Watts AERCO Benchmark BMK4000 Installation And Start-Up Manual Download

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Benchmark Platinum-Edge [ii]: Installation Manual

APPENDIX A

– DIMENSIONAL AND CLEARANCE DRAWINGS

OMM-

136_G • GF-210 • 8/20/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

Benchmark 5000-6000 Zero-Side Clearance Drawing SD-A-919 rev F

Summary of Contents for AERCO Benchmark BMK4000

Page 1: ...0 Boiler Application Guide TAG 0022 GF 2050 Vent Combustion Air Guide TAG 0047 GF 2030 Benchmark Gas Guide TAG 0048 GF 2060 Benchmark Power Guide Applies to serial numbers G 20 1800 and above BMK750 5...

Page 2: ...6 SUPPLY AND RETURN PIPING 23 2 6 1 BMK750 1000 Supply and Return Piping 23 2 6 2 BMK1500 5000N Supply and Return Piping 23 2 6 3 BMK5000 6000 Supply and Return Piping 25 2 6 4 Dual Inlet Return Pipin...

Page 3: ...8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 3 of 62 3 1 INTRODUCTION 47 3 1 1 Connecting the Ethernet Cable 47 3 1 2 Confirming the Ethernet Connection 48 3 1 3 Confirm Etherne...

Page 4: ...Benchmark Platinum Edge ii Installation Manual CONTENTS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 4 of 62 This page intentionally blank...

Page 5: ...00 440 kW 64 500 18 9 kW 1 395 000 409 kW BMK2000 100 000 29 3 kW 2 000 000 586 kW 86 000 25 2 kW 1 860 000 545 kW BMK2500 167 000 48 9 kW 2 500 000 732 kW 144 000 42 2 kW 2 395 000 702 kW BMK3000 200...

Page 6: ...imply 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 BMK Benchmark AERCO s Benchmark series boilers B...

Page 7: ...ut Output I O Box Input Output I O Box currently used on Benchmark boilers IP Internet Protocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN L...

Page 8: ...data based on the RS232 Standard RS485 or EIA 485 A standard for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shie...

Page 9: ...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 an...

Page 10: ...remote shutdown switch or circuit breaker marked for easy identification at a location readily accessible in the event of boiler mis operation Design the system so activation of the emergency shutdown...

Page 11: ...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 i...

Page 12: ...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 insta...

Page 13: ...pping container the unit must be moved by pallet jack or forklift from the front only NOTE AERCO is not responsible for lost or damaged freight Each unit has A Tip N Tell indicator on the outside of t...

Page 14: ...quired by AERCO are listed below for all models However if Local Building Codes require additional clearances these codes shall supersede AERCO s requirements The minimum acceptable clearances require...

Page 15: ...nical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 15 of 62 Figure 2 1a BMK750 1000 Clearances Figure 2 1b BMK1500 2000 Clearances NOTE Ensure that condensate assembly is not located over the house...

Page 16: ...t 800 526 0288 Mon Fri 8 am 5 pm EST Page 16 of 62 Figure 2 1c BMK2500 3000 Clearances Figure 2 1d BMK4000 5000N Clearances Housekeeping Pad NOTE Ensure that condensate assembly is not located over th...

Page 17: ...nd 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 additio...

Page 18: ...nstallation Manual SECTION 2 INSTALLATION OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 18 of 62 Figure 2 2a BMK750 1000 Anchor Bolt Locations Figure 2 2b BMK150...

Page 19: ...NSTALLATION OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 19 of 62 Figure 2 2c BMK2500 3000 Anchor Bolt Locations Figure 2 2d BMK4000 5000N Anchor Bolt Locations...

Page 20: ...k 1500 to 6000 4 to 8 inches 10 2 to 20 3 cm If you are using the AERCO Condensate Neutralizer Tank P N 89030 you must ensure enough height for the condensate to drain into the condensate trap then in...

Page 21: ...low WARNING When using the lifting tab and bar ensure there is no load placed on the gas train or blower Attaching the Lifting Bar BMK750 1000 Instructions 1 Remove the lifting bar from its shipping l...

Page 22: ...o 2 lifting lugs are provided at the top of the primary heat exchanger see Figure 2 3c The location of the lifting tabs is marked on the shrink wrap coving the unit for shipping Remove the four 4 lag...

Page 23: ...on the rear of the unit as shown in Figure 2 4a Figure 2 4a BMK750 1000 Supply and Return Locations 2 6 2 BMK1500 5000N Supply and Return Piping Benchmark 1500 3000 units have the following inlets and...

Page 24: ...owing gas inlet pipes o 3 7 62 cm Natural Gas inlet pipe o 1 5 3 81 cm Propane inlet pipe 10 25 4 cm Air Inlet adapter Figure 2 4b BMK1500 5000N Supply and Return Locations CONDENSATE DRAIN HOT WATER...

Page 25: ...urn temperature zone or AERCO SmartPlate thermal efficiency can improve by up to 6 based on an 80 F 26 7 C minimum return water temperature at full fire Lower return temperatures are possible which wo...

Page 26: ...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 the floor to prev...

Page 27: ...a union be utilized between the exhaust manifold condensate drain port and the trap inlet port If the condensate trap does not connect directly to the exhaust manifold condensate drain port the pipe b...

Page 28: ...OBE PORT 3 4 NPT NIPPLE HOSE CLAMP CONDENSATE TRAP P N 24441 1 DIAM HOSE 3 4 NPT NIPPLES UNION EXHAUST MANIFOLD TO CONDENSATE NEUTRALIZER TRAP INLET INTEGRAL ADAPTOR AND THUMBSCREW TOP COVER THUMB SCR...

Page 29: ...f unit 3 inch 7 62 cm LGP in back of unit 1 1 2 inch 3 81 cm on top of unit Prior to installation all pipes should be de burred and internally cleared of any scale metal chips or other foreign particl...

Page 30: ...rmation On all Benchmark models it is strongly recommended that the pressure regulator be installed a minimum distance of 10 pipe diameters between the pressure regulator and the nearest downstream fi...

Page 31: ...7c BMK1500 5000N Gas Regulator and Manual Shut Off Valve Dual Fuel GAS INLET GAS PRESSURE REGULATOR MANUAL SHUT OFF VALVE NATURAL GAS INLET NATURAL GAS INLET NATURAL GAS PRESSURE REGULATOR PROPANE MA...

Page 32: ...ply regulator must be positioned as shown in Figure 2 7a 2 7d The gas supply regulator must be properly vented to outdoors Consult the local gas utility for detailed requirements concerning venting of...

Page 33: ...z 20 BMK2500 3000 Domestic 208 V 3 60 Hz 20 460 V 3 60 Hz 15 BMK2500 3000 International 380 415 V 3 50 60 Hz 15 BMK4000 5000N Domestic 208V 3 60 Hz 40 480V 3 60 Hz 20 BMK5000 6000 Domestic 208 V 3 60...

Page 34: ...urce 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 sh...

Page 35: ...ny unit covers inhibit service maintenance or prevent access between the unit and walls or another unit 2 11 FIELD CONTROL WIRING I O Board Each unit is fully wired from the factory with an internal o...

Page 36: ...ximum gauge of wires connecting to the I O board is 14 J24 SPARK MONITOR FROM SHELL HARNESS 63216 2 CONNECTOR J9 I O BOARD POWER HARNESS 63232 CONNECTOR J24 VALVE HARNESS INTERLOCK FROM SHELL HARNESS...

Page 37: ...riable Primary application Secondary Loop in a Primary Secondary application Loop 1 in a Multi application Typically used on Manager and Backup Manager units For more information refer to the Benchmar...

Page 38: ...rtPlate Valve input Swing V1 feedback Swing V2 Feedback VS Pump Feedback Variable Speed Pump Feedback Remote Setpoint 2 DHW VSP Fdbk To assign program its function go to the Controller s Main Menu Adv...

Page 39: ...r To assign program its function go to the Controller s Main Menu Advanced Setup Ancillary Devices Relays then set the Relay to Spare 2 Relay and the Name to one of the above devices 2 Spare 2 Relay C...

Page 40: ...es the flue must be pitched back towards the unit a minimum of 1 4 per foot 0 64 cm per 0 3 m to avoid any condensate pooling and to allow for proper drainage While there is a positive flue pressure d...

Page 41: ...free area must take into account restrictions such as louvers and bird screens For Canada installations refer to the requirements specified in CSA B149 1 10 sections 8 4 1 and 8 4 3 2 13 1 DUCTED COM...

Page 42: ...onsists of installing the sequencing isolation valve in the hot water outlet pipe and then connecting it to the pre wired connector on the shell harness as described below NOTE The Sequencing Isolatio...

Page 43: ...Signal 1236 Black 24V Common 1237 Red 24V Hot 1238 White Valve analog input 1239 Green Valve analog feedback 1240 Black Delayed interlock 1241 Black 3 Remove and dispose of the cap with jumper wire at...

Page 44: ...chmark Platinum s power panel includes a secondary output board with a pump relay that is designed to operate a boiler pump This relay provides 120VAC with a maximum pilot duty of 3 amps If the pump p...

Page 45: ...led per the instructions above the next steps are Optionally implement the onAER option which allows your unit to be monitored remotely To implement this option complete the instructions in the next s...

Page 46: ...Benchmark Platinum Edge ii Installation Manual SECTION 2 INSTALLATION OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 46 of 62 This page intentionally blank...

Page 47: ...ctions below provide instructions for implementing only the first option enabling communication through an Ethernet cable connected to the site s network If you ordered a Benchmark Platinum boiler wit...

Page 48: ...thernet Connection Refer to Figure 3 2 below and complete the following instructions to confirm that the Ethernet cable connection is working Confirming the Ethernet Connection Instructions 1 Powered...

Page 49: ...t DHCP Configuration Instructions 1 Connect your computer to the network jack that will be used by the Edge Controller Your computer should be configured to automatically get a network address Boot or...

Page 50: ...Benchmark Platinum Edge ii Installation Manual SECTION 3 ONAER SETUP OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 50 of 62 This page intentionally blank...

Page 51: ...nual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 51 of 62 Appendix A Dimensional and Clearance Drawings Benchmark...

Page 52: ...i Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 52 of 62 Benchmark 750 1000 Single Unit Clearan...

Page 53: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 53 of 62 Benchmark 750 1000 Zero Side Clearanc...

Page 54: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 54 of 62 Benchmark 1500 2000 Dimension Drawing...

Page 55: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 55 of 62 Benchmark 1500 2000 Clearance Drawin...

Page 56: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 56 of 62 Benchmark 2500 3000 Dimension Drawin...

Page 57: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 57 of 62 Benchmark 2500 3000 Clearance Drawin...

Page 58: ...Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 58 of 62 Benchmark 4000 5000N Platinum Dimension...

Page 59: ...tallation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 59 of 62 Benchmark 4000 5000N Clearance Dimensional...

Page 60: ...dge ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 60 of 62 Benchmark 5000 6000 Dimension Dra...

Page 61: ...i Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_G GF 210 8 20 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 61 of 62 Benchmark 5000 6000 Zero Side Clearanc...

Page 62: ...nts in Section 2 4 in favor of references to Benchmark Electrical Power Design Guide TAG 0048 GF 2060 Benchmark Gas Supply Design Guide TAG 0047 GF 2030 Added new Section 2 4 3 Housekeeping Pad Requir...

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