AERCO BMK 1.5 LN User Manual July 2011
Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Revised: 05/09/2012
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 Numbers:
G-11-1938 and above.
USER MANUAL
PR2: 05/09/12 Page 1 of 152
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
Technical Support:
1-800-526-0288
www.aerco.com
(Mon–Fri, 8am-5pm EST)
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 this material, 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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Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Table of Contents
CHAPTER 1 SAFETY PRECAUTIONS ............................................................................. 9
1.1 WARNINGS & CAUTIONS .................................................................................... 9
1.2 EMERGENCY 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
Installation Clearances ............................................................................................. 14 2.4.1
Setting the Unit ........................................................................................................ 15
2.5 SUPPLY AND RETURN PIPING ......................................................................... 16
2.4.2
2.6 CONDENSATE DRAIN ........................................................................................ 16
Exhaust Manifold Condensate Drain ....................................................................... 16 2.6.1
2.7 GAS SUPPLY PIPING ......................................................................................... 17
Gas Supply Specifications. ...................................................................................... 18 2.7.1
Manual Gas Shutoff Valve ....................................................................................... 18 2.7.2
External Gas Supply Regulator ................................................................................ 18 2.7.3
IRI Gas Train Kit ..................................................................................................... 19 2.7.4
2.8 AC ELECTRICAL POWER WIRING .................................................................... 19
Electrical Power Requirements ................................................................................ 20 2.8.1
2.9 MODES OF OPERATION AND FIELD CONTROL WIRING ............................... 21
Constant Setpoint Mode ........................................................................................... 21 2.9.1
Indoor/Outdoor Reset Mode .................................................................................... 21 2.9.2
Boiler Management System Mode ........................................................................... 22 2.9.3
Remote Setpoint and Direct Drive Modes ............................................................... 22
Combination Mode .................................................................................................. 22
2.10 I/O BOX CONNECTIONS .................................................................................. 23
OUTDOOR SENSOR IN (1) ................................................................................ 23 2.10.1
AIR TEMP. SENSOR (2) ..................................................................................... 24 2.10.2
ANALOG IN (3) ................................................................................................... 24 2.10.3
B.M.S. (PWM) IN (4) ........................................................................................... 24 2.10.4
SHIELD (5) ........................................................................................................... 24 2.10.5
mA OUT (6) .......................................................................................................... 25 2.10.6
RS-485 COMM (7) ............................................................................................... 25 2.10.7
TxD, RxD (8) ........................................................................................................ 25 2.10.8
VFD/BLOWER (9) ............................................................................................... 25 2.10.9
EXHAUST SWITCH IN (11) ............................................................................. 25 2.10.10
INTERLOCKS (10, 12) ...................................................................................... 25 2.10.11
2.9.4
2.9.5
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Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
FAULT RELAY (13) ........................................................................................... 26 2.10.12
2.11 AUXILIARY RELAY CONTACTS (14) ............................................................... 26
2.12 FLUE GAS VENT INSTALLATION .................................................................... 26
2.13 COMBUSTION AIR ........................................................................................... 26
Combustion Air From Outside the Building .......................................................... 27 2.13.1
Combustion Air From Inside The Building ........................................................... 27 2.13.2
Sealed Combustion ................................................................................................ 27 2.13.3
Temporary Combustion Air Filtering During Construction .................................. 27 2.13.4
2.14 BENCHMARK PUMP RELAY OPTION ............................................................. 27
CHAPTER 3 CONTROL PANEL OPERATION .............................................................. 29
3.1 INTRODUCTION ................................................................................................. 29
3.2 CONTROL PANEL DESCRIPTION ..................................................................... 29
3.3 CONTROL PANEL MENUS ................................................................................ 33
Menu Processing Procedure ..................................................................................... 33 3.3.1
3.4 OPERATING MENU ............................................................................................ 34
3.5 SETUP MENU ..................................................................................................... 35
3.6 CONFIGURATION MENU ................................................................................... 36
3.7 TUNING MENU ................................................................................................... 37
3.8 COMBUSTION CAL MENU ................................................................................. 37
1.1 START SEQUENCE ............................................................................................ 38
3.9 START/STOP LEVELS ........................................................................................ 41
CHAPTER 4 INITIAL START-UP ...................................................................................... 43
4.1 INITIAL START-UP REQUIREMENTS ................................................................ 43
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION .......... 43
4.2.1 Required Tools & Instrumentation ...................................................................... 44
4.2.2 Installing Gas Supply Manometer ....................................................................... 44
4.2.3 Accessing the Vent Probe Port ............................................................................ 45
4.3 RSI Regulator SAFE TEST .................................................................................. 45
4.4 NATURAL GAS COMBUSTION CALIBRATION ................................................. 47
4.5 UNIT REASSEMBLY ........................................................................................... 51
4.6 OVER-TEMPERATURE LIMIT SWITCHES ........................................................ 52
CHAPTER 5 MODE OF OPERATION .............................................................................. 53
5.1 INTRODUCTION ................................................................................................. 53
5.2 INDOOR/OUTDOOR RESET MODE .................................................................. 53
Reset Ratio ............................................................................................................... 53 5.2.1
Building Reference Temperature ............................................................................. 53 5.2.2
Outdoor Air Temperature Sensor Installation .......................................................... 53 5.2.3
Indoor/ Outdoor Startup ........................................................................................... 53 5.2.4
5.3 CONSTANT SETPOINT MODE .......................................................................... 54
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Setting the Setpoint .................................................................................................. 54 5.3.1
5.4 REMOTE SETPOINT MODES ............................................................................ 55
Remote Setpoint Field Wiring ................................................................................. 55 5.4.1
Remote Setpoint Startup .......................................................................................... 56 5.4.2
5.5 DIRECT DRIVE MODES ..................................................................................... 56
Direct Drive Field Wiring ........................................................................................ 56 5.5.1
Direct Drive Startup ................................................................................................. 57 5.5.2
5.6 BOILER MANAGEMENT SYSTEM (BMS) .......................................................... 57
BMS External Field Wiring ..................................................................................... 57 5.6.1
BMS Setup and Startup ............................................................................................ 58 5.6.2
5.7 COMBINATION CONTROL SYSTEM (CCS) ...................................................... 58
Combination Control System Field Wiring ............................................................. 58 5.7.1
Combination Control System Setup and Startup ..................................................... 59 5.7.2
CHAPTER 6 SAFETY DEVICE TESTING ....................................................................... 61
6.1 TESTING OF SAFETY DEVICES ....................................................................... 61
6.2 LOW GAS PRESSURE FAULT TEST ................................................................. 61
6.3 HIGH GAS PRESSURE TEST ............................................................................ 62
6.4 LOW WATER LEVEL FAULT TEST .................................................................... 63
6.5 WATER TEMPERATURE FAULT TEST ............................................................. 63
6.6 INTERLOCK TESTS ............................................................................................ 65
REMOTE INTERLOCK ......................................................................................... 65 6.6.1
DELAYED INTERLOCK ....................................................................................... 65 6.6.2
6.7 FLAME FAULT TESTs ........................................................................................ 65
6.8 AIR FLOW FAULT TESTS .................................................................................. 67
6.9 SSOV PROOF OF CLOSURE SWITCH .............................................................. 67
6.10 PURGE SWITCH OPEN DURING PURGE ....................................................... 68
6.11 IGNITION SWITCH OPEN DURING IGNITION ................................................ 69
6.12 SAFETY PRESSURE RELIEF VALVE TEST .................................................... 70
CHAPTER 7 MAINTENANCE ............................................................................................ 71
7.1 MAINTENANCE SCHEDULE .............................................................................. 71
7.2 IGNITER-INJECTOR ........................................................................................... 72
7.3 FLAME DETECTOR ............................................................................................ 74
7.4 COMBUSTION CALIBRATION & RSI REGULATOR ADJUSTMENT ................. 74
RSI Regulator Pressure ............................................................................................ 74 7.4.1
7.5 SAFETY DEVICE TESTING ................................................................................ 77
7.6 BURNER ASSEMBLY INSPECTION .................................................................. 77
7.7 CONDENSATE DRAIN TRAP ............................................................................. 80
7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ....... 81
7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN . 81
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Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
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GF-120
CHAPTER 8 TROUBLESHOOTING GUIDE ................................................................... 83
8.1 INTRODUCTION ................................................................................................. 83
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................... 93
CHAPTER 9 RS232 COMMUNICATION ......................................................................... 97
9.1 INTRODUCTION ................................................................................................. 97
9.2 RS232 COMMUNICATION SETUP ..................................................................... 97
9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION ........................... 97
9.4 DATA LOGGING ................................................................................................. 98
Fault Log .................................................................................................................. 98 9.4.1
Operation Time Log ................................................................................................. 99 9.4.2
Sensor Log ............................................................................................................... 99 9.4.3
APPENDIX A: MENU ITEM DESCRIPTIONS .............................................................. 101
APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES ................................ 107
APPENDIX C: SENSOR TEMPERATURE RESISTANCE ......................................... 110
APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHARTS................................. 111
APPENDIX E: BOILER DEFAULT SETTINGS ............................................................ 115
APPENDIX F: PART AND DIMENSIONAL DRAWINGS ........................................... 117
APPENDIX G: PIPING DRAWINGS ............................................................................... 133
APPENDIX H: WIRING SCHEMATICS .......................................................................... 139
APPENDIX I: RECOMMENDED PERIODIC TESTING CHECK LIST .................... 145
APPENDIX J: BENCHMARK CONTROL PANEL FEATURES ................................ 146
APPENDIX K: RECOMMENDED SPARE PARTS LISTS .......................................... 149
STANDARD WARRANTY: Benchmark Gas-Fired Hydronic Boiler .................... 150
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Operation and Maintenance Manual
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
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 District (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: _____________________________________________
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Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
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Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
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).
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.
WARNING
electrical voltages up to 120 vac may be used in this equipment.
Therefore the cover on the unit’s power box (located behind the
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MANUAL GAS SHUTOFF VALVE
VALVE OPEN
VALVE CLOSED
CHAPTER 1: SAFETY PRECAUTIONS
front panel door) must be installed at all times, except during
maintenance and servicing.
CAUTIONS
Must be observed to prevent equipment damage or loss of
operating effectiveness.
CAUTION
Many soaps used for gas pipe leak testing are corrosive to metals.
The piping must be rinsed thoroughly with clean water after leak
checks have been completed.
CAUTION!
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.
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 system-operating
parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close
the manual gas valve located upstream the unit. The installer must identify the emergency shut-off
device.
Figure 11: Manual Gas Shutoff Valve
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Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
• Boiler must be installed by a plumber or a gas fitter who is licensed within the
• Prior to unit operation, the complete gas train and all connections must be leak tested
• If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed
• 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
(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:
CHAPTER 1: SAFETY PRECAUTIONS
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY
Boiler Installations within the Commonwealth of Massachusetts
must conform to the following requirements:
Commonwealth of Massachusetts.
using a non-corrosive soap.
upstream of the Fill/Makeup Valve.
extracted from 248 CMR 5.08 (2):
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,
"GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
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CHAPTER 1: SAFETY PRECAUTIONS
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented
gas fueled equipment shall not approve the installation unless, upon inspection, the
inspector 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 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)__________________
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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 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 Tip-N-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
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.
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CHAPTER 2: INSTALLATION
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.
Installation Clearances 2.4.1
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 they 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
WARNING
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL
COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR
LIQUIDS.
CAUTION
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
1-2 & 1-3.
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CHAPTER 2: INSTALLATION
Setting the Unit 2.4.2
The unit must be installed on a 4 inch to 6 inch housekeeping pad 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 located on the top-right side of the heat
exchanger. USE THESE TWO 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 off the shipping skid and position it on the 4 inch to 6 inch
housekeeping concrete pad (required) in the desired location.
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
Figure 2-2: Partial Top View Showing Lifting Tab Location
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.
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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
EXHAUST
MANIFOLD
PARTIAL REAR VIEW
CONDENSATE DRAIN
CONNECTION
BOILER
RETURN
CHAPTER 2: INSTALLATION
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 to 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.
Exhaust Manifold Condensate Drain 2.6.1
The exhaust manifold drain pipe connection shown in Figure 2-4, must be connected to a
condensate drain trap external to the unit.
Page 16 of 152 PR2: 05/09/12
Figure 2-4: Condensate Drain Connection Location
Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
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Refer to Figure 2-5 and install the trap as follows:
CHAPTER 2: INSTALLATION
NOTE
There are two slightly different types of condensate traps that may
be used in your configuration; 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).
1. Install 3/4” NPT nipples in the tapped inlet and outlet of the condensate trap (part no.
24060).
2. Install a third 3/4” NPT nipple in the tapped condensate outlet of the exhaust manifold.
3. Connect the exhaust manifold nipple to the condensate trap inlet using a female union.
4. install a suitable support under the condensate trap and ensure that the trap is level.
5. Connect a length of 1” I.D. polypropylene hose (part no. 91030) to the nipple on the
outlet side of the condensate trap and secure it with a hose clamp.
6. 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
drain. The maximum condensate flow rate is 20 GPH. The condensate drain trap, associated
fittings and drain lines must be removable for routine maintenance.
Figure 2-5: Condensate Trap Installation: Older (left) 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 thoroughly with clean water after
leak checks have been completed.
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CHAPTER 2: INSTALLATION
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.
Gas Supply Specifications. 2.7.1
The gas supply input specifications to the unit for Natural Gas are as follows:
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 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.
NOTE
Paragraph 2.7.3 applies only to bolier installations within the
Commonwealth of Massachusetts.
External Gas Supply Regulator 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.
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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NATURAL
GAS
SUPPLY
DIRT
TRAP
1-1/2” MANUAL
GAS SHUTOFF
VALVE
GAS PRESSURE
REGULATOR
(REQUIRED FOR
MASSACHUSETTS
INSTALALTIONS
ONLY)
CHAPTER 2: INSTALLATION
Figure 2-6: Manual Gas Shut-Off Valve Location
IRI Gas Train Kit 2.7.4
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).
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.
NOTE
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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
Electrical Power Requirements 2.8.1
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 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 1.5 Electrical Power Wiring
Guide, (GF-4060).
Figure 2-8: AC Terminal Block Configurations
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CHAPTER 2: INSTALLATION
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 the 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
Constant Setpoint Mode 2.9.1
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).
Indoor/Outdoor Reset Mode 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 required. 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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CHAPTER 2: INSTALLATION
Boiler Management System Mode 2.9.3
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, paragraph 5.6 in this
manual. Also, refer to GF-108M, BMS -Operations Guide.
Remote Setpoint and Direct Drive Modes 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 (Direct Drive Mode) of the
Boiler. These formats are:
• 4 to 20 mA/1 to 5 VDC
• 0 to 20 mA/0 to 5 VDC
• PWM – (Pulse Width Modulated signal. See para. 2.10.4)
• Network (RS485 Modbus. See para. 2.10.7)
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 to 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.
Combination Mode 2.9.5
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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CHAPTER 2: INSTALLATION
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 silkscreen designations may slightly differ.
DO NOT make any connections to the I/O Box terminals labeled
“NOT USED”. Attempting to do so may cause equipment
damage.
OUTDOOR SENSOR IN (1) 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.
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
terminals labeled SHIELD in the I/O Box. The sensor end of the shield must be left free and
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CHAPTER 2: INSTALLATION
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.
AIR TEMP. SENSOR (2) 2.10.2
The Air Temperature Sensor is connected to the positive (+) and negative (-) terminals 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-only 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 sensor Part No. 12449.
A resistance chart for this sensor is provided in Appendix C.
ANALOG IN (3) 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 signal, 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 from 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.
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.
B.M.S. (PWM) IN (4) 2.10.4
NOTE
Only BMS Model 168 can utilize Pulse Width Modulation (PWM),
not the BMS II (Model 5R5-384).
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.
SHIELD (5) 2.10.5
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.
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CHAPTER 2: INSTALLATION
IMPORTANT
DO NOT USE the mA OUT output to remotely monitor Setpoint,
Outlet Temp or Fire Rate Out.
mA OUT (6) 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).
RS-485 COMM (7) 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.
TxD, RxD (8) 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.
VFD/BLOWER (9) 2.10.9
These terminals provide a 0 to 10 volt output to control the rotational speed of the blower. This
function is enabled in the Configuration Menu (Chapter 3, Table 3-4).
EXHAUST SWITCH IN (11) 2.10.10
These terminals permit an external exhaust switch to be connected to the exhaust manifold 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.
INTERLOCKS (10, 12) 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 diagram 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.
NOTE
Both the Delayed Interlock and Remote Interlock MUST be in the
closed position to allow the unit to fire.
REMOTE INTERLOCK IN (10) 2.10.11.1
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.
DELAYED INTERLOCK IN (12) 2.10.11.2
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 equipment
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 requires 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. The Aux Start On Dly can be programmed
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CHAPTER 2: INSTALLATION
from 0 to 120 seconds. This option is locate in the Configuration Menu (Chapter 3, Table 3-4).
FAULT RELAY (13) 2.10.12
The fault relay is a single pole double throw (SPDT) relay having a normally open and normally
closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps 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.
2.11 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 satisfied. 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.
2.12 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 installed. U/L listed, positive pressure,
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 temperature 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 lengths 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
)
2.13 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 chemicals 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.
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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 paragraph 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.
CHAPTER 2: INSTALLATION
Combustion Air From Outside the Building 2.13.1
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 restrictions 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.
Combustion Air From Inside The Building 2.13.2
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 account any
restrictions such as louvers.
Sealed Combustion 2.13.3
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.
Temporary Combustion Air Filtering During Construction 2.13.4
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
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.
2.14 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:
PR2: 05/09/12 Page 27 of 152
Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
CHAPTER 2: INSTALLATION
• 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 2-1a and 2-1b.
To identify if the boiler is equipped with the BMK Pump Relay Option (part no. 69102), look for the label
and relay as shown in Figure 2-12.
Diagram 2-1a: Schematic – System Pump Start using Boiler Pump Relay
Diagram 2-1b: Schematic – System Pump Start using a Separate Contact Relay
Figure 2-11: Identifying the Presence of BMK Pump Relay Option 69102
Page 28 of 152 PR2: 05/09/12
Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
CHAPTER 3: CONTROL PANEL OPERATION
3.1 INTRODUCTION
The information in this Chapter provides a guide to the operation of the Benchmark 1.5 Boiler
using the Control Panel mounted on the front of the unit. It is imperative that the initial startup of
this unit be performed by factory trained personnel. Operation prior to initial startup by factory
trained personnel will void the equipment warranty. In addition, the following WARNINGS and
CAUTIONS must be observed at all times.
All of the installation procedures in Chapter 2 must be completed
before attempting to start the unit.
WARNING
ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460,
208 AND 24 VOLTS AC. IT MUST BE SERVICED ONLY BY
FACTORY CERTIFIED SERVICE TECHNICIANS
WARNING
DO NOT ATTEMPT TO DRY FIRE THE BOILER. STARTING
THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY
DAMAGE THE UNIT AND MAY RESULT IN INJURY TO
PERSONNEL OR PROPERTY DAMAGE. THIS SITUATION WILL
VOID ANY WARRANTY.
3.2 CONTROL PANEL DESCRIPTION
The Benchmark 1.5 Control Panel shown in Figure 3-1 contains all of the controls, indicators
and displays necessary to operate, adjust and troubleshoot the Benchmark 1.5 Boiler. These
operating controls, indicators and displays are listed and described in Table 3-1. Additional
information on these items are provided in the individual operating procedures provided in this
Chapter.
PR2: 05/01/11 Page 29 of 152
Benchmark 1.5LN Low NOx Boiler
Operation and Maintenance Manual
OMM-0041_0D
GF-120
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
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CHAPTER 3: CONTROL PANEL OPERATION
Figure 3-1: Control Panel Front View
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