AERCO BMK 6000 Dual Fuel User Manual
Benchmark 6000 DF Installation, Operation & Maintenance Manual
BENCHMARK 6000
USER MANUAL
Installation, Opera ti on and Maintenance
Natural Gas Modulating &
Condensing Hot Water Boiler
DUAL FUEL
Gas-Fired Boiler
Applicable to Serial Numbers:
N-
14-0172 and above
Latest Update: 03/21/2014
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
Disclaimer
The information cont ained in this manual is s ubject to change without notic e from AERCO Internationa l,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied
warranties of m erchantability and f itness for a particul ar application. AERC O Internationa l is not liable for
errors appearing in this manua l. Nor for i ncidental or consequentia l damages oc curring in con nection wit h
the furnishing, performance, or use of this material.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
FOREWORD .............................................................................................................................................. 7
CHAPTER 1. SAFETY PRECAUTIONS ................................................................................................ 11
1.1 WARNINGS & CAUTIONS ..................................................................................................................................... 11
1.2 EMERGENCY SHUTDOWN.................................................................................................................................... 12
1.3 PROLONGED SHUTDOWN ................................................................................................................................... 13
1.4 MASSACHUSETTS INSTALLATIONS ............................................................................................... 13
CHAPTER 2. INSTALLATION ............................................................................................................... 15
2.1 INTRODUCTION ................................................................................................................................................... 15
2.2 RECEIVING THE UNIT ........................................................................................................................................... 15
2.3 MOVING & UNPACKING THE UNIT ...................................................................................................................... 15
2.4 SITE PREPARATION .............................................................................................................................................. 16
2.4.1 Installation Clearances ................................................................................................................................. 16
2.4.2 Setting the Unit ............................................................................................................................................ 18
2.5 SUPPLY AND RETURN PIPING .............................................................................................................................. 20
2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR INSTALLATION ............................................ 20
2.6.1 Pressure Relief Valve Installation ................................................................................................................. 20
2.6.2 Pressure/Temperature Gauge Installation ................................................................................................... 21
2.7 CONDENSATE DRAIN & PIPING ............................................................................................................................ 22
2.8 GAS SUPPLY PIPING ............................................................................................................................................. 23
2.8.1 Gas Supply Specifications ............................................................................................................................. 24
2.8.2 Manual Gas Shutoff Valve ............................................................................................................................ 24
2.8.3 External Gas Supply Regulator ..................................................................................................................... 24
2.8.3.1 Massachusetts Installations Only .......................................................................................................... 24
2.8.3.2 All Installations (Except Massachusetts) ............................................................................................... 25
2.9 AC ELECTRICAL POWER WIRING .......................................................................................................................... 25
2.9.1 Electrical Power Requirements .................................................................................................................... 27
2.10 FIELD CONTROL WIRING .................................................................................................................................... 27
2.10.1 OUTDOOR AIR IN Terminal ......................................................................................................................... 29
2.10.2 COMBUSTION AIR Terminal ....................................................................................................................... 30
2.10.3 O2 SENSOR Terminals ................................................................................................................................. 30
2.10.4 SPARK SIGNAL Terminals ............................................................................................................................ 30
2.10.5 ANALOG IN Terminals ................................................................................................................................. 30
2.10.6 B.M.S. (PWM) IN Terminals ........................................................................................................................ 30
2.10.7 SHIELD Terminals ........................................................................................................................................ 30
2.10.8 ANALOG OUT Terminals ............................................................................................................................. 30
2.10.9 RS485 Comm Terminals .............................................................................................................................. 31
2.10.10 RS232 Comm Terminals ............................................................................................................................ 31
2.10.11 VFD/BLOWER Terminals ........................................................................................................................... 31
2.10.12 Interlock Terminals ................................................................................................................................... 31
2.10.12.1 Remote Interlock In (OUT & IN)......................................................................................................... 31
2.10.12.2 Delayed Interlock In (OUT & IN) ........................................................................................................ 31
2.10.13 FAULT RELAY Terminals ............................................................................................................................ 32
2.10.14 AUX.RELAY Terminals ............................................................................................................................... 32
2.11 FLUE GAS VENT INSTALLATION ......................................................................................................................... 32
2.12 COMBUSTION AIR .............................................................................................................................................. 33
2.12.1 Combustion From Outside the Building ..................................................................................................... 33
2.12.2 Combustion Air from Inside the Building ................................................................................................... 33
2.13 DUCTED COMBUSTION AIR ............................................................................................................................... 34
2.14 SEQUENCING VALVE INSTALLATION .................................................................................................................. 34
CHAPTER 3. OPERATION .................................................................................................................... 37
3.1 INTRODUCTION ................................................................................................................................................... 37
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3.2 CONTROL PANEL DESCRIPTION ........................................................................................................................... 37
3.3 CONTROL PANEL MENUS ..................................................................................................................................... 41
3.3.1 Menu Processing Procedure ......................................................................................................................... 41
3.4 OPERATING MENU .............................................................................................................................................. 43
3.5 SETUP MENU ....................................................................................................................................................... 43
3.6 CONFIGURATION MENU ...................................................................................................................................... 44
3.7 TUNING MENU .................................................................................................................................................... 46
3.8 COMBUSTION CAL MENU .................................................................................................................................... 47
3.9 BST (Boiler Sequencing Technology ) Menu ........................................................................................................ 47
3.10 START SEQUENCE .............................................................................................................................................. 50
3.11 START/STOP LEVELS........................................................................................................................................... 55
CHAPTER 4. INITIAL START-UP.......................................................................................................... 59
4.1 INITIAL START-UP REQUIREMENTS ...................................................................................................................... 59
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION ................................................................... 59
4.2.1 Required Tools & Instrumentation ............................................................................................................... 60
4.2.2 Installing Gas Supply Manometer................................................................................................................. 60
4.2.3 Accessing the Analyzer Probe Port ............................................................................................................... 61
4.3 PILOT IGNITION ................................................................................................................................................... 62
4.4 NATURAL GAS COMBUSTION CALIBRATION ....................................................................................................... 62
4.5 PROPANE GAS COMBUSTION CALIBRATION ....................................................................................................... 67
4.6 DUAL-FUEL SWITCHOVER INSTRUCTIONS ........................................................................................................... 70
4.6.1 Switchover from NATURAL GAS to PROPANE .............................................................................................. 70
4.6.2 Switchover from PROPANE to NATURAL GAS .............................................................................................. 71
4.7 REASSEMBLY AFTER COMBUSTION CALIBRATION .............................................................................................. 72
CHAPTER 5. MODE OF OPERATION .................................................................................................. 73
5.1 INTRODUCTION ................................................................................................................................................... 73
5.2 INDOOR/OUTDOOR RESET MODE ....................................................................................................................... 73
5.2.1 Reset Ratio .................................................................................................................................................... 73
5.2.2 Building Reference Temperature ................................................................................................................. 73
5.2.3 Outdoor Air Temperature Sensor Installation .............................................................................................. 73
5.2.4 Indoor/Outdoor Reset Mode Startup ........................................................................................................... 73
5.3 CONSTANT SETPOINT MODE ............................................................................................................................... 74
5.3.1 Setting the Setpoint ...................................................................................................................................... 74
5.4 REMOTE SETPOINT MODES ................................................................................................................................. 75
5.4.1 Remote Setpoint Field Wiring ...................................................................................................................... 75
5.4.2 Remote Setpoint Startup .............................................................................................................................. 76
5.5 DIRECT DRIVE MODES ......................................................................................................................................... 76
5.5.1 Direct Drive Field Wiring............................................................................................................................... 77
5.5.2 Direct Drive Startup ...................................................................................................................................... 77
5.6 AERCO CONTROL SYSTEM (ACS) .......................................................................................................................... 77
5.6.1 ACS External Field Wiring ............................................................................................................................. 78
5.6.2 ACS Setup and Startup .................................................................................................................................. 78
5.7 COMBINATION CONTROL SYSTEM (CCS) ............................................................................................................. 78
5.7.1 Combination Control System Field Wiring ................................................................................................... 79
5.7.2 Combination Control System Setup and Startup .......................................................................................... 79
CHAPTER 6. SAFETY DEVICE TESTING ............................................................................................ 81
6.1 TESTING OF SAFETY DEVICES ............................................................................................................................... 81
6.2 LOW GAS PRESSURE FAULT TESTs ....................................................................................................................... 81
6.3 HIGH GAS PRESSURE FAULT TEST ........................................................................................................................ 83
6.4 LOW WATER LEVEL FAULT TEST .......................................................................................................................... 84
6.5 WATER TEMPERATURE FAULT TEST .................................................................................................................... 85
6.6 INTERLOCK TESTS ................................................................................................................................................ 87
6.6.1 Remote Interlock Test .................................................................................................................................. 87
6.6.2 Delayed Interlock Test .................................................................................................................................. 87
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6.7 FLAME FAULT TESTs ............................................................................................................................................ 87
6.8 AIR FLOW FAULT TESTS ....................................................................................................................................... 88
6.8.1 Blower Proof Switch Test ............................................................................................................................. 89
6.8.2 Blocked Inlet Switch Test .............................................................................................................................. 90
6.9 SSOV PROOF OF CLOSURE SWITCH ..................................................................................................................... 92
6.10 PURGE SWITCH OPEN DURING PURGE .............................................................................................................. 93
6.11 IGNITION SWITCH OPEN DURING IGNITION ...................................................................................................... 94
6.12 SAFETY PRESSURE RELIEF VALVE TEST............................................................................................................... 95
CHAPTER 7. MAINTENANCE ............................................................................................................... 97
7.1 MAINTENANCE SCHEDULE .................................................................................................................................. 97
7.2 PILOT BURNER ..................................................................................................................................................... 98
7.3 MAIN FLAME DETECTOR ...................................................................................................................................... 99
7.4 O2 SENSOR ......................................................................................................................................................... 100
7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT .................................................................... 101
7.5.1 Pilot Regulator Pressure Testing................................................................................................................. 101
7.5.2 Pilot Regulator Pressure Calibration ........................................................................................................... 103
7.6 SAFETY DEVICE TESTING .................................................................................................................................... 104
7.7 BURNER ASSEMBLY INSPECTION ....................................................................................................................... 105
7.8 REFRACTORY REMOVAL & REPLACEMENT ........................................................................................................ 108
7.8.1 Rear Refractory Removal & Replacement .................................................................................................. 109
7.8.2 Front Refractory Removal & Replacement ................................................................................................. 112
7.9 CONDENSATE DRAIN TRAP ................................................................................................................................ 114
7.10 AIR FILTER CLEANING & REPLACEMENT .......................................................................................................... 114
7.11 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................................................. 116
7.12 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN .................................................. 116
CHAPTER 8. TROUBLESHOOTING GUIDE ...................................................................................... 117
8.1 INTRODUCTION ................................................................................................................................................. 117
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ............................................................................ 130
CHAPTER 9. RS-232 COMMUNICATION ........................................................................................... 135
9.1 INTRODUCTION ................................................................................................................................................. 135
9.1.1 Aquiring the PuTTY Application .................................................................................................................. 135
9.1.2 Logging on to a Remote Machine Using PuTTY .......................................................................................... 135
9.1.3 Running a Command on a Remote Machine Using PuTTY ......................................................................... 136
9.2 RS-232 COMMUNICATION SETUP ..................................................................................................................... 137
9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ............................................................................... 137
9.4 DATA LOGGING .................................................................................................................................................. 138
9.4.1 Fault Log ..................................................................................................................................................... 138
9.4.2 Operation Time Log .................................................................................................................................... 139
9.4.3 Sensor Log .................................................................................................................................................. 140
CHAPTER 10. BOILER SEQUENCING TECHNOLOGY ...................................................................... 141
10.1 INTRODUCTION ............................................................................................................................................... 141
10.2 AERCO BST Quick Start Chart .......................................................................................................................... 142
10.3 BST Implementation Instruction ...................................................................................................................... 143
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor ............................................................ 143
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor......................................................... 144
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor ..... 145
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ...................... 147
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ............... 149
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive............. 150
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive ........................ 151
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive ..................... 153
APPENDIX A – BOILER MENU ITEM DESCRIPTIONS ................................................................................................. 155
APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES ........................................................................................ 161
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APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART ............................................................................................ 165
APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ...................................................................................... 167
APPENDIX E – BOILER DEFAULT SETTINGS .............................................................................................................. 171
APPENDIX F – DIMENSIONAL & CLEARANCE DRAWINGS ........................................................................................ 173
APPENDIX G – PART LIST DRAWINGS ...................................................................................................................... 175
APPENDIX H – PIPING DRAWINGS ........................................................................................................................... 193
APPENDIX I – C-MORE WIRING DIAGRAMS ............................................................................................................. 197
APPENDIX J – RECOMMENDED PERIODIC TESTING ................................................................................................ 205
APPENDIX K – C-MORE CONTROL PANEL VIEWS ..................................................................................................... 207
APPENDIX L – RECOMMENDED SPARES ................................................................................................................. 209
APPENDIX M – LONG TERM BLOWER STORAGE ..................................................................................................... 211
APPENDIX N – ULTRA-LOW NOx CALIBRATION ....................................................................................................... 213
LIMITED WARRANTY ............................................................................................................................. 217
This Page Is Intentionally Blank
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
Minimum
Maximum
Minimum
Maximum
FORWARD
FOREWORD
The AERCO Benchmark 6000 Dual Fuel (BMK 6000) MBH boiler is a modulating and
condensing unit. It represents a true industry advancement that meets the needs of today's
energy and environmental concerns. Designed for application in any closed loop hydronic
system, the Benchmark's modulating capability relates energy input directly to fluctuating system
loads. The maximum turn down ratio for this model is 15:1. This model provides extremely high
efficiency and makes it ideally suited for modern low temperature, as well as, conventional
heating systems.
The Benchmark 6000 operates within the following input and output ranges:
Input Range (BTU/hr.) Output Range (BTU/hr.)
400,000 6,000,000 372,000 5,670,000
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, the Benchmark 6000
boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the Benchmark 6000 offers 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 6000
MBH boiler.
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Building Automation System, often used interchangeably with EMS
(see below)
Symbol rate, or simply the number of distinct symbol changes
currently used in all
EMS
Energy Management System; often used interchangeably with BAS
IGN
Ignition
FORWARD
Phrases, Abbreviations and Acronyms
Phrase, Abbreviation
or Acronym
A (Amp) Ampere
ACS AERCO Control System, AERCO’s boiler management system
ADDR Address
AGND Anal og Ground
ALRM Alarm
ASME American Society of Mechanical Engineers
AUX Auxiliary
BAS
Baud Rate
BMK Benchmark series boilers
Meaning
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
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
Benchmark, Innovation and KC1000 Series product lines.
CO Carbon Monoxide
COMM (Comm) Communication
Cal. Calibration
CNTL Control
DBB
Double Block and Bleed. Used to define boiler gas trains containing 2
Safety Shutoff Valves (SSOVs) and a solenoid operated vent valve.
Also known as IRI gas trains(see below)
DIP Dual In-Line Package
FM Factor y Mutual. Used to define boiler gas trains.
GND Ground
HDR Header
HX Heat Exchanger
Hz Hertz (Cycles Per Second)
I.D. Inside Diameter
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
Meaning
sed to define gas
LN
Low NOx
duplex data transmission protocol developed by AEG
NPT
National Pipe Thread
FORWARD
Phrases, Abbreviations and Acronyms - Continued
IGST Board Ignition/Stepper Board contained in C-More Control Box
INTLK (INTL’K) Interlock
I/O Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
IP Internet Protocol
IRI
Industrial Risk Insurers. A now discontinued code u
trains containing two SSOVs and a solenoid operated vent valve.
ISO Isolated
LED Light Emitting Diode
MA (mA) Milliampere (1 thousandth of an ampere)
MAX (Max) Maximum
MBH Thousand BTUs per Hour
MIN (Min) Minimum
Modbus®
A serial, half-
Modicon
NC (N.C.) Normally Closed
NO (N.O.) Normally Open
NOx Nitrogen Oxide
O2 Oxygen
O.D. Outside Diameter
PMC Board
PPM Par ts Per Million
PTP Point-to-Point (usually over RS-232 networks)
PWM Pulse Width Modulation
REF (Ref) Reference
RES. Resistive
RS232
(or EIA-232)
RS422
(or EIA-422)
RS485
(or EIA-485)
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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 serial, half-duplex (HDX) transmission of data based on
the RS-485 Standard
Benchmark 6000 DF Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
Meaning
order to prevent reflections that may cause invalid data in the
FORWARD
Phrases, Abbreviations and Acronyms - Continued
RTN (Rtn) Return
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield
SSOV Saf ety Shut Off Valve
TEMP (Temp) Temperature
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network in
communication
VAC Volts, Alternating Current
VDC Volts, Direct Current
VFD Vacuum Fluor escent Display, or Variable Frequency Drive
W Watt
W.C. Water Co lumn
µA Micro amp (1 millionth of an ampere)
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
WARNING
WARNING
WARNING
WARNING
WARNING
CHAPTER 1 – SAFETY PRECAUTIONS
CHAPTER 1. SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conf orm 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 14 and 15 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 CAUS E 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 INTO
LIVING SPACES.
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ELECTRICAL VOLTAGES UP TO 480 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE COVER ON THE UNIT ’S POWER BOX
(LOCATED BEHIND T HE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
Benchmark 6000 DF Installation, Operation & Maintenance Manual
WARNING
CAUTION
CAUTION
CHAPTER 1 – SAFETY PRECAUTIONS
A THREE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNI T. THE SWITCH MUST BE INST ALLED 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 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
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VALVE OPEN
POSITION
VALVE CLOSED
POSITION
Benchmark 6000 DF Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
1.3 PROLONGED SHUTDOWN
If the boiler will be shut down for an extended period of time (one year or more), it is
recommended that the steps in Chapter 7, section 7.11 be performed to prepare the boiler.
After a prolonged shutdown, it is recommended that the steps in Chapter 7, section 7.12 be
performed. In addition, the startup procedures in Chapter 4 and the safety device test procedures
in Chapter 6 of this manual should be performed to verify that all s ystem-operating parameters
are correct. If there is an emergency, turn off the electrical power supply to the AERCO boiler
and close the manual gas valve located upstream of the unit. The installer must identify the
emergency shut-off device.
1.4 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.
• AERCO provides an optional external CO Detector, part number 58092. It
can be installed and configured to simply sound an alarm or to shut down
the boiler(s) if CO concentrations rise above a configurable threshold.
Contact your AERCO representative for details.
• 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 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:
• INSTALLATION OF CARBON MONOXIDE DET ECTORS. 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 t he services of q ualified licensed
professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a
crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thir ty (30) day period, a battery
operated carbon monoxide detector with an alarm shall be installed.
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CHAPTER 1 – SAFETY PRECAUTIONS
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 dir ectly 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:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in
the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room
or structure separate from the dwelling, building or structure used in whole or in part for
residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall horizontally vented gas equipment
provides a venting system design or venting system components with the equipment, the
instructions provided by the manufacturer for installation of the equipment and the venting
system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system
components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT
PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the flue gases, but identifies "special
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of the
installation.
[End of Extracted Information From 248 CMR 5.08 (2)]
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
the Benchmark 6000 boiler.
2.2 RECEIVING THE UNIT
Each Benchmark boiler system is shipped as a single crated unit. The shipping weight for the
Benchmark 6000 is approximately 3500 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 TipN-Tell indicator on t he outside of the shipping container. 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 MOVING & UNPACKING THE UNIT
While packaged in the shipping container, the unit can be moved using a forklift.
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either factory installed on the
unit or packed separately with 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 with the unit, factory installed on
the unit, or packed and shipped in a separate container. Any standard or optional accessories
shipped loose should be identified and stored in a safe place until ready for installation or use.
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SHIPPING SKID
CHAPTER 2 – INSTALLATION
Figure 2-1. Benchmark 6000 Mounted on Shipping Skid
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark boiler includes:
• Access to AC Input Power at 208 VAC, Three-Phase, 60 Hz @ 30 Amps
OR 460 VAC, Three-Phase, 60 Hz @ 20 Amps
• Access to both a NATURAL GAS and a PROPANE line at a minimum pressure of 14
inches W.C. with the unit in operation (approximately 20” W.C. static).
2.4.1 Installation Clearances
The Benchmark Model 6000 boiler dimensions and minimum acceptable clearances are shown
in Figure 2-2. 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:
• Front : 36 inches (914 mm)
• Sides: 24 inches (610 mm)
• Rear: 24 inches (610 mm)
• Top: 18 inches (457 mm)
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.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
Housekeeping pad
assembly
4” – 8”
CHAPTER 2 – INSTALLATION
IMPORTANT
Ensure that adequate clearance exists at the rear of the unit to permit
installation and service maintenance of the AERCO Condensate Trap. Refer
to section 2.7 for Condensate Trap installation details.
When using the AERCO Condensate Neutralizer Tank for condensate
drainage, the tank must be installed in a pit, OR the boiler and AERCO
Condensate Trap must be elevated higher than 4” above the floor. See
Condensate Neutralizer Tank Instructions TID-0074 for details.
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4” MINIMUM
Figure 2-2a. Benchmark Boiler Model 6000 Clearances
should not extend
under the condensate
Benchmark 6000 DF Installation, Operation & Maintenance Manual
WARNING
REAR
FRONT
CHAPTER 2 – INSTALLATION
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS
FOR MASSACHUSSETTS ONLY
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter who is licensed within the Commonwealth of Massachusetts. In
addition, the installation must comply with all requirements specified in
Chapter 1 – Safety Precautions.
2.4.2 Setting the Unit
The unit must be installed on a concrete housekeeping pad, a m i nimum of 4 inches and a
maximum of 8 inches thick, to ensure proper condensate drainage (see NOTE below).
NOTE
When using the AERCO Condensate Neutralizer Tank for proper
condensate drainage, the Neutralizer Tank must be stored in a pit , OR the
boiler and AERCO Condensate Trap must be elevated higher than 4” above
the floor. Ensure that t he condensate assembly is not positioned above the
housekeeping pad during installation so as not to interference with
condensate piping. See Condensate Tank Instructions TID-0074 for details.
If anchoring the unit, refer to Figure 2-2b for anchor bolt locations.
.
• All holes are flush with the bottom surface of the frame.
• All dimensions shown are in inches [millimeters]
Figure 2-2b. Benchmark 6000 Anchor Bolt Locations
Two (2) lifting lugs are provided at the top of the primary heat exchang er as shown in Figure 2-3.
Cut the cardboard at marked locations to provide access to the lifting tabs.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
WARNING
LIFTING TABS
TOP VIEW WITH TWO TOP PANELS REMOVED
NOTE:
Remove the four (4) lag screws securing the unit to the shipping skid, and, if still in place,
remove the front and r ear Top Panels. Lift the unit off the shipping skid and position it on the
concrete Housekeeping Pad (required) in the desired location.
WHEN LIFTING OR MOVING THE BOILER: DO NOT ATTEMPT
TO MANIPULATE THE BOILER USING THE GAS TRAIN OR
BLOWER. A SPREADER BAR IS REQUIRED FOR ALL
VERTICAL LIFTS.
Remove the two top panels
to access the lifting tabs.
CHAPTER 2 – INSTALLATION
Figure 2-3. 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 m ust 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 t hem in the proper physical location. Refer to Chapter 5 for
information on Combination Mode Boilers.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
6” WATER
AIR INLET
6” WATER
2” NATURAL
EXHAUST
CONDENSATE
DRAIN
2” PROPANE
CHAPTER 2 – INSTALLATION
2.5 SUPPLY AND RETURN PIPING
The Benchmark boiler utilizes 6” flanged fittings for the water system supply and return piping
connections. The physical location of the supply and return piping connections are shown in
Figure 2-4. For dimensional data, refer to Drawing AP-A-901 in Appendix F.
OUTLET
INLET
GAS INLET
INLET
Figure 2-4. Supply and Return Locations
2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR INSTALLATION
2.6.1 Pressure Relief Valve Installation
Depending on the pressure required, the Benchmark 6000 is supplied with either a single 2” or
two (2) 1¼“ ASME rated Pressure Relief Valves. The pressure rating for the relief valve must be
specified on the sales order. Available press ure ratings range from 30 psi to 160 psi, depending
on pressure vessel maximum rated pressure. Each pressure relief valve is furnished as a kit
(92102-Tab) which consists of the relief valve for the pressure rating specified on the Sales
Order. The appropriate size reducing bushing and nipple are also included in the kit. The
pressure relief valves, nipples and bushings are connected to 45º street elbows already installed
on the heat exchanger of the boiler. The relief valves are installed on the top of the boiler as
shown in Figure 2-5A. A suitable pipe joint compound should be used on all threaded
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
PRESSURE RELIEF
CHAPTER 2 – INSTALLATION
connections. Any excess should be wiped off to avoid getting any joint compound into the valve
body. Each relief valve must be piped to within 12 inches of the floor to prevent injury in the
event of a discharge. The discharge piping m ust be full size, without reduction. No valve or size
reductions 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.
VALVES
Figure 2-5A. Pressure Relief Valve Installation Locations
2.6.2 Pressure/Temperature Gauge Installation
A manual Pressure/Temperature Gauge is included in the loose parts kit for installation for
installation in the boiler outlet piping. It must be installed so that the sensing bulb is inserted into
the hot water outlet flow from the boiler. Refer to Figure 2-5B for sample installations.
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Figure 2-5B. Pressure/Temperature Gauge Installation Location
Benchmark 6000 DF Installation, Operation & Maintenance Manual
ANALYZER PORT S
EXHAUST
CONDENSATE
2” NATURAL GAS
2” PROPANE INLET
CHAPTER 2 – INSTALLATION
2.7 CONDENSATE DRAIN & PIPING
The Benchmark boiler is designed to condense water vapor from the flue products. Therefore,
the installation must have provisions for suitable condensate drainage or collection.
The condensate drain port is located on the exhaust manifold (Figure 2-6) at the rear of the unit.
This drain port must be connected to the condensate trap (part no. 24060), which is packed
separately within the unit’s shipping container. The condensate trap outlet connection features a
tapped 3/4” NPT drain port.
INLET
MANIFOLD
(2, one on each side)
Figure 2-6. Partial Rear View – Condensate Drain Location
A sample condensate trap installation is shown in Figure 2-7. However, the actual installation
details for the trap will vary depending on the available clearances, housekeeping pad height/
dimensions and other prevailing conditions at the site. The following general guidelines must be
observed to ensure proper condensate drainage:
• The condensate trap inlet (Figure 2-7) 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:
Condensate Trap Installat ion
1. Connect the condensate trap inlet to the exhaust manifold drain connection by sliding the
trap inlet onto the drain port. Tighten the thumbscrew on the trap inlet.
2. At the condensate trap outlet, install a stainless steel or PVC 3/4” NPT nipple.
3. Connect a length of 1” I.D. polypropylene hose to the trap outlet and secure with a hose
4. Route the hose on the trap outlet to a nearby floor drain.
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clamp.
Benchmark 6000 DF Installation, Operation & Maintenance Manual
CAUTION
WARNING
CAUTION
COMBUTION
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLES
DRAIN
TRAP (P/N 24060)
TOP
(4 each)
1” DIAM.
HOSE
ASSEMBLY.
TRAP INLET
EXHAUST
gravity flow
CHAPTER 2 – INSTALLATION
If a floor drain is not available, a condensate pump can be used to remove the condensate to
drain. The maximum condensate flow rate is 40 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
INT E G RAL ADAPT OR
AND THUMBSCREW
COVER
THUMB
SREWS
CONDENSATE
NOTE
HOUSKEEPING
PAD MUST NOT
EXTEND
UNDER THE
CONDENSATE
2.8 GAS SUPPLY PIPING
The AERCO Benchmark Gas Supply Design Guide, GF-2030 must be consulted prior to
designing or installing any gas supply piping.
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MANIFOLD
DRAIN PORT
Tilt down 2° for
T O
FLOOR
Figure 2-7. Sample Condensate Trap Installation – Side View
NEVER USE MATCHES, CANDLES, FLAMES OR OTHER
SOURCES OF IGNITION TO CHECK FOR GAS LEAKS
.
Many soaps used for gas pipe leak testing are corrosive to metals.
Therefore, piping must be rinsed thoroughly with clean water after leak
checks have been completed.
Benchmark 6000 DF Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
NOTE
All gas piping must be arranged so that it does not interfere with removal of
any covers, inhibit service/maintenance, or restrict access between the unit
and walls, or another unit.
Benchmark 6000 DF units contain a 2 inch natural gas inlet and a 2 inch propane gas inlet on the
back of the unit, as shown in Figure 2-4.
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 and propane, should be used.
Any excess must be wiped off to prevent clogging of components.
To avoid unit damage when pressure testing gas piping, isolate the unit from the gas supply
piping. At no time should the gas pressure applied to the unit exceed 56” W.C. (2 psig). Leak
test all external piping thoroughly using a soap and water solution or suitable equivalent. The gas
piping used must meet all applicable codes.
2.8.1 Gas Supply Specifications
The gas supply input specifications to the unit for both NATURAL GAS and PROPANE gas are
as follows:
• The maximum static pressure to the unit must not exceed 56 inches W.C. (2 psi).
• The gas supply pressure to the unit must be sufficient to provide 6000 cfh while
maintaining a gas pr essure of 14 inches W.C. for FM gas trains while in operation.
2.8.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply lines upstream of the boiler as shown
in Figure 2-8. Maximum allowable gas pressure to the boiler is 56” W.C. (2 psi).
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 regulator must be capable of regulating 300,000 – 6,000,000
BTU/HR of natural gas while maintaining a gas pressure of 14” W.C. minimum to the unit.
• A lock-up style regulator MUST be used on all Benchmark 6000 DF units.
NOTE
The external regulator must be capable of regulating 300,000 – 6,360,000
BTU/HR of natural ga s while maintaining a gas pressure of 14” W.C. to the
unit while in operation.
2.8.3.1
For Massachusetts installations, a mandatory external gas supply regulator must be positioned
as shown in Figure 2-8. 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.
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Massachusetts Installations Only
Benchmark 6000 DF Installation, Operation & Maintenance Manual
NATURAL
PROPANE
MANUAL
GAS PRESSURE REGULATORS
CHAPTER 2 – INSTALLATION
2.8.3.2 All Installations (Except Massachusetts)
For all installations (other than Massachusetts) that EXCEED 1 PSI gas pressure, a mandatory
external gas supply regulator must be positioned as shown in Figure 2-8. No regulator is required
for gas pressures below 1 PSI of pressure. Consult the local gas utility for detailed requirements
concerning venting of the supply gas regulator.
GAS
SUPPLY
GAS
SUPPLY
SHUT-OFF
VALVES
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. Rem ove the unit’s front panel to access the Power
Box, which is mounted in the upper right corner of t he unit as shown in Figure 2-9. Loosen the
four Power Box cover screws and remove the cover to access the AC terminal block
connections, and other internal components shown in Figure 2-10.
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Figure 2-8. Manual Gas Shut-Off Valve Location
Benchmark 6000 DF Installation, Operation & Maintenance Manual
PARTIAL FRONT VIEW
TERMINAL BLOCKS
CHAPTER 2 – INSTALLATION
TRANSFORMER
24V POWER
SUPPLY
12V POWER
SUPPLY
FUSE BLOCKS (2)
Figure 2-9. Power Box With Cover Closed
WIRE CONDUITS
POWER
BREAKER
With the exception of the transformer shown in Figur e 2-10, all of the components in the Power
Box are mounted on a DIN rail.
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Figure 2-10. Power Box Internal Components (Cover Removed)
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.
Benchmark 6000 DF Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
2.9.1 Electrical Power Requirements
The Benchmark boiler is available in two voltage configurations:
• 208 VAC, three-phase, 60 Hz @ 30A
• 460 VAC, three-phase, 60 Hz @ 15A.
The Power Box contains terminal blocks as shown in Figure 2-10. In addition, a label showing
the required AC power connections is provided on the front cover of the Power Box, as shown in
Figure 2-11.
Figure 2-11 Power Box Cover Labels – 208VAC (Left) and 460VAC (Right)
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD
BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.
A double-pole switch must be installed on the electrical supply line in an easily accessible
location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet
metal enclosures of the unit.
After placing the unit in service, the ignition safety shutoff device must be tested. If an external
electrical power source is used, the installed boiler must be electrically bonded to ground in
accordance with the requirements of the authority having jurisdiction. In the absence of such
requirements, the installation shall conform to National Electrical Code (NEC), ANSI/NFPA 70
and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.
For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF-
2060).
2.10 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an internal operating control system. No field control
wiring is required for normal operation. However, the C-More Control system used with all
Benchmark units does allow for some additional control and monitoring features. Wiring
connections for these features are made on the Input/Output (I/O) board located behind the
removable front panel assembly of the unit. The I/O board is located in the I/O Box. The I/O
board terminal strip connections are shown in Figure 2-13. All f ield wiring is installed fr om the
rear of the panel by routing the wires through one of the four bushings provided on the sides of
the I/O board.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
CAUTION
TERMINAL STRIPS
COVER SCREWS (X2)
CHAPTER 2 – INSTALLATION
Refer to the wiring diagram provided below the I/O Box (Figure 2-13) when making all wiring
connections.
I/O PCB
BOARD
FRONT VIEW
Figure 2-12. Input/Output (I/O) Box Location
NOTE
Use Figure 2-13 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. T here 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.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
Figure 2-13. I/O Box Terminal Strips
2.10.1 OUTDOOR AIR IN Terminal
An OUTDOOR AIR IN terminal is used f or connecting an outdoor temperature sensor (AERCO
Part No. 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 SENSOR COMMON terminals of the I/O Box (see Figure 2-13).
Wire the sensor using a twisted shielded pair wire between 18 and 22 AWG. There is no polarity
to observe when terminating these wires. The shield is to be connected only to the terminals
labeled SHIELD in the I/O Box. The sensor end of the shield must be left free and ungrounded.
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 f rom direct sunlight
as well as impingement by the elements. If a shield cover is used, it must allow for free air
circulation.
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Benchmark 6000 DF Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
2.10.2 COMBUSTION AIR Terminal
The COMBUSTION AIR terminal is used to m onitor the combustion air temperature sensor . T h is
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 Part No. 12449. A resistance chart for this sensor is
provided in APPENDIX C. This sensor is an active part of the combustion control system and
must be operational for accurate air/fuel mixing control.
2.10.3 O2 SENSOR Terminals
The O2 SENSOR (–) and O2 SENSOR (+) terminals are used to connect an external oxygen
sensor to the I/O box. The O
Control system after a 60 second warm-up period.
2.10.4 SPARK SIGNAL Terminals
The SPARK SIGNAL terminals are not in use on the Benchmark 6000.
2.10.5 ANALOG IN Terminals
The ANALOG IN terminals (+ and –) 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-More
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 Control Box. Refer to Appendix D of the C-More Control Panel
OMM, GF-112, for information on setting DIP switches.
All supplied signals must be floating (ungrounded) signals. Connections between the source and
the boiler’s I/O Box must be made using twisted shielded pair of 18–22 AWG wire such as
Belden 9841. Polarity must be maintained and the shield must be connected only at the source
end and must be left floating (not connected) at the boiler’s I/O Box.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to 240°F
setpoint or a 0% to 100% air/fuel valve position. No scaling for these signals is provided
2.10.6 B.M.S. (PWM) IN Terminals
The two B.M.S. (PWM) IN terminals are only used to connect the legacy AERCO Boiler
Management Systems (BMS), which utilize a 12 millisecond, ON/OFF duty cycle and is Pulse
Width Modulated (PWM) to control valve position. A 0% valve position = a 5% ON pulse and a
100% valve position = a 95% ON pulse. Note that these connections cannot be used with the
ARECO Control System (ACS).
2.10.7 SHIELD Terminals
The two SHIELD terminals are used to terminate any shields used on sensor wires connected t o
the unit. Shields must only be connected to these terminals.
2.10.8 ANALOG OUT Terminals
The ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor
Setpoint, Outlet Temperature, Valve Position 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 30 of 219 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0096_0B
03/21/2014 Ph.: 800-526-0288 GF-141
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