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Benchmark 5000-6000 Boiler Installation & Startup Manual

 

 SECTION 2:

  INSTALLATION 

 

 

OMM-0123_E   

•   GF-207  •   12/17/2019             Technical Support  •  (800) 526-0288  •  Mon-Fri, 8 am - 5 pm EST            Page 

33

  of 

95

 

   

 

Figure 2-15:  Pump Relay Location  

 

 

 

 

 

Figure 2-16:  Schematic 

 System Pump Start using Boiler Pump Relay 

 

If pump/valve load exceeds the above contact ratings, use a separate contact relay, as shown in 
Figure 2-17. 

 

Figure 2-17:  Schematic 

 System Pump Start using a Separate Contact Relay 

 

The Benchmark pump relay (SPDT) contact is rated for: 

10 A Resistive @ 277 VAC/28 VDC 

1/3 HP N/O @ 120/240 VAC 

1/6 HP N/C @ 120/240 VAC 

480 VAC Pilot Duty @ 240-277 VAC Pilot Duty 

Heating Pump  
 

Pump Relay Terminals 
 

(Orange) 

– N/O 

(Yellow) - COM 

Contact Relay 
(Supplied by Others) 
 

N  

 

 

POWER PUMP(S) FROM 
INDEPENDENT FUSED 
CIRCUITS 
 

(Orange) 

– N/O 

(Yellow) - COM 

Heating Pump  

Pump Relay Terminals 

POWER BOX 

PUMP RELAY 

Summary of Contents for Aerco Benchmark OMM-0124

Page 1: ...Power Guide Applies to serial numbers N 19 0001 and above Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty...

Page 2: ...ATE DRAIN AND PIPING 20 2 9 GAS SUPPLY PIPING 22 2 9 1 Gas Supply Specifications 22 2 9 2 Manual Gas Shutoff Valve 22 2 9 3 External Gas Supply Regulator 22 2 10 AC ELECTRICAL POWER WIRING 24 2 10 1 E...

Page 3: ...7 DUAL FUEL SWITCHOVER 58 4 7 1 Switchover from NATURAL GAS to PROPANE 59 4 7 2 Switchover from PROPANE to NATURAL GAS 60 4 8 OVER TEMPERATURE LIMIT SWITCHES 61 4 8 1 Digital Alarm Switch Checks and A...

Page 4: ...tdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor 83 6 3 5 OPTION 5 Remote Setpoint With Direct Wired Header Sensor And 4 20ma Setpoint Drive 85 6 3 6 OPTION 6 Remote Setpoint With Direc...

Page 5: ...rk 5000 and 6000 Intake and Output Ranges MODEL INPUT RANGE BTU HR OUTPUT RANGE BTU HR MINIMUM MAXIMUM MINIMUM MAXIMUM 5000 400 000 117 kW 5 000 000 1465 kW 348 000 102 kW 4 750 000 1392 kW 6000 400 0...

Page 6: ...ement Systems BLDG Bldg Building BST AERCO on board Boiler Sequencing Technology BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound 0 45 kg of water 1...

Page 7: ...rotocol 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 MBH 1000 B...

Page 8: ...based on the RS422 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 Shield SPD...

Page 9: ...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 p...

Page 10: ...than a boiler room provide a manually operated remote shutdown switch or circuit breaker marked for easy identification at a location readily accessible in the event of boiler mis operation Design the...

Page 11: ...ed 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 al...

Page 12: ...sign 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 th...

Page 13: ...ight 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 The unit is shippe...

Page 14: ...static PROPANE GAS Dual Fuel and Propane only units Access to 1 1 2 inch 3 8 cm line with a minimum pressure of 14 inches W C 3 49 kPa with the unit at FULL FIRE approximately 20 W C 4 98 kPa static...

Page 15: ...equate clearance exists at the rear of the unit to permit installation and service maintenance of the AERCO Condensate Trap Refer to Section 2 8 for Condensate Trap installation details When using the...

Page 16: ...s must be installed on a level 4 to 8 inch 10 2 to 20 3 cm thick housekeeping pad to ensure proper condensate drainage If anchoring the unit refer to Figure 2 3 for anchor locations NOTE When using th...

Page 17: ...the gas train or blower A spreader bar is required for all vertical lifts Failure to use a spreader bar can put excessive force on the unit and can cause boiler failure Figure 2 4 Lifting Lug Locatio...

Page 18: ...e 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 See Sections 2 12 and 2 13 for info...

Page 19: ...ected to 45 street elbows already installed on the heat exchanger of the boiler The relief valve is installed on the top of the boiler as shown in Figure 2 6 A suitable pipe joint compound should be u...

Page 20: ...hipping container The condensate trap outlet connection features a tapped 3 4 NPT drain port Figure 2 8 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2...

Page 21: ...olypropylene hose to the trap outlet and secure 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...

Page 22: ...ed 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 exce...

Page 23: ...nstallations Except Massachusetts For installations with 3 or more units other than Massachusetts that exceed 1 PSI 6 9 kW gas pressure a separate external gas supply regulator as shown in Figure 2 10...

Page 24: ...rical 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...

Page 25: ...ocks as shown in Figure 2 12 With the exception of the transformer all of the components in the Power Box are mounted on a DIN rail NOTE All electrical conduit and hardware must be installed so that i...

Page 26: ...d monitoring features Wiring connections for these features are made on the Input Output I O board located behind unit s removable front panel The I O board is located in the I O Box The I O board ter...

Page 27: ...enable disable feature which 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...

Page 28: ...ory default setting is 4 to 20 mA 1 to 5 VDC however this may be changed to 0 to 20 mA 0 5 VDC in the Configuration menu see Section 2 6 CONFIGURATION Menu item 6 in the Benchmark 5000 6000 Operation...

Page 29: ...valve A 0 20 mA signal is used 20 mA closed 0 mA open NOTE When driving an isolation valve shorting jumper JP2 MUST be installed on the I O Board On older legacy Benchmark units the two ANALOG OUT te...

Page 30: ...layed interlock is connected to a proving device that requires time to close make a time delay AUX START ON DLY that holds the start sequence of the unit long enough for a proving switch to make close...

Page 31: ...AG 0022 GF 2050 for additional information While there is a positive flue pressure during operation the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet 42...

Page 32: ...for the BMK 5000 The free area must take into account restrictions such as louvers and bird screens For Canada installations refer to the requirements specified in CSA B149 1 10 sections 8 4 1 and 8 4...

Page 33: ...ratings use a separate contact relay as shown in Figure 2 17 Figure 2 17 Schematic System Pump Start using a Separate Contact Relay The Benchmark pump relay SPDT contact is rated for 10 A Resistive 27...

Page 34: ...for a programmed interval default 1 minute then closes When the system load is satisfied the BST system will open the isolation valves for all of the boilers The implementation of BST and the install...

Page 35: ...d inside the unit s enclosure One end is connected to the DELAYED INTERLOCK IN terminals in the I O board while the other end contains a Molex connector with a cap containing a jumper wire inserted in...

Page 36: ...nchmark 5000 6000 Boiler Installation Startup Manual SECTION 2 INSTALLATION OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 36 of 95 This page intentionally blan...

Page 37: ...ull water level can seriously damage the unit and may result in injury to personnel or property damage This situation will void any warranty CAUTION All of the installation procedures in Section 2 mus...

Page 38: ...ty device switches closed a purge cycle will be initiated and the following events will occur a The Blower relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge p...

Page 39: ...vents occur a The Air Fuel Valve rotates to the low fire Ignition Position position and closes the ignition switch The dial on the Air Fuel Valve will read between 45 and 50 see Figure 3 4 to indicate...

Page 40: ...stream SSOV actuator 7 A maximum of 14 seconds are allowed for the entire ignition sequence from applying power to the ignition transformer through actual Burner flame establishment The igniter relay...

Page 41: ...ore Controller Scanner Power Ignition Power SSOV Power Pilot Valve Closed Pilot Valve Open Ignition Transformer Off Ignition Transformer On UV Scanner Powered UV Scanner Ignored UV Scanner In Use Rela...

Page 42: ...s section show the relationship between the energy input and Air Fuel Valve position for the BMK models covered in this document 3 4 1 Benchmark 5000 Air Fuel Valve Position and Energy Input BMK 5000...

Page 43: ...Input BTU Hr of Full Capacity 0 0 0 10 0 0 18 Stop Level 385 000 113 kW 6 20 400 000 117 kW 7 30 540 000 158 kW 9 40 770 000 226 kW 13 50 1 160 000 340 kW 19 60 1 650 000 484 kW 28 70 2 386 000 699 k...

Page 44: ...Energy Input Charts Figure 3 5 Relationship Between BMK 5000 Air Fuel Valve Position and Energy Input Figure 3 6 Relationship Between BMK 6000 Air Fuel Valve Position and Energy Input 0 1 000 000 2 00...

Page 45: ...000 6000 Boiler Installation Startup Manual SECTION 3 START SEQUENCE OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 45 of 95 Figure 3 7 Burner Ignition Sequence...

Page 46: ...chmark 5000 6000 Boiler Installation Startup Manual SECTION 3 START SEQUENCE OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 46 of 95 This page intentionally bla...

Page 47: ...a unit without the proper piping venting or electrical systems can be dangerous and may void the product warranty The following start up instructions should be followed precisely in order to operate...

Page 48: ...se with gas supply manometer or gauge Small and large flat blade screwdrivers Tube of silicone adhesive 4 2 2 Installing Gas Supply Manometer The gas supply manometer or gauge is used to monitor the g...

Page 49: ...ively you can remove the 1 4 inch plug shown in Figure 4 1 above and install a hose barb fitting in that location 4 Attach one end of the plastic tubing to the port or barbed fitting and the other end...

Page 50: ...e is proven by two Pilot Flame Detectors located above and below the Pilot The two Pilot Flame Detectors are optical sensors inserted into tubes with quartz windows they observe the Pilot through hole...

Page 51: ...gure 4 3 Gas Pressure Adjustment Screw and TAC Screw Location 4 5 1 NATURAL GAS Combustion Calibration The instructions below apply only to units running on NATURAL GAS Instructions for doing combusti...

Page 52: ...ve the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Make gas pressure adjustments using a flat tip screwdriver to obtain a gas pressure in the range specif...

Page 53: ...ey increases the oxygen level and pressing the down arrow key decreases the oxygen level 25 Once the oxygen level is within the specified range at 100 press the ENTER key to store the selected blower...

Page 54: ...5 5 5 0 5 20 ppm 6 0 1 0 9 ppm 100 ppm 50 65 5 5 0 5 20 ppm 6 0 1 0 9 ppm 100 ppm 40 45 5 5 0 5 20 ppm 6 0 1 0 9 ppm 50 ppm 30 30 5 5 0 5 20 ppm 6 0 1 0 9 ppm 50 ppm 18 18 6 0 1 0 20 ppm 6 5 1 5 9 ppm...

Page 55: ...OV is open and the manometer is attached and functioning properly 9 Set the ON OFF switch to the ON position 10 Press the MENU key on the front panel of the C More until COMBUSTION CAL MENU appears on...

Page 56: ...Nitrogen Oxide NOx Carbon Monoxide CO Single Fuel Dual Fuel 5000 5 5 0 5 5 5 0 5 100 ppm 100 ppm 6000 5 0 0 5 5 0 0 5 100 ppm 100 ppm 21 Next press the Down arrow key until CAL Voltage 100 is displaye...

Page 57: ...osition Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO Single Fuel Dual Fuel 70 5 5 0 5 100 ppm 150 ppm 50 5 5 0 5 100 ppm 150 ppm 40 5 5 0 5 100 ppm 150 ppm 30 5 5 0 5 100 ppm 150 ppm 18 6 0 1 0 100...

Page 58: ...Shut off the gas supply to the unit 4 Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound 5 Remove the combustion analyzer probe from the 1 4 ven...

Page 59: ...sing the CLEAR key 7 Set the ON OFF switch on the C More Controller to the ON position 8 Press the MENU key once SETUP MENU will be displayed 9 Press the arrow key once PASSWORD will be displayed 10 P...

Page 60: ...ressing the CLEAR key 7 Apply AC power to the boiler 8 Press the MENU key once SETUP MENU will be displayed 9 Press the arrow key once PASSWORD will be displayed 10 Press the CHANGE key PASSWORD will...

Page 61: ...imit switch is manually adjustable from 32 F 212 F 0 C 100 C This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the dial Set the dial on this...

Page 62: ...the required over temperature alarm setting press the or arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting 210 F is displayed pres...

Page 63: ...ck 5 2 LOW GAS PRESSURE TEST The steps and pressure setting required to check the Low Gas Pressure switch are described below This switch is in the normally open N O position Refer to Figure 5 1 for t...

Page 64: ...ed minimum 11 Slowly turn the indicator dial on the Low Gas Pressure switch until the unit shuts down due to a gas pressure fault 12 Readjust the inlet gas pressure to what it was prior to the test 13...

Page 65: ..._ max gas pressure Propane Gas Pressure ______ x 1 5 ______ max gas pressure 5 Remove the cover from the High Gas Pressure switch and set the dial indicator to 20 the maximum 6 Open the external gas s...

Page 66: ...the PROPANE gas train starting with opening the port on the side of the PROPANE High Gas Pressure Switch as shown in Figure 5 3 Figure 5 3 High Gas Pressure Switch Locations Test Ports Alternative lo...

Page 67: ...fault message is displayed and the FAULT indicator flashes 5 Place the unit in the MANUAL mode and raise the valve position above 30 6 Set the ON OFF switch to the ON position The READY light should r...

Page 68: ...he displayed OUTLET TEMPERATURE 3 Once the adjustable Over Temperature switch setting is approximately at or just below the actual outlet water temperature the unit should shut down The FAULT indicato...

Page 69: ...ition between 25 and 30 3 If there is a jumper across the REMOTE INTL K IN terminals remove one side of the jumper If the interlock is being controlled by an external device either open the interlock...

Page 70: ...to start the unit 6 The unit should purge and light the Pilot flame and then shut down after reaching the main Burner Ignition cycle and display FLAME LOSS DURING IGN 7 Open the valve previously close...

Page 71: ...rew drive to remove the front cover from the switch to reveal the switch setting indicator dial 0 3 in the Figure below COVER WITH LABEL COVER REMOVED Figure 5 6 Blower Proof Switch 4 Set the Controll...

Page 72: ...clip away from bare metal parts until step 4c 4 Complete the following with the boiler operating in MANUAL mode a Ramp the boiler up to 100 fire rate and then turn the main ON OFF switch on the front...

Page 73: ...ween 25 and 30 3 Remove the cover from the SSOV by loosening the screw shown in Figure 5 8 Lift off the cover to access the terminal wiring connections 4 Disconnect wire 148 from the SSOV to open the...

Page 74: ...s ON OFF switch to the OFF position 2 Place the unit in MANUAL mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it...

Page 75: ...s 1 Set the unit s ON OFF switch to the OFF position 2 Place the unit in MANUAL mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 5 9 above by rotating the cov...

Page 76: ...5 SAFETY DEVICE TESTING OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 76 of 95 5 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in...

Page 77: ...Rate One unit the BST network is defined as the Manager unit and all other units on the network are defined as Client units The Manager monitors the system Header Temperature and also monitors all Cli...

Page 78: ...ce the installation is working properly as a BST system install the ProtoNode device f Make sure that the Modbus load and bias resistors are properly configured for the system to operate with the Prot...

Page 79: ...the plant s supply water header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O t...

Page 80: ...for the shield is at the SHLD terminal in the I O the Box The header sensor must be installed between 2 and 10 feet 0 61 and 3 1m downstream of the LAST boiler in the plant s supply water header Ther...

Page 81: ...of the LAST boiler in the plant s supply water header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD...

Page 82: ...em to Enabled 2 Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client for now On MANAGER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Men...

Page 83: ...erature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD termi...

Page 84: ...t free and ungrounded Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration menu and set the BST Menu item to Enabled 2 Go to the Boiler Sequencing Menu and set the BST Mode item...

Page 85: ...on the P 1 Harness Via the terminal block labeled Header Temp sensor in the I O Box NOTES The header sensor must be installed between 2 and 10 feet 0 61 and 3 1m downstream of the LAST boiler in the...

Page 86: ...d set the BST Menu item to Enabled 2 Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client for now On MANAGER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go...

Page 87: ...the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES Polarity must be observed for the RS485 connections The ground for the shield is at the SH...

Page 88: ...eft free and ungrounded Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration menu and set the BST Menu item to Enabled 2 Go to the Boiler Sequencing Menu and set the BST Mode ite...

Page 89: ...ler units 2 Using Shielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor P N 24410 to pins 2 and 3 of the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of th...

Page 90: ...u and set the BST Mode item to BST Client for now On MANAGER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpo...

Page 91: ...ts and Pin A of the Temperature Transmitter to the RS485 terminal on the I O Box of any of the Boiler units 2 Using Shielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor P N 24410...

Page 92: ...Menu and set the BST Mode item to BST Client for now On MANAGER only 3 Go to the BST Setpoint item and enter the failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST S...

Page 93: ...on Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 93 of 95 Appendix A Dimensional and Clearance Dra...

Page 94: ...0 6000 Boiler Installation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 94 of 95 Drawing Number S...

Page 95: ...ion 5 8 1 DIR 19 04 Added additional requirements to Section 1 2 Emergency Shutdown DIR 19 15 Modified requirement for that housekeeping pad must be level in Section 2 4 2 DIR 19 34 Revised descriptio...

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