient capacity to provide 1500 cfh
while maintaining the gas pressure at 4.0 inches W.C. for FM, or 4.2 inches W.C. for IRI gas trains.

Manual Gas Shutoff Valve

NOTE
Paragraph 2.7.3 applies only to bolier installations within the Commonwealth of Massachusetts.

External Gas Supply Regulator

NOTE
The external regulator must be capable of regulating 1,500,000 BTU/HR of natural gas while maintaining a gas pressure of 4.0” W.C. to the boiler.
CAUTION
A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C.
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Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
NATURAL
GAS
SUPPLY
DIRT
TRAP
1-1/2” MANUAL GAS SHUTOFF
VALVE
GAS PRESSURE
REGULATOR
(REQUIRED FOR
MASSACHUSETTS
INSTALALTIONS
ONLY)
CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual
Figure 2-6: Manual Gas Shut-Off Valve Location

2.7.4 IRI Gas Train Kit

The IRI gas train is an optional gas train configuration which is required in some areas for code compliance or for insurance purposes. The IRI gas train is factory pre-piped and wired. See Appendix F, Drawing AP-A-830 for details.

2.8 AC ELECTRICAL POWER WIRING

The AERCO Benchmark 1.5 Electrical Power Wiring Guide, GF-4060, 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 on the front panel of the unit. Remove the front door of the unit to access the Power Box mounted directly above the Control Box. Loosen the four Power Box cover screws and remove cover to access the AC terminal connections inside the Power Box (Figure 2-7).
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.
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GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
UPPER RIGHT CORNER OF FRONT PANEL
TERMINAL BLOCK
GND
NEU
L1
120 VAC, 1 PHASE
CHAPTER 2
INSTALLATION
Figure 2-7: AC Input Terminal Block Location

2.8.1 Electrical Power Req u irem ent s

The AERCO Benchmark 1.5 Boiler accepts 120 VAC, single-phase, 60 Hz @ 20 A. The Power Box contains a terminal block as shown in Figure 2-8. In addition, a wiring diagram showing the required AC power connections is provided on the front cover of the Power Box.
Each Benchmark 1.5 Boiler must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BENCHMARK 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 boiler in service, the ignition safety shutoff device must be test ed. If an exter nal 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 1. 5 Electrical Power Wiring Guide, (GF-4060).
Figure 2-8: AC Terminal Block Configurations
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Benchmark 1.5LN Low NOx Boiler
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CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual

2.9 MODES OF OPERATION AND FIELD CONTROL WIRING

The Benchmark 1.5 Boiler is available in several different modes of operation. While each unit is factory configured and wired for its intended mode, some additional field wiring may be required to complete the installation. This wiring is typically connected to the Input/Output (I/O) Box located on the lower portion of the unit front panel (Figure 2-9) behind the removable front door.
To access the I/O Box terminal strips shown in Figure 2-10, loosen the four cover screws and remove the cover. All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided.
Refer to the wiring diagram provided on the cover of t he I/O Box (Figure 2-10) when making all wiring connections.
Brief descriptions of each mode of operation, and their wiring requirements, are provided in the following paragraphs. Additional information concerning field wiring is provided in paragraphs
2.9.1 through 2.9.9. Refer to Chapter 5 for detailed information on the available modes of operation.
Figure 2-9: Input/Output (I/O) Box Location

2.9.1 Constant Setpoint Mode

The Constant Setpoint Mode is used when it is desired to have a fixed setpoint that does not deviate. No wiring connections, other than AC electrical power connections, are required for this mode. However, if desired, fault monitoring or enable/disable interlock wiring can be utilized (see paragraphs 2.9.9.1 and 2.9.10).
2.9.2
This mode of operation increases supply water temperature as outdoor temperatures decrease. An outside air temperature sensor (AERCO Part No. 122790) is req uired. The sensor MUST BE wired to the I/O Box wiring terminals (see Figure 2-10). Refer to paragraph 2.10.1 for additional information on outside air temperature sensor installation.
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Indoor/Outdoor Reset Mode

GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION

2.9.3 Boiler Management System Mode

NOTE
BMS Model 168 can utilize either pulse width modulation (PWM) or RS485 Modbus signaling to the Boiler. BMS II Model 5R5-384 can utilize only RS485 signaling to the Boiler.
When using an AERCO Boiler Management System (BMS), the field wiring is connected between the BMS Panel and each Boiler’s I/O Box terminal strip (Figure 2-10). Twisted shielded pair wire from 18 to 22 AWG must be utilized for the connections. The BMS Mode can utilize either pulse width modulation (PWM) signaling, or RS485 Modbus signaling. For PWM signaling, connections are made from the AERCO Boiler Management System to the B.M.S. (PWM) IN terminals on the I/O Box terminal strip. For RS485 Modus signaling, connections are made from the BMS to the RS485 COMM terminals on the I/O Box terminal strip. Polarity must be maintained and the shield must be connected only at the AERCO BMS. The boiler end of the shield must be left floating. For additional instructions, refer to Chapter 5, paragr aph 5.6 in this manual. Also, refer to GF-108M, BMS -Operations Guide.
2.9.4
The Benchmark 1.5 Boiler can accept several types of signal formats from an Energy Management System (EMS), Building Automation System (BAS) or other source, to control either the setpoint (Remote Setpoint Mode) or air/fuel valve position (Dir ect Drive Mode) of the Boiler. These formats are:
While it is possible to control a boiler or boilers using one of the previously described modes of operation, it may not be the method best suited for the application. Prior t o selecting one of these modes of operation, it is recommended that you consult with your local AERCO representative or the factory for the mode of operation that will work best with your application. For more information on wiring the 4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5 VDC, see paragraph 2.9.3.
2.9.5

Remote Setpoint and Direct Drive Modes

• 4 to 20 mA/1 to 5 VDC
• 0 to 20 mA/0 to 5 VDC
• PWM – (Pulse W idth Modulated signal. See para. 2.10.4)
• Network (RS485 Modbus. See para. 2.10.7)

Combination Mode

NOTE
Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5R5-384).
With a Combination Mode unit, field wiring is between the unit’s I/O Box wiring terminals, the CCP (Combination Control Panel), and the BMS (Boiler Management System). The wiring must be accomplished using twisted-shielded pair wire from 18 to 22 AWG. Polarity must be maintained. For further instructions and wiring diagrams, refer to the GF-108 Boiler Management System Operations Guide and the CCP-1 data sheet.
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Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual
Figure 2-10. I/O Box Terminal Locations and Functions

2.10 I/O BOX CONNECTIONS

The types of input and output signals and devices to be connected to the I/O Box terminals shown in Figure 2-10 are described in the following paragraphs.
NOTE
Older I/O PCBs are wired the same as new ones, even if silk-screen designations may slightly differ.
NOTE
DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage.
2.10.1
An outdoor air temperature sensor (AERCO Part No. 122790) will be required primarily for the Indoor/Outdoor reset 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 DISABLED. To enable the sensor and/or select an enable/disable outdoor temperature, see the Configuration menu in Chapter 3.

OUTDOOR SENSOR IN (1)

The outdoor sensor may be wired up to 200 feet from the boiler. It is connected to the OUTDOOR SENSOR IN and SENSOR COMMON terminals in the I/O Box (see Figures 2-9 and 2-10). 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
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OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION
terminals labeled SHIELD in the I/O Box. The sensor end of the shield must be left free and ungrounded.
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
The Air Temperature Sensor is connected to the positive (+) and negat ive (-) terminal s of the AIR TEMP. SENSOR on the I/O board. This sensor measures the temperature of the air input to the Air/Fuel Valve. This temperature reading is one of the components used to calculate the rotational speed of the blower used in the combustion Calibration process (Chapter 4).
The AIR TEMP. SENSOR terminals can be used to add an additional temperature sensor for monitoring purposes. This input is always enabled and is a view-onl y input that can be seen in the Operating Menu. The sensor must be wired to the positive (+) and negative (-) terminals of the AIR TEMP. SENSOR and must be similar to AERCO BALCO wire sens or Part No. 12449. A resistance chart for this sensor is provided in Appendix C.
2.10.3
The ANALOG IN + and – terminals are used when an external signal is used to drive the air/fuel valve position (Direct Drive Mode) or 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 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 sig nal, a DIP switch must be set on the PMC Board located inside the Control Box. Contact the AERCO factory for information on setting DIP switches.
All of the supplied signals must be floating (ungrounded) signals. Connections between the signal source and the Boiler’s I/O Box must be made using twisted shielded pair wire fr om 18 to 22 AWG, such as Belden 9841 (see Figure 2-10). Polarity must be maintained. The shield must be connected only at the source end and must be left floating (not connected) at the Boiler’s I/O Box.

AIR TEMP. SENSOR (2)

ANALOG IN (3)

Regardless of whether voltage or current is used for the drive signal, they are linearly mapped to a 40°F to 240°F setpoint or a 0% to 100% valve position. No scaling for these signals is provided.
2.10.4
These terminals are used to connect the AERCO Boiler Management System (BMS) to the unit. The BMS utilizes a 12 millisecond, ON/OFF duty cycle. This duty cycle 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.
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B.M.S. (PWM) IN (4)

Only BMS Model 168 can utilize Pulse Width Modulation (PWM), not the BMS II (Model 5R5-384).
NOTE
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
CHAPTER 2 INSTALLATION

2.10.5 SHIELD (5)

The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit. Only shields must be connected to these terminals.
Installation, Operation and Maintenance Manual
IMPORTANT
DO NOT USE the mA OUT output to remotely monitor Setpoint, Outlet Temp or Fire Rate Out.
2.10.6
These terminals provide a 4 to 20 mA output to the VFD ( if so equipped) to control the rotational speed of the blower. This function is enabled in the Configuration Menu (Chapter 3, Table 3-4).
2.10.7
These terminals are used for RS-485 MODBUS serial communication between the unit and an external “Master” such as a Boiler Management System (BMS), Energy Management System (EMS), Building Automation System (BAS) or other suitable device.
2.10.8
These terminals provide a parallel connection to the connector on the C -More Controller front panel, for connecting a computer or laptop.
2.10.9
These terminals provide a 0 to 10 volt output to control t he rotational speed of the blower. This function is enabled in the Configuration Menu (Chapter 3, Table 3-4).
2.10.10
These terminals permit an external exhaust switch to be connected to the exhaust manif old of the boiler. The exhaust switch should be a normally open type switch (such as AERCO Part No.
123463) that closes (trips) at 500°F.

mA O UT (6)

RS-485 COMM (7)

TxD, RxD (8)

VFD/BLOWER (9)

EXHAUST SWITCH IN (11)

2.10.11
The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers. These interlocks are called the Remote Interlock and Delayed Interlock (Figure 2-10). The wiring terminals for these interlocks are located inside the I/O Box on the unit front panel. The I/O Box cover contains a wiring diag ram which shows the terminal strip locations for these interlocks (REMOTE INTL’K IN and DELAYED INTL’K IN). Both interlocks, described below, are factory wired in the closed position.
2.10.11.1 REMOTE INTERLOCK IN (10)
The remote interlock circuit is provided to remotely start (enable) and stop (disable) the Boiler, if desired. The circuit is labeled REMOTE INTL’K IN and is located inside the I/O Box on the front panel. The circuit is 24 VAC and is factory pre-wired in the closed (jumpered) position.
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INTERLOCKS (10, 12)

Both the Delayed Interlock and Remote Interlock MUST be in the closed position to allow the unit to fire.
NOTE
GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION
2.10.11.2 DELAYED INTERLOCK IN (12)
The delayed interlock is typically used in conjunction with the auxiliary relay described in paragraph 2.11. This interlock circuit is located in the purge section of the start string. It can be connected to the proving device (end switch, flow switch etc.) of an auxiliary piece of equipm ent started by the Boiler’s auxiliary relay. The delayed interlock must be closed for the boiler to fire.
If the delayed interlock is connected to a proving device that r equires time to close (make), a time delay (Aux Start On Dly) that holds the start sequence of the boiler long enough for a proving switch to make can be programmed. Should the proving switch not prove within the programmed time frame, the boiler will shut down. T he Aux Start On Dly can be programmed from 0 to 120 seconds. This option is locate in the Configuration Menu (Chapter 3, Table 3-4).
2.10.12

FAULT R ELAY (13)

The fault relay is a single pole double throw (SPDT) relay having a normally open and normally closed set of relay contacts that are rat ed for 5 amps at 120 VAC and 5 am ps at 30 VDC. The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed. The fault relay connections are shown in Figure 2-10.
2.10.13

AUXILIARY RELAY CONTACTS (14)

Each Boiler is equipped with a single pole double throw (SPDT) relay that is energized when there is a demand for heat and de-energized after the demand for heat is satisf ied. The relay is provided for the control of auxiliary equipment, such as pumps and louvers, or can be used as a Boiler status indictor (firing or not firing). Its contacts are rated for 120 VAC @ 5 amps. Refer to Figure 2-10 to locate the AUX RELAY terminals for wiring connections.

2.11 FLUE GAS VENT INSTALLATION

The minimum allowable vent diameter for a single Benchmark 1.5 Boiler is 6 inches. The AERCO Benchmark Venting and Combustion Air Guide, GF-2050, must be consulted
before any flue gas vent or inlet air venting is designed or inst alled. U/L listed, posit ive pressur e, watertight vent materials as specified in AERCO’s GF-2050, must be used for safety and code compliance. Since the unit is capable of discharging low temper ature exhaust gases, horizontal sections of the flue vent system must be pitched back to the unit a minimum of 1/4 inch per foot to avoid condensate pooling and allow for proper drainage.
The combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet of 6 inch ducting. Fittings as well as pipe leng ths must be calculated as part of the equivalent length.
For a natural draft installation the draft must not exceed ±0.25 inch W.C. These factors must be planned into the vent installation. If the maximum allowable equivalent lengths of piping are exceeded, the unit will not operate properly or reliably.
For Massachusetts boiler installations, the Heatfab Division of the Selkirk Corporation provides vent systems which conform to all applicable requirements within the Commonwealth of Massachusetts. Contact information for this supplier is as follows:
Selkirk Corporation Heatfab Division ( www.heat-fab.com 130 Industrial Blvd. Turners Falls, MA 01376 Phone: 1-800-772-0739
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)
Benchmark 1.5LN Low NOx Boiler
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CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual

2.12 COMBUSTION AIR

The AERCO Benchmark Venting and Combustion Air Guide, GF-2050 MUST be consulted before any flue or combustion supply air venting is designed or implemented. Combustion air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be consulted before a permanent design is determined.
The combustion air must be free of chlorine, halogenated hydrocarbons, or other c hemicals that can become hazardous when used in gas-fired equipment. Common sources of these compounds are swimming pools, degreasing compounds, plastic processing and refrigerants. Whenever the environment contains these types of chemicals, combustion air must be supplied from a clean area outdoors for the protection and longevity of the equipment.
The AERCO Benchmark 1.5 Boiler is UL listed for 100% sealed combustion. It can also be installed using room air, provided there is an adequate supply. (See par agraph 2.13.3 for more information concerning sealed combustion air). If the sealed combustion air option is not being used, an inlet screen will be attached at the air inlet on the top of the unit
The more common methods of supplying combustion air are outlined below. For more information concerning combustion air, consult the AERCO Benchmark Venting and Combustion Air Guide, GF-2050.
2.12.1
Air supplied from outside the building must be provided through two permanent openings. Each opening must have a free area of not less than one square inch for each 4000 BTU/H boiler input. The free area must take into account r estrictions such as louvers and bird screens. For Canada installations, refer to the requirements specified in CSA B149.1-10, 8.4.1 and 8.4.3.
2.12.2
When combustion air is provided from within the building, it must be supplied through two permanent openings in an interior wall. Each opening must have a free area of not less than one square inch per 1000 BTU/H of total boiler input . The free area must take into ac count any restrictions such as louvers.
2.12.3
The AERCO Benchmark 1.5 Boiler is UL listed for 100%-sealed combustion. For sealed combustion installations, the screen on the air inlet duct of the unit must be removed. The inlet air ductwork must then be attached directly to the unit’s air inlet.
In a sealed combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run. See the AERCO Benchmark Venting and Combustion Air Guide, GF-2050. When using the boiler in a sealed combustion air configuration, each unit must have a minimum 6 inch diameter connection at the unit.

Combustion Air From Outside the Building

Combustion Air From Inside The Building

Sealed Combustion

2.12.4
When the Benchmark 1.5 Boiler is used to provide heat temporarily during ongoing building construction, accumulated drywall dust, sawdust and similar particles can accumulate in the unit’s combustion air intake filter and block combustion air flow. In these situations, AERCO recommends that a disposable air intake filter be installed, temporarily, above the boiler combustion air inlet.
AERCO recommends that the temporary air filter be cut from a McMaster-Carr part no. 2122K315 Polyester Air Filter Roll Tackfield, ½” thick, 16” wide, or equivalent. Cover the Benchmark 1.5 air inlet with the blue side of the filter material facing outward to hold the dust on
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Temporary Combustion Air Filtering During Construction

GF-120
OMM-0041 0E
Benchmark 1.5LN Low NOx Boiler
CHAPTER 2
INSTALLATION
the outside surface. Maximize the surface area of the filter covering the 8" diameter opening by creating a dome out of the filter material.
Cover the flared duct opening with the blue side facing outward. During construction check the filter for dust accumulation and replace it when the accumulation becomes noticeable.

2.13 BENCHMARK PUMP RELAY OPTION

An optional Benchmark pump relay allows the user to turn a pump on/off and open/close a motorized valve as the boiler cycles on and off on demand. The Pump Delay Timer feature allows the user to keep the pump running and keep the motorized valve open for up to 30 minutes after the boiler has shut down and the demand is satisfied.
The Benchmark pump relay (SPDT) contact is rated for:
• 10 A Resistive @ 277 VAC/28 VDC
• 1/3 HP N/O @ 120/240 VAC
• 1/6 HP N/C @ 120/240 VAC
• 480 VA Pilot Duty @ 240-277 VAC
If pump/valve load exceeds the above contact ratings, use a separate contact relay. See Diagrams 2-11a and 2-11b.
To identify if the boiler is equipped with the BMK Pump Relay Option (part no. 69102), look for the label and relay in the Power Box as shown in Figure 2-12.
Figure 2-11a: Schematic – System Pump Start using Boiler Pump Relay
PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 29 of 166
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041 0E
CHAPTER 2 INSTALLATION
Installation, Operation and Maintenance Manual
Figure 2-11b: Schematic – System Pump Start using a Separate Contact Relay
Figure 2-12: Identifying the Presence of BMK Pump Relay Option 69102
Page 30 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12
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