Aerco BMK 750, BMK 2000, BMK 2500, BMK 1500DF, BMK 2000DF Installation And Startup Manual
...
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
GF-200
Natural Gas:
• BMK 2000P
APPLIES TO MODELS:
750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers
SEE ALSO:
USER MANUAL (1 of 2)
INSTALLATION and STARTUP GUIDE
®
Natural Gas, Propane Gas, or Dual Fuel Fired Modulating, Condensing Boilers
AND MAINTENANCE GUIDE (GF-201)
• BMK 750
• BMK 1000
• BMK 1500
• BMK 2000
• BMK 2500
• BMK 3000
Propane:
• BMK 750P
• BMK 1000P
• BMK 1500P
OPERATION, SERVICE,
Dual-Fuel (NG/P):
• BMK 1500DF
• BMK 2000DF
• BMK 2500DF
• BMK 3000DF
• BMK 2500P
• BMK 3000P
Latest Update: 03/15/2017
OMM-0115_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 128
GF-200 Ph.: 800-526-0288 03/15/2017
Applies to Seria l Numbers:
G-17-0001 and above.
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CONTENTS
TABLE OF CONTENTS
FOREWORD ...................................................................................................... 5
SECTION 1: SAFETY PRECAUTIONS ................................................................... 9
1.1 WARNINGS & CAUTIONS ................................................................................................... 9
1.2 EMERGENCY SHUTDOWN ...............................................................................................10
1.3 PROLONGED SHUTDOWN ...............................................................................................10
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ...............................................11
SECTION 2: INSTALLATION ............................................................................. 13
2.1 INTRODUCTION.................................................................................................................13
2.2 RECEIVING THE UNIT .......................................................................................................13
2.3 UNPACKING .......................................................................................................................13
2.4 SITE PREPARATION .........................................................................................................14
2.4.1 Installation Clearances ................................................................................................................... 14
2.4.2 Setting the Unit .............................................................................................................................. 17
2.5 LIFTING PROVISIONS .......................................................................................................19
2.5.1 BMK 750 – 1000 lifting Provisions .................................................................................................. 19
2.5.2 BMK 1500 – 2000 Lifting Provisions ............................................................................................... 20
2.6 SUPPLY AND RETURN PIPING .........................................................................................21
2.6.1 BMK 750 – 1000 Supply and Return Piping .................................................................................... 21
2.6.2 BMK 1500 – 3000 Supply and Return Piping .................................................................................. 21
2.6.3 Dual Inlet Return Piping ................................................................................................................. 22
2.7 PRESSURE RELIEF VALVE INSTALLATION ....................................................................23
2.8 CONDENSATE DRAIN AND PI PING ..................................................................................24
2.9 GAS SUPPLY PIPING ........................................................................................................26
2.9.1 Gas Supply Specifications ............................................................................................................... 27
2.9.2 Manual Gas Shutoff Valve .............................................................................................................. 27
2.9.3 External Gas Supply Regulator ....................................................................................................... 28
2.10 AC ELECTRICAL POWER WIRING ..................................................................................30
2.10.1 Electrical Power Requirements .................................................................................................... 30
2.10.2 Power Box Locations .................................................................................................................... 32
2.10.3 Electrical Power Box Internal Components .................................................................................. 33
2.11 FIELD CONTROL WIRING ...............................................................................................35
2.11.1 Outdoor Air & Air Sensor Common .............................................................................................. 36
2.11.2 AIR TEMP SENSOR ........................................................................................................................ 37
2.11.3 O
2.11.4 SPARK SIGNAL (+ & –) ................................................................................................................... 37
2.11.5 ANALOG IN ................................................................................................................................... 37
2.11.6 VALVE FEEDBACK .......................................................................................................................... 37
2.11.7 SHIELD (SHLD & SHLD) .................................................................................................................. 38
2.11.8 ANALOG OUT ................................................................................................................................ 38
2.11.9 RS485 Comm (+, GND, & -) ........................................................................................................... 38
2.11.10 RS232 Comm (TxD & RxD) .......................................................................................................... 38
2.11.11 VFD/Blower (0-10 & AGND) ....................................................................................................... 38
2.11.12 Interlocks .................................................................................................................................... 39
SENSOR (+ & –) ........................................................................................................................ 37
2
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CONTENTS
2.11.13 Fault Relay (NC, COM, & NO) ..................................................................................................... 39
2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) ................................................................................ 39
2.12 FLUE GAS VENT INSTALLATION ....................................................................................40
2.12.1 MASSACHUSETTS INSTALLATIONS ............................................................................................... 40
2.13 COMBUSTION AIR ...........................................................................................................41
2.13.1 DUCTED COMBUSTION AIR .......................................................................................................... 41
2.14 BENCHMARK PUMP RELAY ...........................................................................................42
2.15 SEQUEN CING ISOLATION VALVE INSTALLATION ........................................................43
SECTION 3: START SEQUENCE ........................................................................ 45
3.1 INTRODUCTION.................................................................................................................45
3.2 START SEQUENCE ...........................................................................................................45
3.3 START/STOP LEVELS .......................................................................................................51
3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT .....................................................52
3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input ............................................................. 52
3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input ..................................................................... 53
3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input ..................................................................... 54
3.4.4 BMK 2500 (Nat. Gas) Air/Fuel Valve Position and Energy Input .................................................... 55
3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input ..................................................................... 56
SECTION 4: INITIAL START-UP ........................................................................ 57
4.1 INITIAL S TA RT-UP REQUIREMENTS ................................................................................57
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION ........................................57
4.2.1 Required Tools & Instrumentation ................................................................................................. 57
4.2.2 Installing Gas Supply Manometer .................................................................................................. 58
4.2.3 Accessing the Analyzer Probe Port ................................................................................................. 60
4.3 FUEL TYPES AND COMBUSTI ON CALIBRATION ............................................................61
4.4 COMBUSTION CALIBRATION ...........................................................................................62
4.4.1 NATURAL GAS Combustion Calibration .......................................................................................... 63
4.4.2 PROPANE GAS COMBUSTION CALIBRATION .................................................................................. 67
4.5 REASSEMBLY ....................................................................................................................71
4.6 DUAL FUEL SWITCHOVER ...............................................................................................71
4.6.1 Switchover from NATURAL GAS to PROPANE ................................................................................ 72
4.6.2 Switchover from PROPANE to NATURAL GAS ................................................................................ 73
4.7 OVER-TEMPERATURE LIMIT SWITCHES ........................................................................74
4.7.1 Digital Alarm Switch Checks and Adjustments ............................................................................... 75
SECTION 5: SAFETY DEVICE TESTING .............................................................. 77
5.1 TESTING OF SAFETY DEVI CES .......................................................................................77
5.2 LOW GAS PRESSURE TEST .............................................................................................78
5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500 .................................................................................. 78
5.2.2 LOW GAS PRESSURE TEST: BMK 3000 Only.................................................................................... 80
5.3 HIGH GAS PRESSURE TEST ............................................................................................82
5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500 ................................................................................. 82
5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 Only ................................................................................... 84
5.4 LOW WATER LEVEL FAULT TEST ....................................................................................86
5.5 WATER TEMPERATURE FAULT TEST .............................................................................87
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CONTENTS
5.6 INTERLOCK TESTS ...........................................................................................................89
5.6.1 Remote Interlock Test .................................................................................................................... 89
5.6.2 Delayed Interlock Test .................................................................................................................... 89
5.7 FLAME FAULT TEST ..........................................................................................................90
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES ..............91
5.8.1 Blower Proof Switch Test ............................................................................................................... 91
5.8.2 Blocked Inlet Switch Test................................................................................................................ 93
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK ................................................................94
5.10 PURGE SWITCH OPEN DURING PURGE .......................................................................94
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................97
5.12 SAFETY PRESSURE RELIEF VALVE TEST ....................................................................97
SECTION 6: BOILER SEQUENCING TECHNOLOGY ............................................ 99
6.1 INTRODUCTION.................................................................................................................99
6.1.1 INSTALLATION NOTES ................................................................................................................... 100
6.2 AERCO BST QUICK START CHART ............................................................................... 100
6.3 BST IMPLEMENTATIO N INST RUCTION ......................................................................... 101
6.3.1 OPTION 1 - CONSTANT SETPOINT WITH DIRECT WIRED HEADER SENSOR .................................. 101
6.3.2 OPTION 2 - CONSTANT SETPOINT WITH MODBUS WIRED HEADER SENSOR .............................. 102
6.3.3 OPTION 3 - OUTDOOR RESET WITH DIRECT WIRED HEADER SENSOR AND DIRECT WIRED
OUTDOOR SENSOR ................................................................................................................................ 103
6.3.4 OPTION 4 - OUTDOOR RESET WITH MODBUS HEADER SENSOR AND MODBUS OUTDOOR SENSOR
............................................................................................................................................................... 105
6.3.5 OPTION 5 - REMOTE SETPOINT WITH DIRECT WIRED HEADER SENSOR AND 4-20MA SETPOINT
DRIVE ..................................................................................................................................................... 107
6.3.6 OPTION 6 - REMOTE SETPOINT WITH DIRECT WIRED HEADER SENSOR AND MODBUS SETPOINT
DRIVE ..................................................................................................................................................... 109
6.3.7 OPTION 7 - REMOTE SETPOINT WITH MODBUS HEADER SENSOR AND 4-20MA SETPOINT DRIVE
............................................................................................................................................................... 111
6.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive......... 113
SECTION 7: ONAER SETUP ............................................................................ 115
7.1 INTRODUCTION............................................................................................................... 115
7.1.1 Connecting the Ethernet Cable .................................................................................................... 115
7.1.2 Confirming the Ethernet Connection ........................................................................................... 117
7.1.3 Confirm Ethernet DHCP Configuration ......................................................................................... 117
SECTION 8: TROUBLESHOOTING .................................................................. 119
APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ............................. 121
Page 4 of 128 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-115_0A
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
BMK 750
50,000 (14.6 kW)
750,000 (220 kW)
47,750 (14.0 kW)
716,250 (210 kW)
BMK 1000
50,000 (14.6 kW)
1,000,000 (293 kW)
48,300 (14.2 kW)
968,000 (284 kW)
BMK 1500
75,000 (22 kW)
1,500,000 (440 kW)
64,500 (18.9 kW)
1,395,000 (409 kW)
BMK 2000
100,000 (29.3 kW)
2,000,000 (586 kW)
86,000 (25.2 kW)
1,860,000 (545 kW)
BMK 2500
167,000 (48.9 kW)
2,500,000 (732 kW)
144,000 (42.2 kW)
2,395,000 (702 kW)
BMK 3000
200,000 (58.6 kW)
3,000,000 (879 kW)
174,000 (51.0 kW)
2,874,000 (842 kW)
FORWARD
FOREWORD
The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas and
propane fueled boilers are modulating and condensing units. They represent a true industry
advance that meets the needs of today's energy and environmental concerns. Designed for
application in any closed loop hydronic system, the Benchmark's modulating capability relates
energy input directly to fluctuating system loads. These BMK models provide extremely high
efficiency operation and are ideally suited for modern low temperature, as well as, conventional
heating systems.
IMPORTANT!
Unless otherwise specified all descriptions provided in this document apply to the Benchmark
Platinum Series of boiler.
The Benchmark models operate within the input and output ranges listed below. All
measurements apply to both natural gas and propane models, unless otherwise specified.
BMK PLATINUM BOILER INTAKE and OUTPUT RANGES
BMK
MODEL
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 NO
(SCAQMD), Rule 1146.2. In addition, the BMK 750 & 1000 comply with the Bay Area Air
Quality Management District regulation 9, Rule 7.
Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting
flexibility with minimum installation space requirements. These boilers are Ca tegory II and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:
• Room Combustion Air :
• Ducted Combustion Air:
emission standards outlined in: South Coast Air Quality Management District
x
o Vertical Discharge
o Horizontal Discharge
o Vertical Discharge
o Horizontal Discharge
INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.)
MINIMUM MAXIMUM MINIMUM MAXIMUM
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In
addition, the BMK 750 & 1000 models are also approved for PVC and CPVC, 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.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
British Thermal Unit. A unit of energy approximately equal to the
A control system developed by AERCO and currently used in all
CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
CNTL
Control
Double Block and Bleed, a gas trains containing 2 Safety Shutoff
GF-xxxx
Gas Fired (an AERCO document numbering system)
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
A (Amp) Ampere
ACS AERCO Control System, AERCO’s boiler management systems
ADDR Address
AGND Anal og Ground
ALRM Alarm
ANSI American National Standards Institute,
ASME American Society of Mechanical Engineers
AUX Auxiliary
BAS
Baud Rate
BMK (Benchmark) AERCO’s Benchmark series boilers
BMS or BMS II AERCO Boiler Management Systems
BLDG (Bldg) Building
BST AERCO on-board Boiler Sequencing Technology
BTU
BTU/HR BTUs per Hour (1 BTU/hr = 0.29 W)
CCP Combination Control Panel
CCS Combination Control System
C-More Controller
(or Control Box)
CFH Cubic Feet per Hour (1 CFH = 0.028 m3/hr)
Building Automation System, often used interchangeably with EMS
(see below)
Symbol rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)
Benchmark, Innovation and KC1000 Series product lines.
CPU Central Processing Unit
DBB
DIP Dual In-Line Package, a type of switch
ECU Electronic Control Unit (O2 sensor)
EMS Energy Management System; often used interchangeably with BAS
FM Factory Mutual. Used to define boiler gas trains.
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Valves (SSOVs) and a solenoid operated vent valve.
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
MBH
1000 BTUs per Hour
duplex data transmission protocol developed by AEG
onAER
P/N
Part Number
POC
Proof of Closure
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
GND Ground
HDR Header
Hex Hexadecimal Number (0 – 9, A – F)
HP Horse Power
HX Heat Exchanger
Hz Hertz (Cycles Per Second)
I.D. Inside Diameter
IGN Ignition
IGST Board Ignition/Stepper Board, contained in C-More Control Box
INTLK (INTL’K) Interlock
I/O Input/Output
I/O Box
IP Internet Protocol
ISO International Organization for Standardization
Lbs. Pounds (1 lb = 0.45 kg)
LED Light Emitting Diode
LN Low Nitrogen Oxide
MA (mA) Milliampere (1 thousandth of an ampere)
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
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
A serial, halfModicon
O.D. Outside Diameter
OMM & O&M Operation and Maintenance Manual
AERCO’s on-line remot e monitoring sys tem
PCB Printed Circuit Board
PMC Board Primary Micro-Contr oller (PMC) board, contained in the C-More
PPM Part s per Million
PSI Pounds per Square Inch (1 PSI = 6.89 kPa)
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duplex (FDX) transmission of data based
duplex (FDX) transmission of data based
data in the
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, also Variable Frequency Drive
W
Watt
W.C.
Water Column, a unit of pressure (1 W.C. = 249 Pa)
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
PTP Point-to-Point (usually over RS232 networks)
P&T Pressure and Temperature
ProtoNode Hardware interface between BAS and a boiler or water heater
PVC Poly Vinyl Chloride, a common synthetic plastic
PWM Pulse Width Modulation
REF (Ref) Reference
RES. Resistive
RS232
(or EIA-232)
RS422
(or EIA-422)
RS485
(or EIA-485)
RTN (Rtn) Return
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield
SPDT Single Pole Double Throw, a type of switch
SSOV Safety Shut Off Valve
TEMP (Temp) Temperature
Terminating Resistor
Tip-N-Tell A device that indicates if a package was tipped during shipping
UL A business that tests and validates products
VAC Volts, Alternating Current
A standard for serial, full-
on the RS232 Standard
A standard for serial, full-
on the RS422 Standard
A standard for serial, half-duplex (HDX) transmission of data based
on the RS485 Standard
A resistor placed at each end of a daisy-chain or multi-drop network
in order to prevent reflections that may cause invalid
communication
µA Micro amp (1 millionth of an ampere)
Page 8 of 128 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-115_0A
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 1 – SAFETY PRECAUTIONS
SECTION 1: SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be g iven the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
See section 1.4 for important information regarding installation of units within the
Commonwealth of Massachusetts.
IMPORTANT!
This 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!
• Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.
• Fluids under pressure may cause injury to personnel or damage to equipment when
released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully
decrease all trapped pressures to zero before performing maintenance.
• Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
• The exhaust vent pipe of the unit may operate under a positive pressure and therefore must
be completely sealed to prevent leakage of combustion products into living spaces.
• Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK 2500/3000)
may be used in this equipment. Therefore the cover on the unit’s power box (located behind
the front panel door) must be installed at all times, except during maintenance and servicing.
• A single-pole (120 VAC units) or three-pole (220 VAC or higher units) 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.
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VALVE
OPEN
VALVE
CLOSED
SECTION 1 – SAFETY PRECAUTIONS
CAUTION!
• Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
• DO NOT use this boiler if any part has been under water. Call a qualified service technician
to inspect and replace any part that has been under water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
NOTE:
The Installer must identify and indicate the location of the emergency shutdown manual gas
valve to operating personnel.
MANUAL GAS SHUT-OFF VALVE
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the initial startup procedures in Section 4 and
the safety device test procedures in Section 5, 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.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS
Boiler Installations within the Commonwealth of Massachusetts must conform to the
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
monoxide detector with an alarm is installed on each additional level of the dwelling,
be the responsibility of the property owner to secure the services of qualified licensed
the above requirements; provided, however, that during said thirty (30) day period, a
Each carbon monoxide detector as
accordance with the above provisions shall comply with NFPA 720 and be
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)
SECTION 1 – SAFETY PRECAUTIONS
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
following requirements:
• Boiler must be installed by a plumber or a gas fitter who is licensed within the
Commonwealth of Massachusetts.
• Prior to unit operation, the complete gas train and all connections must be leak
tested using a non-corrosive soap.
• The vent termination must be located a minimum of 4 feet above grade level. If
side-wall venting is used, the installation must conform to the following
requirements extracted from 248 CMR 5.08 (2):
building or structure used in whole or in part for residential purposes, including those owned or
operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
building or structure served by the side wall horizontal vented gas fueled equipment. It shall
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
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS:
required in
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
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS
observes carbon monoxide detectors and signage installed in accordance with the
venting system design or venting system components with the equipment, the instructions
When the manufacturer of a Product Approved side wall horizontally vented gas fueled
nd the
SECTION 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
provisions of 248 CMR 5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in
the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a
room or structure separate from the dwelling, building or structure used in whole or in
part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When
the manufacturer of Product Approved side wall horizontally vented gas equipment provides a
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.
equipment does not provide the parts for venting the flue gases, but identifies "special venting
systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, a
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of
the installation.
……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 2 – INSTALLATION
SECTION 2: INSTALLATION
2.1 INTRODUCTION
This Section provides the descriptions and procedures necessary to unpack, inspect and install
the AERCO Benchmark Platinum Boilers, models 750, 1000, 1500, 2000, 2500 and 3000.
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 as follows:
• BMK 750: 1100 lbs. (499 kg)
• BMK 1000: 1200 lbs. (544 kg)
• BMK 1500/2000: 1800 lbs. (817 kg).
• BMK 2500/3000: 2200 lbs. (1000 kg)
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.
CAUTION!
While packaged in the shipping container, the unit must be moved by pallet jack or fork lift f rom
the FRONT ONLY.
NOTE:
AERCO is not responsible for lost or dam aged 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, make a close inspection of the unit 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 pac ked separately within
the unit’s shipping container or are factory installed on the unit:
• Pressure/Temperature Gauge
• ASME Pressure Relief Valve
• Condensate Drain Trap (P/N 24441)
• A 1 “ or 2” Natural Gas Supply Shutoff Valve, and a Propane Shutoff Valve on Propane
and Dual Fuel units
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SECTION 2 – INSTALLATION
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 Platinum Boiler includes:
• Access to AC input power specified in Section 2.10.1.
• Access to a natural gas or propane gas with minimum pressure specified in Section
2.9.1.
2.4.1 Installation Clearances
All Benchmark models are the same height, but vary in depth according to model pairs;
750/1000, 1500/2000, and 2500/3000. The unit must be installed with the prescribed clearances
for service as shown in Figure 2-1a, 2-1b and 2-1c. The minimum clearance dimensions,
required by AERCO, are listed below f or all models. However, if Local Building Codes require
additional clearances, these codes shall supersede AERCO’s requirements. The minimum
acceptable clearances required are as follows:
• Sides: 24 inches (61 cm)
• Front: 24 inches (61 cm)
• Rear: 24 inches (61 cm)
• Top: 18 inches (45.7 cm)
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.
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 (CCP) system using an ACS panel, it is important to identify the
Combination Mode Boilers in advance and place them in the proper physical location. For
information on Combination Mode Boilers refer to Section 3.7 of th e BMK 750-3000 Platinum
Boiler Operation and Maintenance Guide, OMM-0116 (GF-201).
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
NOTE:
housekeeping
NOTE:
pad.
4” High Pad
SECTION 2 – INSTALLATION
Ensure that
condensate
assembly is
not located
over the
housekeeping
Ensure that
condensate
assembly is
not located
over the
Figure 2-1a: BMK 750/1000 Clearances
Figure 2-1b: BMK 1500/2000 Clearances
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
Housekeeping Pad.
FRONT
REAR
NOTE:
SECTION 2 – INSTALLATION
Ensure that
condensate
assembly is
not located
over the
Figure 2-1c: BMK 2500/3000 Clearances
WARNING!
Keep the unit area clear and free from all combustible materials and flammable vapors or
liquids.
FOR MASSACHUSETTS 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 Section 1.4, above.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 2 – INSTALLATION
2.4.2 Setting the Unit
BMK 750/1000 units must be installed on a 4 to 6 inch (10.2 to 15.2 cm) while BMK 1500 –
3000 units must be installed on a 4 to 8 inch (10.2 to 20.3 cm) housekeeping pad to ensure
proper condensate drainage. If anchoring the unit, refer to Figure 2-2a, 2-2b and 2-2c for anchor
locations.
• All holes are flush with the bottom surface of the frame.
• All dimensions shown are in inches [millimeters]
Figure 2-2a: BMK 750/1000 Anchor Bolt Locations
Figure 2-2b: BMK 1500/2000 Anchor Bolt Locations
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
FRONT
REAR
SECTION 2 – INSTALLATION
NOTES:
1) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME
2) ALL DIMENSIONS SHOWN ARE IN INCHES [MILLIMETERS]
Figure 2-2c: BMK 2500/3000 Anchor Bolt Locations
Page 18 of 128 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-115_0A
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
ATTACHING THE LIFTING BAR: BMK 750/1000 Instructions
, lift the boiler and
LIFTING
TAB
VIEW B - LIFTING POSITION
SECTION 2 – INSTALLATION
2.5 LIFTING PROVISIONS
WARNING!
When lifting or moving the boiler, DO NOT attempt to manipulate the boiler using the gas train
or blower.
2.5.1 BMK 750 – 1000 lifting Provisions
Unpack and inspect the unit, then remove the four (4) lag screws securing the boiler to the
shipping pallet. The boiler can be lifted and moved by inserting forklift tines in the front slots
provided in the base of the unit, or it can be lifted by attaching a lifting bar to the unit’s heat
exchanger. A lifting bar (P/N 59174), with attaching hardware, is supplied with each unit. W hen
shipped, this bar is attached to the rear of the unit as shown in Figure 2-3a (View A). One (1)
lifting tab is provided at the top of the unit’s heat exchanger as shown. This tab is used to attach
the lifting bar to the unit, as described below.
WARNING!
When using the lifting tab and bar, ensure there is no load placed on the gas train or blower.
1. Remove the lifting bar from its shipping location at the rear of the unit (Figure 2-3a, View
A). Retain the two (2) hex head cap screws, hex nuts and flat washers.
2. Remove the top shroud from the boiler and locat e the lift ing t ab at the t op-rear of the heat
exchanger.
3. Attach the lifting bar to the heat exchanger lifting tab using the hardware removed in step 1
(Fig. 2-3a, Vie w B). The upper end of the lifting bar containing the oval cutout should be
positioned over the top of the heat exchanger as shown.
4. Using proper rigging equipment capable of lifting 1200 lbs. (544 kg)
position it on the housekeeping pad.
5. After the boiler is properly set on the pad, detach the lifting bar and replace the shroud on
the top of the unit, but retain the lifting bar for possible reuse at the installation site.
LIFTING BAR
IN LIFTING
POSITION
LIFTING
BAR IN
SHIPPING
POSITION
VIEW A - SHIPPING POSITION
Figure 2-3a: BMK 750/1000 Boiler Lifting Provisions
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SECTION 2 – INSTALLATION
2.5.2 BMK 1500 – 2000 Lifting Provisions
Three lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-3.
Remove the front top panel from the unit to provide access to the lifting lugs. 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 8 inch ( 10.2 cm to 20.3 cm) housekeeping concrete pad (required)
in the desired location.
LIFTING LUGS (3 POSITIONS)
YELLOW ARROWS
2” NATURAL
GAS OR 1”
PROPANE GAS
INLET
Figure 2-3: Boiler Lifting Provisions – BMK 1500/2000 Shown
Page 20 of 128 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-115_0A
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
1” (2.54cm) NATURAL GAS INLET
1/4” ANALYZER
NPT PORT
COOLER
3” SECONDARY WATER INLET
WARMER WATER RETURN
EXHAUST
MANIFOLD
1” (2.54cm) PROPANE INLET
SECTION 2 – INSTALLATION
2.6 SUPPLY AND RETURN PIPING
2.6.1 BMK 750 – 1000 Supply and Return Piping
Benchmark 750 and 1000 Boiler utilizes 3” (7.62cm) 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 2-4a. Refer to Appendix A for dimens ional data.
When connecting the hot water outlet and cold water inlet to building piping, first make sure the
mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the
mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
3” HOT WATER O UTLET
(SUPPLY)
AIR INLET
3” PRIMARY WATER INLET
WATER RETURN
DRAIN VALVE
CONDENSATE DRAIN
Figure 2-4a: BMK 750/1000 Supply and Return Locations – Two Inlet Option Shown
2.6.2 BMK 1500 – 3000 Supply and Return Piping
All Benchmark 1500, 2000, 2500 and 3000 units have one 4” (10.2 cm) 150# flanges for the
water INLET (supply) and one 4” (10.2 cm) 150# flanges for the hot water OUTLET (return)
piping connections. Some units have an optional second 4” (10.2 cm) 150# flange for the water
INLET, as shown in Figure 2-4b. Refer t o Appendix A for dimensional data.
When connecting the hot water outlet and cold water inlet to building piping, first make sure the
mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the
mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECONDARY WATER INLET
PRIMARY
(COOLER WATER
EXHAUST MANIFOLD
BMK 1500/2000
BMK 2500/3000
SECTION 2 – INSTALLATION
2” NATURAL GAS OR
1” PROPANE INLET
HOT WATER
OUTLET
(SUPPLY)
AIR INLET
(WARMER WATER RETURN)
WATER INLET
CONDENSATE DRAIN
Figure 2-4b: BMK 1500/2000 and BMK 2500/3000 Supply and Return Locations
2.6.3 Dual Inlet Return Piping
The standard dual inlet connections allow these units to be configured with a separate cooler
return temperature zone, rather than blending high and low return temperature zones. Utilizing
the dual return capability, these boilers can take further advantage of the condensing
capabilities. When configured with a lower return temperature zone or AERCO SmartPlate,
thermal efficiency can improve by up to 6% (Based on an 80 °F (26.7 °C) minimum return wat er
temperature at full fire. Lower return temperatures are possible which would yield even greater
efficiency gains. The maximum temperature differential across the boiler heat exchanger is 100
°F (37.8 °C)).
To use the secondary inlet, pipe the warmer return water to the secondary (upper) inlet and
the cooler return water to the primary (lower) inlet. If the flow through b oth the pr imar y an d the
secondary return is constant, then the combined minimum flows must equal the specified
minimum flow of t he boiler. If the flow through either of the inlet returns is intermittent, then the
minimum flow through one of the return connections m ust always equal the specified minimum
flow of the boiler. Contact your AERCO representative for additional information.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 2 – INSTALLATION
2.7 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 3 0 to 160 ps i (207 to 1103 kPa). The relief valve is installed on the hot water outlet of the
boiler as shown in Figure 2-5a and 2-5b. A su itable 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. The relief valve must be piped to within 12 inches (30.5 cm) of t he floor t o
prevent injury in the event of a discharge. No valves, restrictions, or other blockages are
allowed in the full port discharge line. In multiple unit installations the discharge lines must NOT
be manifolded together. Each must be individually run to a suitable discharge location.
PRESSURE
RELIEF VALVE
3” HOT BOILER
WATER OUTLET
PRESSURE
RELIEF VALVE
4” HOT BOILER
WATER OUTLET
Figure 2-5b: BMK 1500/2000/2500/3000 P&T Relief Valve Location
INSTALL
TRIDICATOR GAUGE
HERE
(P/N 123675-TAB)
Figure 2-5a: BMK 750/1000 P&T Relief Valve Location
INSTALL
TRIDICATOR GAUGE
HERE
(P/N 123675-TAB)
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CONDENSATE DRAIN INSTALL ATIO N Instructions
d drain connection using the
BMK Model
Maximum Condensate Flow Per Boiler
BMK 750
6 gallons (23 L) per hour
BMK 1000
8 gallons (30 L) per hour
BMK 1500
9 gallons (34 L) per hour
BMK 2000
10 gallons (38 L) per hour
BMK 3000
20 gallons (76 L) per hour
SECTION 2 – INSTALLATION
2.8 CONDENSATE DRAIN and PIPING
The Benchmark Boiler is designed to condense wat er vapor from the flue products. Therefore,
the installation must have provisions for suitable condensate drainage or collection. See the
following subsections for information on the condensate drain and piping for the various models.
The condensate drain port located on the exhaust manifold (see Figure 2-4a and 2-4b) must be
connected to the condensate trap (P/N 24441), which is packed separately within the unit’s
shipping container. The condensate trap inlet and outlet connections contain tapped 3/4” NPT
ports.
A sample condensate trap installation is shown in Figure 2-6a and 2-6b. However, the actual
installation details for the trap will vary depending on the available clearances, housekeeping
pad height/dimensions and other prevailing conditions at the site. The following general
guidelines must be observed to ensure proper condensate drainage:
• The condensate trap inlet must be level with, or lower than 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. AERCO recommends that a union
be utilized between the exhaust manifold condensate drain port and the trap inlet port.
While observing the above guidelines, install the condensate trap as follows:
1. Connect the condensate trap inlet to the exhaust manifol
appropriate piping components (nipples, reducers, elbows, etc.).
2. At the condensate trap outlet, install a 3/4” NPT nipple.
3. Connect a length of 1” (2.54 cm) I.D. polypropylene hose to the trap outlet and sec ure with a
hose clamp.
4. Route the hose on the trap outlet to a nearby floor drain.
If a floor drain is not available, a condensate pump can be used to remove the condensate to an
appropriate drain. The maximum condensate flow rate is:
BMK 2500 17 gallons (64 L) per hour
WARNING!
Use PVC, stainless steel, aluminum or polypropylene for condensate drain piping. Do NOT use
carbon or copper components.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
3/4” NPT
NIPPLE
HOSE
CLAMP
1” DIAM.
HOSE
3/4” NPT
NIPPLES
UNION
EXHAUST
MANIFOLD
DRAIN
4”
THICK
COMBUSTION
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLES
HOSE
CLAMP
T O
DRAIN
(4 each)
1” (2.54 cm) DIAM.
HOSE
4”
4-8” (10-20 cm)
THICK
SECTION 2 – INSTALLATION
COMBUSTION
ANALYZER
PROBE PORT
NOTE
HOUSEKEEPING
PAD MUST NOT
EXTEND UNDER
THE CONDENSATE
ASSEMBLY
4-6” (10-15.2 cm)
TRAP INLET
INTEGRAL ADAPTOR AND
THUMBSCREW
TOP COVER THUMB
SCREWS (4 each)
CONDENSATE
TRAP
(P/N 24441)
T O
FLOOR
Figure 2-6a: BMK 750/1000 Sample Condensate Trap Installation
ANALYZER
NOTE
HOUSEKEEPING
PAD MUST NOT
EXTEND UNDER
THE CONDENSATE
ASSEMBLY
EXHAUST
MANIFOLD
DRAIN PORT
TRAP INLET
INTEGRAL ADAPTOR AND
THUMBSCREW
TOP
COVER
THUMB
SCREWS
CONDENSATE
TRAP (P/N 24441)
FLOOR
Figure 2-6b: BMK 1500/2000/2500/3000 Sample Condensate Trap Installation
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 2 – INSTALLATION
2.9 GAS SUPPLY PIPING
AERCO’s Benchmark Gas Components and Supply Design Guide, TAG-0047 (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.
CAUTION!
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 750 and 1000: Features a 1 inch (2.54 cm) NATURAL GAS gas inlet connection
on the rear of the unit.
Benchmark 750P and 1000P: Features a 1 inch (2.54 cm) PROPANE gas inlet connection on
the rear of the unit.
Benchmark 1500/2000/2500/3000: Features a 2 inch (5.08 cm) NATURAL GAS gas inlet
connection on the top of the unit.
Benchmark 1500P, 2000P, 2500P, and 3000P (Propane): Features a 1 inch (2.54 cm)
PROPANE gas inlet connection on the top of the unit.
Benchmark 1500DF, 2000DF, 2500DF, and 3000DF (Dual Fuel): Features a 2 inch (5.08 cm)
NATURAL GAS and a 1 inch (2.54 cm) PROPANE gas inlet connection on the top of the unit.
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 the g as
supply piping. The gas pressure applied to the unit must never exceed 14” W.C. (3.49 kPa). 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.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
TABLE 2-1: MAXIMUM STATIC GAS PRESSURE
TABLE 2-2: MINIMUM GAS PRESSURE REQUIREMENTS
Minimum
Pressure
Minimum
Pressure
/hr)
SECTION 2 – INSTALLATION
2.9.1 Gas Supply Specifications
The gas supply input specifications to the unit are as follows:
The maximum static pressure to the unit must not exceed the following:
MODEL
BMK 750 - BMK 3000
NATUR AL GAS PROPANE
14” W.C. (3.49 kPa) 14” W.C. (3.49 kPa)
Supply piping and pressure to the unit must be sufficient to provide the volume of gas while
maintaining gas pressure listed below while operating at maximum capacity:
NATUR AL GAS PROPANE
MODEL
BMK 750
BMK 1000
BMK 1500
BMK 2000 *
BMK 2500
BMK 3000
Gas Volume
3
750 CFH (21.2 m
/hr) 4” W.C. (1.0 kPa) 300 CFH (8.5 m3/hr) 7” W.C. (1.74 kPa)
1000 CFH (28.3 m3/hr)
1500 CFH (42.5 m3/hr)
2000 CFH (56.6 m3/hr)
2500 CFH (70.8 m3/hr)
3000 CFH (85.0 m3/hr)
4” W.C. (1.0 kPa)
6” W.C. (1.5 kPa)
6” W.C. (1.5 kPa)
4” W.C. (1.0 kPa)
4” W.C. (1.0 kPa)
Gas Volume
400 CFH (11.3 m
600 CFH (17.0 m
800 CFH (22.6 m
1000 CFH (28.3 m
1200 CFH (34 m
3
3
/hr) 11” W.C. (2.74 kPa)
3
/hr) 4” W.C. (1.0 kPa)
3
/hr) 4” W.C. (1.0 kPa)
3
4” W.C. (1.0 kPa)
/hr) 4” W.C. (1.0 kPa)
* The BMK 2000 may derate by up to 150,000 BTU’s when operated below 5” W.C. (1245 Pa)
at full fire.
2.9.2 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 1-1.
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TABLE 2-3a: NATURAL GAS Regulator Ca pacity
TABLE 2-3b: PROPANE Gas Regul a t or Capacity
SECTION 2 – INSTALLATION
2.9.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions
(see, below). Regulators must conform to the specifications shown in the tables below.
The external natural gas regulator must be capable of regulating the following BTU per hour
while maintaining the minimum gas pressure listed below:
Model BTU/HR (kW) Minimum Gas Pressure
BMK 750/1000
BMK 1500
BMK 2000
BMK 2500/3000
Model BTU/HR (kW) Minimum Gas Pressure
BMK 750/1000
BMK 1500/2000
BMK 2500/3000
A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C. (3.49
kPa).
49,000 – 1,020,000 (14.3 – 299) 4.0” W.C. (1.0 kPa)
100,000 – 2,120,000 (29.3 - 621.3) 6.0” W.C. (1.49 kPa)
100,000 – 2,120,000 (29.3 - 621.3) 8.5” W.C. (2.12 kPa)
150,000 – 3,180,000 (44 - 932) 8.0” W.C. (1.99 kPa)
49,000 – 1,020,000 (14.3 – 299) 11.0” W.C. (2.74 kPa)
100,000 – 2,120,000 (29.3 - 621.3) 4.0” W.C. (1.0 kPa)
150,000 – 3,180,000 (44 - 932) 4.0” W.C. (1.0 kPa)
2.9.3.1 Massachusetts Installations Only
For Massachusetts installations, a mandatory external gas supply regulator must be
positioned as shown in Figure 2-7a, 2-7b and 2-7c. 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.
2.9.3.2 All Installations (Except Massachusetts)
For installations with 3 or more units (other than Massachusetts) that EXCEED 7” W.C. (1.7
kPa) gas pressure, a separate external gas supply r egulator, as shown in Figure 2-7a, 2-7b
and 2-7c, is highly recommended. No regulator is required for gas pressures below 7”
W.C. (1.7 kPa) of pressure. Consult the local gas utility for detailed requirements concerning
venting of the supply gas regulator.
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 your AERCO sales r epresentative
for more information.
Page 28 of 128 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-115_0A
03/15/2017 Ph.: 800-526-0288 GF-200
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
DIRT TRAP
SECTION 2 – INSTALLATION
1” MANUAL
SHUTOFF
VALVE
GAS INLET
GAS PRESSURE
REGULATOR
Figure 2-7a: BMK 750/1000 Manual Gas Shut-Off Valve and Gas Regulator
GAS PRESSURE REGULATOR
NATURAL GAS
INLET
MANUAL
SHUT-OFF
VALVE
GAS INLET
Figure 2-7b: BMK 1500-3000 Manual Gas Shut-Off Valve and Gas Regulator
OMM-0115_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 128
GF-200 Ph.: 800-526-0288 03/15/2017
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
NATURAL GAS
SUPPLY
PROPANE
SUPPLY
PROPANE PRESSURE
piping and
components shown in
will not be
present.
SECTION 2 – INSTALLATION
NATURAL GAS MANUAL
SHUT-OFF VALVE
NATURAL GAS PRESSURE REGULATOR
NATURAL GAS INLET
PROPANE MANUAL SHUT-
OFF VALVE
REGULATOR
PROPANE INLET
NOTE
In propane-only units, the
natural gas
Figure 2-7c
Figure 2-7c: BMK 1500-3000DF Dual Fue l Manual Gas Shut-Off Valve & Gas
Regulator
2.10 AC ELECTRICAL POWER WIRING
AERCO’s Benchmar k Electrical Power Guide, TAG-0048 (GF-2060), must be consulted prior to
connecting any AC power wiring to the unit.
2.10.1 Electrical Power Requirements
The BMK models covered by this manual are available in the following voltage configurations:
• BMK 750/1000: 12 0 VAC, Sin gle-Phase, 60 Hz @ 20 Amps
• BMK 1500/2000: 120 VAC, Sin gle-Phase, 60 Hz @ 20 Amps
• BMK 2500-3000/208: 208 VAC, Three-Phase, 60 Hz @ 20 Amps
• BMK 2500-3000/460: 460 VAC, Three-Phase, 60 Hz @ 15 Amps
A label showing the required AC power connections is provided on the front cover of the Power
Box as shown below in Figures 2-8a and 2-8b. The location of the power box is shown in
Section 2.10.2, below.
Page 30 of 128 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-115_0A
03/15/2017 Ph.: 800-526-0288 GF-200
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