AERCO BMK 1500, BMK 2000 User Manual
Benchmark 1500 - 2000 Boilers
BENCHMARK
Installation, Operation & Maintenance Manual (IOMM)
Natural Gas Modulating
& Condensing Hot Water
USER MANUAL
Installation, Opera ti on and Maintenance
Boiler Models:
• BMK 1500
• BMK 2000
Applicable to Serial Numbers:
G-14-0304 and Above
Latest Update: 03/20/2014
1500 / 2000
Gas-Fired Boilers
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Benchmark 1500 - 2000 Boilers
Installation, Opera ti on & Maintenance Manual (IOMM)
Technical Support
(Mon-Fri, 8am-5pm EST)
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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. AE RCO 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 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
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Benchmark 1500 - 2000 Boilers
Installation, Operation & Maintenance Manual (IOMM)
TABLE OF CONTENTS
FOREWORD 7
CHAPTER 1. SAFETY PRECAUTIONS ......................................................................................... 11
1.1 WARNINGS & CAUTIONS ................................................................................................................... 11
1.2 EMERGENC Y SHUT D OWN ................................................................................................................. 12
1.3 PROLONGED SHUTDOWN ................................................................................................................. 12
CHAPTER 2. INSTALLATION ........................................................................................................ 15
2.1 INTRODUCTION ................................................................................................................................... 15
2.2 RECEIVING THE UNIT ......................................................................................................................... 15
2.3 UNPACKING ......................................................................................................................................... 15
2.4 SITE PREPARATION ........................................................................................................................... 15
2.4.1 Installation Clearances .................................................................................................................................... 16
2.4.2 Setting the Unit ............................................................................................................................................... 17
2.5 SUPPLY AND RET UR N PIPING .......................................................................................................... 19
2.6 PRESSURE RELIEF VALVE INSTALLATION ..................................................................................... 19
2.7 CONDENSATE DRAIN & PIPING ........................................................................................................ 20
2.8 GAS SUPPLY PIPIN G .......................................................................................................................... 22
2.8.1 Gas Supply Specifications. .............................................................................................................................. 22
2.8.2 Manual Gas Shutoff Valve .............................................................................................................................. 22
2.8.3 External Gas Supply Regulator ........................................................................................................................ 23
2.9 AC ELECTRICAL POWER WIRING ..................................................................................................... 24
2.9.1 Electrical Power Requirements ....................................................................................................................... 25
2.10 FIELD CONTROL WIRING ................................................................................................................. 26
2.10.1 Outdoor Air In (OUT) & Air Sensor Common (COM) .................................................................................... 27
2.10.2 COMBUSTION AIR Terminal .......................................................................................................................... 28
2.10.3 O2 SENSOR (O2+ & O2-) ................................................................................................................................ 28
2.10.4 SPARK SIGNAL (FLW+ & FLW-) ...................................................................................................................... 28
2.10.5 Analog In (+ & -) ............................................................................................................................................ 28
2.10.6 B.M.S. (PWM) In (BMS+ & BMS-) .................................................................................................................. 28
2.10.7 Shield (SHLD & SHLD) .................................................................................................................................... 28
2.10.8 Analog Output (+ & -) ................................................................................................................................... 28
2.10.9 RS-485 Comm (+, GND, & -) .......................................................................................................................... 29
2.10.10 RS-232 Comm (TxD & RxD) ......................................................................................................................... 29
2.10.11 VFD/Blower (0-10 & AGND) ........................................................................................................................ 29
2.10.12 Interlocks .................................................................................................................................................... 29
2.10.13 Fault Relay (NC, COM, & NO) ...................................................................................................................... 30
2.10.14 Auxiliary Relay Contacts (NC, COM, & NO) ................................................................................................. 30
2.11 FLUE GAS VENT INSTAL LATION ..................................................................................................... 30
2.12 COMBUSTION AIR ............................................................................................................................. 31
2.12.1 Combustion From Outside the Building ....................................................................................................... 31
2.12.2 Combustion Air from Inside the Building ...................................................................................................... 31
2.13 DUCTED COMBUSTION AIR ............................................................................................................. 31
2.14 SEQUENCING VALVE INSTALLATION............................................................................................. 31
CHAPTER 3. OPERATION .............................................................................................................. 33
3.1 INTRODUCTION ................................................................................................................................... 33
3.2 CONTROL PANEL DESCRIPTION ...................................................................................................... 33
3.3 CONTROL PANEL MENUS .................................................................................................................. 37
3.3.1 Menu Processing Procedure ........................................................................................................................... 37
3.4 OPERATING MENU ............................................................................................................................. 39
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3.5 SETUP MENU ....................................................................................................................................... 39
3.6 CONFIGURATION MENU .................................................................................................................... 40
3.7 TUNING MENU ..................................................................................................................................... 42
3.8 COMBUSTION CAL MENU .................................................................................................................. 43
3.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU ....................................................................... 43
3.10 START SEQUENCE ........................................................................................................................... 46
3.11 START/STOP LEVELS ....................................................................................................................... 50
CHAPTER 4. INITIAL START-UP .................................................................................................. 51
4.1 INITIAL START-UP REQUIREMENTS ................................................................................................. 51
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION .......................................... 51
4.2.1 Required Tools & Instrumentation ................................................................................................................. 52
4.2.2 Installing Gas Supply Manometer ................................................................................................................... 52
4.2.3 Accessing the Analyzer Probe Port ................................................................................................................. 53
4.3 NATURAL GAS COMBUSTION CALIBRATION .................................................................................. 54
4.4 REASSEMBLY ...................................................................................................................................... 60
4.5 OVER-TEMPERATURE LIMIT SWITCHES ......................................................................................... 61
4.5.1 Digital Alarm Switch Checks and Adjustments ............................................................................................... 61
CHAPTER 5. MODE OF OPERATION ........................................................................................... 63
5.1 INTRODUCTION ................................................................................................................................... 63
5.2 INDOOR/OUTDOOR RESET MODE ................................................................................................... 63
5.2.1 Reset Ratio ...................................................................................................................................................... 63
5.2.2 Building Reference Temperature .................................................................................................................... 63
5.2.3 Outdoor Air Temperature Sensor Installation ................................................................................................ 63
5.2.4 Indoor/Outdoor Startup ................................................................................................................................. 63
5.3 CONSTANT SETPOINT MODE ........................................................................................................... 64
5.3.1 Setting the Setpoint ........................................................................................................................................ 64
5.4 REMOTE SETPOINT MODES ............................................................................................................. 65
5.4.1 Remote Setpoint Field Wiring ......................................................................................................................... 65
5.4.2 Remote Setpoint Startup ................................................................................................................................ 66
5.5 DIRECT DRIVE MODES....................................................................................................................... 66
5.5.1 Direct Drive Field Wiring ................................................................................................................................. 67
5.5.2 Direct Drive Startup ........................................................................................................................................ 67
5.6 AERCO CONTROL SYSTEM (ACS) .................................................................................................... 67
5.6.1 ACS External Field Wiring................................................................................................................................ 67
5.6.2 ACS Setup and Startup .................................................................................................................................... 68
5.7 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 68
5.7.1 Combination Control System Field Wiring ...................................................................................................... 69
5.7.2 Combination Control System Setup and Startup ............................................................................................ 69
CHAPTER 6. SAFETY DEVICE TESTING ..................................................................................... 71
6.1 TESTING OF SAFETY DEVI CE S ......................................................................................................... 71
6.2 LOW GAS PRESSURE FAULT TEST .................................................................................................. 72
6.3 HIGH GAS PRESSURE TEST ............................................................................................................. 73
6.4 LOW WATER LEVEL FAULT TEST ..................................................................................................... 74
6.5 WATER TEMPERATURE FAULT TEST .............................................................................................. 75
6.6 INTERLOCK TESTS ............................................................................................................................. 76
6.6.1 Remote Interlock Test..................................................................................................................................... 76
6.6.2 Delayed Interlock Test .................................................................................................................................... 76
6.7 FLAME FAULT TESTS ......................................................................................................................... 77
6.8 AIR FLOW FAULT TESTS .................................................................................................................... 79
6.8.1 Blower Proof Switch Test ................................................................................................................................ 79
Installation, Opera ti on & Maintenance Manual (IOMM)
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6.8.2 Blocked Inlet Switch Test ................................................................................................................................ 79
6.9 SSOV PROOF OF CLOSURE SWITCH ............................................................................................... 81
6.10 PURGE SWITCH OPEN DURING PURGE ........................................................................................ 82
6.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................................. 83
6.12 SAFETY PRESSURE RELIEF VALVE TEST ..................................................................................... 84
CHAPTER 7. MAINTENANCE ......................................................................................................... 85
7.1 MAINTENANCE SCHEDULE ............................................................................................................... 85
7.2 IGNITER-INJECTOR ............................................................................................................................ 86
7.3 FLAME DETECTOR ............................................................................................................................. 88
7.4 O2 SENSOR 89
7.5 SAFETY DEVIC E TESTING ................................................................................................................. 89
7.6 BURNER ASSEMB LY INSPECTION ................................................................................................... 90
7.7 CONDENSATE DRAIN TRAP .............................................................................................................. 94
7.8 AIR FILTER CLEANING & REPLACEMENT ........................................................................................ 95
7.9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ....................................... 96
7.10 PLACING THE BOI L E R BACK IN SER VI C E AF TER A PRO LO N GED SHUTDOWN ....................... 96
CHAPTER 8. TROUBLESHOOTING GUIDE ................................................................................ 97
8.1 INTRODUCTION ................................................................................................................................... 97
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................. 109
CHAPTER 9. RS-232 COMMUNICATION................................................................................. 111
9.1 INTRODUCTION ................................................................................................................................. 111
9.1.1 Acquiring the PuTTY Application .................................................................................................................. 111
9.1.2 Logging on to a Remote Machine Using PuTTY ............................................................................................ 111
9.1.3 Running a Command on a Remote Machine Using PuTTY ........................................................................... 112
9.2 RS-232 COMMUNICATION SETUP ................................................................................................... 113
9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ........................................................ 113
9.4 DATA LOGGING ................................................................................................................................. 114
9.4.1 Fault Log ....................................................................................................................................................... 115
9.4.2 Operation Time Log ...................................................................................................................................... 115
9.4.3 Sensor Log ..................................................................................................................................................... 116
CHAPTER 10. BOILER SEQUENCING TECHNOLOGY ............................................................. 117
10.1 INTRODUCTION ............................................................................................................................... 117
10.2 AERCO BST QUICK START CHART ............................................................................................... 118
10.3 BST IMPLEMENTATION INSTRUCTION ........................................................................................ 119
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor .............................................................. 119
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor ........................................................... 120
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor ....... 121
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ........................ 123
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ................. 125
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive ............... 126
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive .......................... 127
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive ....................... 129
APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ............................................................. 131
APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES .................................................. 137
APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART ...................................................... 141
APPENDIX D: BOILER DEFAULT SETTINGS ............................................................................ 143
APPENDIX E: RECOMMENDED PERIODIC TESTING ............................................................ 145
APPENDIX F: INDOOR/OUTDOOR RESET RATIO CHARTS ............................................... 147
APPENDIX G: DIMENSIONAL AND CLEARANCE DRAWINGS ............................................. 151
Installation, Operation & Maintenance Manual (IOMM)
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Benchmark 1500 - 2000 Boilers
APPENDIX H: PART DRAWINGS ................................................................................................. 155
APPENDIX I: WIRING DIAGRAMS ............................................................................................. 167
APPENDIX J: PIPING DRAWINGS .............................................................................................. 175
APPENDIX K: C-MORE CONTROL PANEL VIEWS ................................................................... 181
APPENDIX L: RECOMMENDED SPARES ................................................................................... 183
LIMITED WARRANTY ...................................................................................................................... 185
Installation, Opera ti on & Maintenance Manual (IOMM)
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Benchmark 1500 - 2000 Boilers
Minimum
Maximum
Minimum
Maximum
FORWARD
FOREWORD
The AERCO Benchmark (BMK) 1500 and 2000 MBH boilers are modulating and condensing
units. They represent a true industry advance that meets the needs of today's energy and
environmental concerns. Designed for application in any closed loop hydronic system, the
Benchmark's modulating capability relates energy input directly to fluctuating system loads. The
turn down ratios for these boilers is 20:1. These BMK models provide extremely high efficiency
operation and are ideally suited for modern low temperature, as well as, conventional heating
systems.
The Benchmark Model BMK 1500 and BMK 2000 boilers operate within the following input and
output ranges:
Benchmark Model
BMK 1500 75,000 1,500,000 64,500 1,395,000
Input Range (BTU/hr.) Output Range (BTU/hr.)
BMK 2000 100,000 2,000,000 86,000 1,860,000
The output of the boiler is a function of the unit’s firing rate (valve position) and return water
temperature.
When installed and operated in accordance with this Instruction Manual, these boilers comply
with the NOx emission standards outlined in:
South Coast Air Quality Management District (SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the BMK 1500 and BMK 2000 offer the
maximum venting flexibility with minimum installation space requirements. These boilers are
Category II, III and IV, positive pressure appliances. Single and/or multiple breeched units are
capable of operation in the following vent configurations:
Conventional, Vertical
Conventional, Sidewall
Conventional, Direct Vent, Vertical
Sealed, Direct Vent, Horizontal
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.
IMPORTANT
Unless otherwise specified, all descriptions and procedures provided in this
Installation, Operation & Maintenance Manual apply to the Benchmark
series of boiler.
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ASME
American Society of Mechanical Engineers
(see below)
Symbol rate, or simply the number of distinct symbol changes
COMM (Comm)
Communication
Double Block and Bleed. Used to define boiler gas trains
containing 2 Safety Shutoff Valves (SSOVs) and a solenoid
Energy Management System; often used interchangeably with
FORWARD
Phrases, Abbreviations and Acronyms
Phrase, Abbreviation or
Acronym
Meaning
A (Amp) Ampere
ACS AERCO Control System
ADDR Address
AGND Anal og Ground
ALRM Alarm
AUX Auxiliary
BAS
Baud Rate
Building Automation System, often used interchangeably with EMS
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BMK Benchmark series boilers
BMS or BMS II AERCO Boiler Management Systems
BLDG (Bldg) Building
BST AERCO on-board Boiler Management Technology
BTU
British Thermal Unit. A unit of energy approximately equal to the
heat required to raise 1 pound of water 1° F.
CCP Combustion Control Panel
C-More Controller
(or Control Box)
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CO Carbon Monoxide
Cal. Calibration
CNTL Control
DBB
operated vent valve. Also known as IRI gas trains(see below)
DIP Dual In-Line Package
EMS
BAS
FM Factory Mutual. Used to define boiler gas trains.
GND Ground
HDR Header
HX Heat Exchang er
Hz H ertz (Cycles Per Second)
I.D. Inside Diameter
IGN Ignition
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Benchmark 1500 - 2000 Boilers
Phrase, Abbreviation or
Acronym
FORWARD
Phrases, Abbreviations and Acronyms – Continued
Meaning
IGST Board Ignition/Stepper Board contained in C-More Control Box
INTLK (INTL’K) Interlock
I/O Input/Output
I/O Box
IP Internet Protocol
IRI
ISO Isolated
LED Light Emitting Diode
LN Low NOx
MA (mA) Milliampere (0.001 Amp), one thousandth of an amp
MAX (Max) Maximum
MIN (Min) Minimum
Modbus®
NC (N.C.) Normally Closed
NO (N.O.) Normally Open
NOx Nitrogen Oxide
NPT National Pipe Thread
O2 Oxygen
O.D. Outside Diameter
PMC Board
PPM Parts Per Million
PTP Point-to-Point (usually over RS-232 networks)
PWM Pulse Width Modulation
REF (Ref) Reference
RES. Resistive
RS-232
(or EIA-232)
RS-422
(or EIA-422)
RS-485
(or EIA-485)
RTN (Rtn) Return
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
Industrial Risk Insurers. A now discontinued code used to define gas
trains containing two SSOVs and a solenoid operated vent valve.
A serial, half-duplex data transmission protocol developed by AEG
Modicon
A Primary Micro-Controller (PMC) board is contained in the C-More
Control Box used on all Benchmark units.
A standard for serial, full-duplex (FDX) transmission of data based on the
RS-232 Standard
A standard for serial, full-duplex (FDX) transmission of data based on the
RS-422 Standard
A standard for ser ial, half-duplex (HDX) trans mission of data based on
the RS-485 Standard
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Phrase, Abbreviation or
Acronym
TEMP (Temp)
Temperature
vent reflections that may cause invalid data in the
VDC
Volts, Direct Current
W.C.
Water Column (W.C.)
FORWARD
Phrases, Abbreviations and Acronyms – Continued
Meaning
SSOV Safety Shut Off Valve
A resistor placed at each end of a dais y-chain or multi-drop network in
Terminating Resistor
uA Microamp (0.000001 amp), one millionth of an amp
VAC Volts, Alternating Current
VFD Vacuum Fluorescent Display, or Variable Frequency Drive
W Watt
order to pre
communication
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Benchmark 1500 - 2000 Boilers
WARNING
WARNING
WARNING
WARNING
CHAPTER 1 – SAFETY PRECAUTIONS
CHAPTER 1. SAF ETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
See pages 13 and 14 for important information regarding installation of units within the
Commonwealth of Massachusetts.
IMPORTANT
This Instruction Manual is an integral part of the product and must be
maintained in legible condition. It must be given to the user by the installer
and kept in a safe place for future reference.
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE
UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.
THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A
POSITIVE PRESSURE AND THEREFORE MUST BE COMPLETELY
SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS I NTO
LIVING SPACES.
WARNING
ELECTRICAL VOLTAGES UP TO 480 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFO RE THE COVER ON THE UNI T’S POWER BOX
(LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
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WARNING
CAUTION
CAUTION
CHAPTER 1 – SAFETY PRECAUTIONS
A THREE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNIT. T HE SWIT CH MUST BE INSTALLED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY
DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO
UNIT SHEET METAL ENCLOSURES.
Many soaps used for gas pipe leak testing are corrosive to metals. The
piping must be rinsed thoroughly with clean water after leak checks have
been completed.
DO NOT use t his boiler if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
NOTE
The Installer must identify and indicate the location of the
emergency shutdown manual gas valve to operating personnel.
MANUAL GAS SHUT-OFF VALVE
VALVE OPEN VALVE CLOSED
Figure 1-1: Manual Gas Shutoff Valve
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.
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Benchmark 1500 - 2000 Boilers
CHAPTER 1 – SAFETY PRECAUTIONS
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Boiler Installations within the Commonwealth of Massachusetts must
conform to the following requirements:
• Boiler must be installed by a plumber or a gas fitter who is licensed
within the Commonwealth of Massachusetts.
• Prior to unit operation, the complete gas train and all connections must
be leak tested using a non-corrosive soap.
• The vent termination must be located a minimum of 4 feet above gr ade
level. If side-wall venting is used, the installation must conform to the
following requirem ent s extract ed from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
building or structure used in whole or in part for residential purposes, including those owned or
operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBO N MONOXIDE DETECTORS. At the time of installation of
the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented gas fueled equipment. It shall be the
responsibility of the property owner to secure the services of qualified licensed professionals
for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally ve nted 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 direc tly 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".
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:
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CHAPTER 1 – SAFETY PRECAUTIONS
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 f lue gases, but identifies "special
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of the
installation.
____________________________________________________________________________
[End of Extracted Information From 248 CMR 5.08 (2)]
Page 14 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
Benchmark 1500 - 2000 Boilers
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 Boiler Model BMK 1500 and BMK 2000.
2.2 RECEIVING THE UNIT
Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for these
BMK models is approximately 1800 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
After unpacking, 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.
The following accessories come standard with each unit and are either packed separately within
the unit’s shipping container or are factory installed on the unit:
• Pressure/Temperature Gauge
• ASME Pressure Relief Valve
• Condensate Drain Trap (part no. 24060)
• 2” Gas Supply Shutoff Valve
When optional accessories are ordered, they may be packed within the unit’s shipping
container, factory installed on the unit, or packed and shipped in a separate container. Any
standard or optional accessories shipped loose should be identified and stored in a safe place
until ready for installation or use.
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark 1500/2000 Boiler includes:
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 15 of 188
GF-142 Ph.: 800-526-0288
Benchmark 1500 - 2000 Boilers
WARNING
CHAPTER 2 – INSTALLATION
• Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps
• Access to Natural Gas line at a minimum pressure of 8 inches W.C. at gas flow for
1,500,000 BTU/hr energy input for the BMK 1500 OR 2,000, 000 BTU/hr energy input for
the BMK 2000.
2.4.1 Installation Clearances
The Benchmark Model 1500 and 2000 are packaged in an enclosure having identical exterior
dimensions. The unit must be installed with the prescribed clearances for service as shown in
Figure 2-1a. The minimum clearance dimensions, required by AERCO, are listed below.
However, if Local Building Codes require additional clearances, these codes shall supersede
AERCO’s requirements. Minimum acceptable clearances required are as follows:
• Sides: 24 inches
• Front : 24 inches
• Rear: 24 inches
• Top: 18 inches
All gas piping, water piping and electrical conduit or cable must be arranged so that t hey do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
Page 16 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
NOTE
Ensure that
condensate
assembly is not
located over the
housekeeping
pad.
Figure 2-1a: Benchmark Boiler Model 1500/2000 Clearances
KEEP THE UNIT AREA CLEAR AND FREE FR OM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS
.
Benchmark 1500 - 2000 Boilers
CAUTION
WARNING
CHAPTER 2 – INSTALLATION
While packaged in the shipping container, the unit must be moved by pallet
jack or forklift from the FRONT ONLY.
FOR MASSACHUSSETTS ONLY:
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter licensed within the Commonwealth of Massachusetts. In addition,
the installation must comply with all requirements specified in Chapter 1
(Safety Precautions), pages 11 and 12.
2.4.2 Setting the Unit
The unit must be installed on a 4 inch to 8 inch thick housekeeping pad to ensure proper
condensate drainage. If anchoring the unit, refer to Figure 2-1b for anchor locations.
A total of 3 lifting lugs are provided at the top of the primary heat exchanger as shown in Figure
2-2. Remove the front 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 housek eeping concrete pad (requir ed) in the
desired location.
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 188
GF-142 Ph.: 800-526-0288
Figure 2-1b: Benchmark 1500/2000 Anchor Bolt Locations
WHEN LIFTING OR MOVING THE BOILER, DO NOT ATTEMPT
TO MANIPULATE THE BOILER USING THE GAS TRAIN OR
BLOWER.
Benchmark 1500 - 2000 Boilers
CHAPTER 2 – INSTALLATION
LIFTING LUGS
(3 POSITIONS)
2” GAS INLET
Figure 2-2: Boiler Lifting Provisions
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.
Page 18 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
Benchmark 1500 - 2000 Boilers
BOILER HOT
(SUPPLY)
EXHAUST
MANIFOLD
CONDENSATE
DRAIN PORT
CHAPTER 2 – INSTALLATION
2.5 SUPPLY AND RETURN PIPING
The Benchmark Boiler utilizes 4” 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.
2” GAS INLET
WATER OUTLET
AIR INLET
PRIMARY
WATER INLET
(RETURN)
DRAIN VALVE
Figure 2-3: Supply and Return Locations
2.6 PRESSURE RELIEF VALVE INSTALLATION
An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler. The pressure
rating for the relief valve must be specified on the sales order. Available pressure ratings range
from 30 psi to 160 psi. The relief valve is installed on the hot water outlet of the boiler as shown
in Figure 2-4. A suitable pipe joint compound should be used on the threaded connections. Any
excess should be wiped off to avoid getting any joint compound into the valve body. T he relief
valve must be piped to within 12 inches of the floor to prevent injury in the event of a discharge.
are allowed in the discharge line. In multiple unit installations the discharge lines must not be
manifolded together. Each must be individually run to a suitable discharge location.
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 188
GF-142 Ph.: 800-526-0288
Benchmark 1500 - 2000 Boilers
AIR INLET
PRIMARY
WATER INLET
1/4” AN AL Y Z E R
NPT PORT
EXHAST
MANIFOLD
CHAPTER 2 – INSTALLATION
PRESSURE
RELIEF VALVE
4” HOT BOILER
WATER OUTLET
Figure 2-4: P&T Relief Valve Location
2.7 CONDENSATE DRAIN & PIPING
The Benchmark Boiler is designed to condense water vapor from the flue products. T herefore,
the installation must have provisions for suitable condensate drainage or collection.
The condensate drain port located on the exhaust manifold (Figure 2-5) must be connected to
the condensate trap (P/N 24060) which is packed separately within the unit’s shipping container.
The condensate trap inlet features two integral O-rings and a thumbscrew to allow direct
connection of the drain port into the trap inlet. See the Condensate trap Installation instructions
and Figure 2-6 on the next page.
A sample condensate trap installation is shown in Figure 2-6. The following general guidelines
must be observed to ensure proper condensate drainage:
• The condensate tr ap inlet (Figure 2-6) must be level the exhaust manifold drain port.
• The base of the condensate trap must be supported to ensure that it is level (horizontal).
• The trap must be removable for routine maintenance.
Page 20 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
DR AIN VALV E
CONDENSATE DRAIN PORT
Figure 2-5: Condensate Drain Connection Location
Benchmark 1500 - 2000 Boilers
CAUTION
COMBUTION
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLES
HOSE
CLAMP
DRAIN
TRAP INLET
TOP
(4 ea.)
1” DIAM.
HOSE
NOTE
ASSEMBLY.
4” MINIMUM
(8” MAXIMUM)
4”
CHAPTER 2 – INSTALLATION
While observing the above guidelines, install the condensate trap as follows:
Condensate Trap Installat ion
1. Connect t he condensate trap inlet to the exhaust manifold drain connection by inserting
the drain port directly into the trap adaptor inlet, and t hen t ightening the inlet thumbscrew,
as shown in Figure 2-6. The inlet features two integral O-rings to prevent leakage.
2. At t he condensate trap outlet, install a 3/4” NPT nipple.
3. Connect a lengt h of 1” diameter polypropylene hose to the trap outlet and secure with a
hose clamp.
4. Route t he 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 c ondensate to
drain. The maximum condensate flow rate is 30 GPH. The condensate drain trap, associated
fittings and drain line must be removable for routine maintenance.
Use PVC, stainless steel, aluminum or polypropylene for condensate drain
piping (Figure 2-6). DO NOT use carbon or copper components.
ANALYZER
HOUSKEEPING
PAD MUST NOT
EXTEND
UNDER THE
CONDENSATE
EXHAUST
MANIFOLD
DRAIN PORT
INTEGRAL
ADAP TOR AND
THUMBSCREW
COVER
THUMB
SREWS
CONDENSATE
TRAP (P/N 24060)
T O
FLOOR
Figure 2-6: Sample Condensate Trap Installation (Right Side View)
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 21 of 188
GF-142 Ph.: 800-526-0288
Benchmark 1500 - 2000 Boilers
CAUTION
CHAPTER 2 – INSTALLATION
2.8 GAS SUPPLY PIPING
The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be
consulted prior to designing or installing any gas supply piping.
WARNING
NEVER USE MATCHES, CANDLES, FLAMES OR OTHER
SOURCES OF IGNITION TO CHECK FOR GAS LEAKS
.
Many of the soaps used for gas pipe leak testing are corrosive to
metals. Therefore, piping must be rinsed thoroughly 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.
Benchmark 1500 MBH and 2000 MBH units contain a 2 inch NPT gas inlet connection on the
top of the unit, as shown in Figure 2-2 and 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, the unit must be isolated fr om t he g as
supply piping. At no time should the gas pressure applied to the unit exceed 14” W.C. A
thorough leak test of all external piping must be performed using a soap and water solution or
suitable equivalent. The gas piping used must meet all applicable codes.
2.8.1 Gas Supply Specifications.
The gas supply input specifications to the unit for Natural Gas are as follows:
• The maximum static pressure to the unit must not exceed 14” W.C.
• The gas s upply piping and pressure to the unit must be of sufficient capacity to provide
2000 cfh while maintaining the gas pressure at 6 inches W.C. for FM gas trains
operating at maximum capacity.
2.8.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply line upstream of the boiler as shown
in Figure 2-7. Maximum allowable gas pressure to the boiler is 14” W.C.
Page 22 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
Benchmark 1500 - 2000 Boilers
NATURAL GAS INLET
CHAPTER 2 – INSTALLATION
2.8.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions
(see sections 2.8.3.1 and 2.8.3.2, below). Regulators must conform to the following
specifications:
• The external natural gas regulat or must be capable of regulating 200,000 – 3,180,000
BTU/HR of natural gas while maintaining a gas pressure of 8.0 ” W.C. minimum to the
unit.
• A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C.
2.8.3.1
Massachusetts Installations Only
For Massachusetts installations, a mandatory external gas supply regulator must be positioned
as shown in Figure 2-7. The gas supply regulator must be properly vented to outdoors. Consult
the local gas utility for detailed requirements concerning venting of the supply gas regulator.
2.8.3.2
All Installations (Except Massachusetts)
For multi-unit installations (other than Massachusetts) that EXCEED 7” W.C. gas pressure, a
mandatory external gas supply regulator, as shown in Figure 2-7, is highly recommended. No
regulator is required for gas pressures below 7” W.C. of pressure. Consult the local gas ut ility
for detailed requirements concerning venting of the supply gas regulator.
GAS PRESSURE REGULATOR
NATURAL
GAS SUPPLY
2” MANUAL
SHUT-OFF
VALVE
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 23 of 188
GF-142 Ph.: 800-526-0288
Figure 2-7: Manual Gas Shut-Off Valve Location
NOTE
It is the responsibility of the customer to source and purchase the
appropriate gas regulator as described above. However, AERCO
offers for sale an appropriate regulator, which may be ordered at
the time of unit purchase or separately. Contact AERCO for more
information.
Benchmark 1500 - 2000 Boilers
WARNING
TERMINAL BLOCKS
CHAPTER 2 – INSTALLATION
2.9 AC ELECTRICAL POWER WIRING
The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to
connecting any AC power wiring to the unit. External AC power connections are made to the
unit inside the Power Box on the front of the unit. Remove the front panel to access the Power
Box, which is mounted in the upper right corner of the unit as shown in Figure 2-8. Loosen the
two upper screws of the Power Box cover and remove cover to access the internal connections
shown in Figure 2-9.
TRANSFORMER
24V POWER
SUPPLY
12V POWER
SUPPLY
Figure 2-8: Power Box Location with Cover Closed
THE POWER BREAKER SHOWN IN FIGURE 2-9 DOES NOT
REMOVE POWER FROM THE TERMINAL BLOCKS.
WIRE CONDUITS
POWER
BREAKER
With the exception of the transformer shown in Figure 2-9, all of t he components in the Power
Box are mounted on a DIN rail.
Page 24 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
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FUSE BLOCKS (2)
Figure 2-9: Power Box Internal Components
Benchmark 1500 - 2000 Boilers
CHAPTER 2 – INSTALLATION
NOTE
All electrical conduit and hardware must be installed so that it
does not interfere with the removal of any unit covers, inhibit
service/maintenance, or prevent access between the unit and
walls or another unit.
2.9.1 Electrical Power Requirements
The Benchmark 1500 and Benchmark 2000 models are available in one voltage configuration:
• 120 VAC, Single-Phase, 60 Hz @ 20 Amps
The Power Box contains terminal blocks as shown in Figure 2-9. In addition, a label showing the
required AC power connections is provided on the front cover of the Power Box as shown in
Figure 2-10.
Figure 2-10: Power Box Cover Labels – 120VAC
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD
BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.
A three-pole switch must be installed on the electrical supply line in an easily accessible location
to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet metal
enclosures of the unit.
After placing the unit in service, the ignition safety shutoff device must be tested. If an external
electrical power source is used, the installed boiler must be electrically bonded to ground in
accordance with the requirements of the authority having jurisdiction. In the absence of such
requirements, the installation shall conform to National Electrical Code (NEC), ANSI/ NFPA 70
and/or the Canadian Electrical Code (CEC) Part I, CSA C22 .1 Electrical Code.
For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF-
2060).
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 25 of 188
GF-142 Ph.: 800-526-0288
Benchmark 1500 - 2000 Boilers
CAUTION
BOARD
CHAPTER 2 – INSTALLATION
2.10 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an internal operating control system. No field control
wiring is required for normal operation. However, the C-More Control system used with all
Benchmark units does allow for some additional control and monitoring features. Wiring
connections for these features are made on the Input/Output (I/O) board located behind the
removable front panel assembly of the unit. The I/O board is located in t he upper-left portion on
the front of the unit as shown in Figure 2-11. The I/O board terminal strip connections are shown
in Figure 2-12. All field wiring is installed from the rear of the panel by routing the wires through
one of the four bushings provided on the sides of the I/O board.
Refer to the wiring diagram provided below the I/O Box (Figure 2-12) when making all wiring
connections.
TERMINAL STRIPS
Page 26 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
I/O PCB
Figure 2-11: Input/Output (I/O) Box Location
NOTE
Use Figure 2-12 to determine the functions of the I/O PCB
connections. Do not use the silkscreened labels on the PCB itself,
as these may not match the function names.
There is a diagram of the connection functions on the cover of the
I/O Box as well.
DO NOT make any connections to the I/O Box terminals labeled
“NOT USED”. Attempting to do so may cause equipment damage.
Benchmark 1500 - 2000 Boilers
CHAPTER 2 – INSTALLATION
Figure 2-12: I/O Box Terminal Strips
2.10.1 Outdoor Air In (OUT) & Air Sensor Common (COM)
The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO
P/N GM-123525) as 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 AIR IN and AIR SENSO R COMMON terminals of the I/O PCB (Figure 2-12). Wire
the sensor using a twisted shielded pair wire from 18 to 22 AWG. There is no polarity to
observe when terminating these wires. The shield is to be connected only to the terminals
labeled SHIELD in the I/O Box PCB. 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.
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 188
GF-142 Ph.: 800-526-0288
Benchmark 1500 - 2000 Boilers
CHAPTER 2 – INSTALLATION
2.10.2 COMBUSTION AIR Terminal
The COMBUSTIAN AIR term in al is used to monitor the combustion air temperature sensor. This
input is always enabled and is a “to view only” input that can be seen in the operating menu.
The sensor is an AERCO BALCO wire sensor P/N 12449. A resistance chart for this sensor is
provided in APPENDIX C. This sensor is an active part of the combustion control system and
must be operational for accurate air/fuel mixing control.
2.10.3 O2 SENSOR (O2+ & O2-)
The O2 SENSOR (+) and O2 SENSOR (–) terminals are used to connect an integrated oxygen
sensor to the I/O Box PCB. The O
More Control system after a 60 second warm-up period.
2.10.4 SPAR K SIGNAL (FLW+ & FLW-)
The two SPARK SIGNAL terminals permit an external current sensor to be connected for
ignition spark monitoring purposes. If no spark is present during the ignition sequence, the
controller will shut down and display a fault message.
2.10.5 Analog In (+ & -)
The two ANALOG IN terminals are used when an external signal is used to change the setpoint
(Remote Setpoint Mode) of the boiler.
concentration is displayed in the operating menu of the C -
2
Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA/ 0 to 5 VDC signal may be used to vary the setpoint or air/fuel valve position. The factory default setting is for 4 to 20 mA / 1 to 5 VDC,
however this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu
described in Chapter 3.
If voltage rather than current is selected as the drive signal, a DIP switch must be set on the
PMC Board located inside the C-More Control Box. Contact the AERCO factory for information
on setting DIP switches.
All supplied signals must be floating (ungrounded) signals. Connections between the source
and the boiler’s I/O PCB (Figure 2-12) must be made using twisted shielded pair of 18–22 AWG
wire such as Belden 9841. Polarity must be maintained and the shield must be connected only
at the source end and must be left floating (not connected) at the Boiler’s I/O PCB.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to
240°F setpoint or a 0% to 100% air/fuel valve position. No scaling for these signals is provided
2.10.6 B.M.S. (PWM) In (BMS+ & BMS-)
These terminals are only used to connect to legacy AERCO Boiler Management Systems
(BMS), which ut ilize a 12 millisecond, ON/OFF duty cycle and is Pulse W idth Modulated (PWM)
to control valve position. A 0% valve position = a 5% ON pulse and a 100% valve position = a
95% ON pulse. Note that thes e connections cannot be used with the AERCO Control System
(ACS).
2.10.7 Shield (SHLD & SHLD)
The SHIELD terminals are used to terminate any shields used on sensor wires connected to the
unit. Shields must only be connected to these terminals.
2.10.8 Analog Output (+ & -)
The ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor
Setpoint, Outlet Temperature, Valve Pos ition 4-20 mA, Valve Position 0-10v or be set to OFF.
Default sett ing in th e C-More controller is Valve Position 0-10v and settings behave as follows:
Page 28 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
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Benchmark 1500 - 2000 Boilers
CHAPTER 2 – INSTALLATION
• When 0-10VDC is selected, the voltage output is used by the controller to modulat e the
combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.10.11).
• If On Board Boiler Sequencing Technology (BST) is enabled, the Analog Output
terminals are used to drive the isolation valve, open and closed.
• When the 4-20mA is selected for the Analog Output, the 0-10VDC is disabled at the
VFD/Blower terminals, and the selected output is available at the terminals labeled
Analog Output +/-.
2.10.9 RS-485 Comm (+, GND, & -)
The RS-485 communication terminals are used when the boiler plant is being controlled by an
Energy Management System (EMS) or an AERCO Control System (ACS) using Modbus (RS-
485) communication.
2.10.10 RS-232 Comm (TxD & RxD)
The RS-232 communication term inals permit a laptop computer or other suitable terminal to be
connected to the boiler. The RS-232 communication feature permits viewing or changing of
Control Panel menu options and also provides access to data logs showing fault and sensor log
displays.
2.10.11 VFD/Blower (0-10 & AGND)
These terminals (0-10 & AGND) send an analog signal to control the blower speed. When any
of the 4-20mA opt ions is selected for the Analog Outputs (Section 2.10.8), the output from the
VFD/Blower terminals is disabled.
2.10.12 Interlocks
The unit offers two interlock circuits for interfacing with Energy Management Systems and
auxiliary equipment such as pumps or louvers or other accessories. These interlocks are called
the Remote Interlock and Delayed Interlock ((REMOTE INT L’K IN and DELAYED INTL’K IN in
Figure 2-12). Both interlocks, described below, are factory wired in the closed position (using
jumpers).
NOTE
Both the Delayed Interlock and Remote Interlock must be in the
closed position for the unit to fire.
2.10.12.1
The remote interlock circuit is provided to remotely start (enable) and stop (disable) t he unit
if desired. The circuit is 24 VAC and comes factory pre-wired closed (jumped).
2.10.12.2
The Delayed Interlock terminals can be used in one of two ways:
Remote Interlock In (OUT & IN)
Delayed Interlock In (OUT & IN)
• In conjunction with the optional external sequencing valve (see section 2.14 and
Chapter 10 – BST), a component of AERCO’s on-board Boiler Sequencing
Technology (BST) solution. By default a cable of the boiler’s wiring harness is
connected to these terminals. If BST is im plemented, the other end of that cable is
connected to the sequencing valve.
• If BST is NOT implemented, the second use is typically in conjunction with the
AUXILIARY RELAY CONTACTS described in section 2.10.14. 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
OMM-0097_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 188
GF-142 Ph.: 800-526-0288
Benchmark 1500 - 2000 Boilers
Selkirk Corporation - Heatfab Division
Watertown Supply
M. A. Peacard
www.mapeacard.com
Glover Sheet Metal, Inc.
www.gloversheetmetal.com
CHAPTER 2 – INSTALLATION
the unit’s auxiliary relay. 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 unit long enough for a proving switch to make (close) can
be programmed.
To use this option, you must disconnect the harness from the Delayed Interlock
terminals and connect the proving device in its place.
Should the proving switch not prove within the programmed time frame, the unit will
shut down. The AUX START ON DLY can be programmed from 0 to 120 seconds.
This option is located in the Configuration Menu (Chapter 3).
2.10.13 Fault Relay (NC, COM, & NO)
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 2-12.
2.10.14 Auxiliary Relay Contacts (NC, COM, & NO)
Each unit 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
unit status indictor (firing or not firing). Its c ontacts are rated for 120 VAC @ 5 amps. Refer t o
Figure 2-12 to locate th e AUXILLIARY RELAY terminals for wiring connections.
2.11 FLUE GAS VENT INSTALLATION
AERCO Gas Fired Venting and Combustion Air Guide, GF-2050 must be consulted before any
flue or combustion air venting is designed or installed. Suitable, U/L approved, positive
pressure, watertight vent materials MUST be used for safety and UL certification. Because the
unit is capable of discharging low temperature exhaust gases, the flue must be pitched back
towards the unit a minimum of 1/4" per foot to avoid any condensate pooling and to allo w for
proper drainage.
While there is a positive flue pressure during operation, the combined pressure drop of vent and
combustion air systems must not exceed 140 equivalent feet or 0.8” W.C. 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” W.C. These f actors must be planned into t he vent installation.
If the maximum allowable equivalent lengths of piping are exceeded, the unit will not operate
properly or reliably.
For Massachusetts installations, the following companies provide vent systems which conform
to all applicable requirements for installations within the Commonwealth of Massachusetts.
Contact information is as follows:
130 Industrial Blvd.
Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
33Grove St.
Watertown, MA 02472
Phone: (617) 924-2840
http://www.watertownsupply.com/
1250 Massachusetts Ave.
Boston MA 02125-1689
Phone: (617) 288-0629
Page 30 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0D
Ph.: 800-526-0288 GF-142
44 Riverdale Ave.
Newton, MA 02485
Phone: (617) 527-8178
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