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Benchmark 750-6000 with Edge [i]: Install-Startup Manual

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144_B • GF-217 • 5/25/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

AERCO Technical Terminology Meanings

TERMINOLOGY

MEANING

Factory Mutual. Used to define boiler gas trains.

GF-xxxx

Gas Fired (an AERCO document numbering system)

GND

Ground

HDR

Header

Hex

Hexadecimal Number (0

– 9, A – F)

Horse Power

Heat Exchanger

Hertz (Cycles Per Second)

I.D.

Inside Diameter

IGN

Ignition

IGST Board

Ignition/Stepper Board, contained in Edge Controller

INTLK (INTL’K)

Interlock

I/O

Input/Output

I/O Box

Input/Output (I/O) Box currently used on Benchmark boilers

Internet Protocol

ISO

International Organization for Standardization

Lbs.

Pounds (1 lb = 0.45 kg)

LED

Light Emitting Diode

Low Nitrogen Oxide

MA (mA)

Milliampere (1 thousand

of an ampere)

MAX (Max)

Maximum

MBH

1000 BTUs per Hour

MIN (Min)

Minimum

Modbus®

A serial, half-duplex data transmission protocol developed by AEG
Modicon

NC (N.C.)

Normally Closed

NO (N.O.)

Normally Open

Nitrogen Oxide

NPT

National Pipe Thread

Oxygen

O.D.

Outside Diameter

OMM, O&M

Operation and Maintenance Manual

onAER

AERCO’s on-line remote monitoring system

PCB

Printed Circuit Board

PMC Board

Primary Micro-Controller (PMC) board, contained in the Edge
Controller

P/N

Part Number

POC

Proof of Closure

Содержание Aerco BMK 750

Страница 1: ...de 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 0100 and above BMK750 5000N N 20 0050 and above...

Страница 2: ...RETURN PIPING 23 2 6 1 BMK750 1000 Supply and Return Piping 23 2 6 2 BMK1500 5000N Supply and Return Piping 24 2 6 3 BMK5000 6000 Supply and Return Piping 25 2 7 PRESSURE RELIEF VALVE INSTALLATION 25...

Страница 3: ...1 2 12 FLUE GAS VENT INSTALLATION 42 2 12 1 MASSACHUSETTS INSTALLATIONS 42 2 13 COMBUSTION AIR 43 2 13 1 DUCTED COMBUSTION AIR 43 2 14 BENCHMARK PUMP RELAY 43 2 15 BST SEQUENCING ISOLATION VALVE INSTA...

Страница 4: ...Benchmark 750 6000 with Edge i Install Startup Manual CONTENTS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 4 of 62 This page intentionally blank...

Страница 5: ...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 200 000 5...

Страница 6: ...ol rate or simply the number of distinct symbol changes signaling events transmitted per second It is not equal to bits per second unless each symbol is 1 bit long BMK Benchmark AERCO s Benchmark seri...

Страница 7: ...O Input 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...

Страница 8: ...n of 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...

Страница 9: ...use matches candles flames or other sources of ignition to check for gas leaks Fluids under pressure may cause injury to personnel or damage to equipment when released Be sure to shut off all incomin...

Страница 10: ...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 switch...

Страница 11: ...d 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 ala...

Страница 12: ...gn 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...

Страница 13: ...r 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 the crate which indicates if the unit has been turned on...

Страница 14: ...l Fuel and Propane only units Access to a 1 1 2 inch 3 81 cm line with a minimum pressure of 14 inches W C 3 49 kPa with the unit at full fire A level concrete housekeeping pad as described below Benc...

Страница 15: ...nly The perimeter clearances still apply See drawings in Appendix A Dimensions and Clearance Drawings If installing a Combination Control System CCS using an ACS panel ACS is not needed for combinatio...

Страница 16: ...nical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 16 of 62 Figure 2 1b BMK1500 2000 Clearances Figure 2 1c BMK2500 3000 Clearances NOTE Ensure that condensate assembly is not located over the hous...

Страница 17: ...OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 17 of 62 Figure 2 1d BMK4000 5000N Clearances Figure 2 1e Benchmark Model 5000 6000 Clearances NOTE Ensure that co...

Страница 18: ...ETTS ONLY For Massachusetts installations the unit must be installed by a plumber or gas fitter licensed within the Commonwealth of Massachusetts In addition the installation must comply with all requ...

Страница 19: ...Startup Manual SECTION 2 INSTALLATION OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 19 of 62 Figure 2 2b BMK1500 2000 Anchor Bolt Locations Figure 2 2c BMK2500...

Страница 20: ...ting Provisions Unpack and inspect the unit then remove the four 4 lag screws securing the boiler to the shipping pallet The boiler can be lifted and moved by inserting forklift tines in the front slo...

Страница 21: ...op rear of the heat exchanger 3 Attach the lifting bar to the heat exchanger lifting tab using the hardware removed in step 1 Figure 2 3a View B The upper end of the lifting bar containing the oval cu...

Страница 22: ...s Two 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...

Страница 23: ...appropriate size for the pipe flange must be provided in the field 2 6 1 BMK750 1000 Supply and Return Piping Benchmark 750 and 1000 Boiler utilizes 3 7 62cm 150 flanges for the water system supply a...

Страница 24: ...o 2 5 08 cm Natural Gas inlet pipe o 1 2 54 cm Propane inlet pipe BMK 1500 2000 o 2 5 08 cm Propane inlet pipe BMK 2500 3000 8 20 3 cm Air Inlet adapter Benchmark 4000 and 5000N units have 6 15 2 CM 1...

Страница 25: ...pressure rating for the relief valve must be specified on the sales order Available pressure ratings range from 30 to 160 psi 207 to 1103 kPa The relief valve is installed on the hot water outlet of...

Страница 26: ...5a BMK750 1000 P T Relief Valve Location Figure 2 5b BMK1500 5000N P T Relief Valve Location Figure 2 5c BMK5000 6000 P T Relief Valve Location PRESSURE RELIEF VALVE 4 HOT BOILER WATER OUTLET INSTALL...

Страница 27: ...at 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 pip...

Страница 28: ...PROBE 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...

Страница 29: ...t 3 7 62 cm LGP in back of unit 1 1 2 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 particles Do NOT insta...

Страница 30: ...RCO sales representative for more information On all Benchmark models it is strongly recommended that the pressure regulator be installed a minimum distance of 10 pipe diameters between the pressure r...

Страница 31: ...re 2 7c BMK1500 3000 Dual Fuel Gas Regulator and Manual Shut Off Valve GAS INLET GAS PRESSURE REGULATOR MANUAL SHUT OFF VALVE NATURAL GAS INLET NATURAL GAS INLET NATURAL GAS PRESSURE REGULATOR PROPANE...

Страница 32: ...s supply 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 venti...

Страница 33: ...K2500 3000 Domestic 208 V 3 60 Hz 20 480 V 3 60 Hz 15 BMK2500 3000 International 380 415 V 3 50 60 Hz 15 BMK4000 5000N Domestic 480V 3 60 Hz 15 BMK5000 6000 Domestic 208 V 3 60 Hz 30 480 V 3 60 Hz 20...

Страница 34: ...n 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 re...

Страница 35: ...2 9a BMK750 1000 Power Box Internal Components Figure 2 9b BMK1500 2000 Power Box Internal Components 12V POWER SUPPLY FUSE BLOCKS 2 TERMINAL BLOCKS POWER BREAKER TRANSFORMER 24V POWER SUPPLY WIRE CO...

Страница 36: ...RING I O Board 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 Edge Controller used with these...

Страница 37: ...re 2 11 below to determine the functions of the I O board connections Do not use the silkscreened label on the I O board itself as some labels may not match the functions There is also a diagram of th...

Страница 38: ...use the outdoor sensor 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 OFF To enable the sen...

Страница 39: ...ANALOG IN The two ANALOG IN terminals and are used when an external signal is used to change the setpoint Remote Setpoint operating mode of the boiler Either a 4 to 20 mA 1 5 VDC or a 0 to 20 mA 0 5 V...

Страница 40: ...ed for the voltage output used by the Controller to modulate the combustion blower via the I O Box terminals labeled VFD BLOWER Section 2 11 11 If Boiler Sequencing Technology BST is enabled the Analo...

Страница 41: ...nction with the AUXILIARY RELAY CONTACTS described in section 2 11 14 below This interlock circuit is located in the purge section of the start string It can be connected to the proving device end swi...

Страница 42: ...y condensate pooling and to allow for proper drainage While there is a positive flue pressure during operation the combined pressure drop of vent and combustion air systems must not exceed 140 equival...

Страница 43: ...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 COMBUSTION AIR For ducted combustion air installations the air du...

Страница 44: ...BMK1500 6000 Pump Relay Location BMK2500 3000 Shown See Figures 2 13 and 2 14 for wiring details Figure 2 13 Schematic System Pump Start using Boiler Pump Relay The Benchmark pump relay SPDT contact...

Страница 45: ...SH Valve Close Delay parameter in the Main Menu Advanced Setup BST Cascade Operating Controls Sequencing Controls menu default 1 minute then closes Once system load is satisfied and all Client units...

Страница 46: ...ted to the I O board and to a power supply Figure 2 16 Sequencing Isolation Valve Molex Connector and Jumper Wire Isolation Valve Harness Wire Color Signal 1236 Black 24V Common 1237 Red 24V Hot 1238...

Страница 47: ...e sections 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 boiler with the...

Страница 48: ...hernet 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 t...

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

Страница 50: ...Benchmark 750 6000 with Edge i Install Startup Manual SECTION 3 ONAER SETUP OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 50 of 62 This page intentionally blank...

Страница 51: ...LEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 51 of 62 Appendix A Dimensional and Clearance Drawings Benchmark 750 1000 Dimension Drawing AP A...

Страница 52: ...Edge i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 52 of 62 Benchmark 750 1000 Clearance...

Страница 53: ...i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 53 of 62 Benchmark 750 1000 Zero Side Clear...

Страница 54: ...Edge i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 54 of 62 Benchmark 1500 2000 Dimension...

Страница 55: ...Edge i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 55 of 62 Benchmark 1500 2000 Clearance...

Страница 56: ...Edge i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 56 of 62 Benchmark 2500 3000 Dimension...

Страница 57: ...i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 57 of 62 Benchmark 2500 3000 Zero Side Clea...

Страница 58: ...dge i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 58 of 62 Benchmark 4000 5000N Dimensiona...

Страница 59: ...tall Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 59 of 62 Benchmark 4000 5000N Clearance Dimension...

Страница 60: ...Edge i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 60 of 62 Benchmark 5000 6000 Dimension...

Страница 61: ...i Install Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 144_B GF 217 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 61 of 62 Benchmark 5000 6000 Zero Side Clea...

Страница 62: ...tion Changed By 12 6 2019 Rev A Initial release internal ref DIR 19 46 Chris Blair 5 25 2020 Rev B DIR 20 13 Updated Figure 2 5a to show new location for Tridicator on BMK 750 1000 units Added BMK 500...

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