Benchmark Platinum-Edge [ii]: Installation Manual FORWARD FOREWORD The AERCO Benchmark (BMK) 750 through 6000 natural gas and propane fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
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Benchmark Platinum-Edge [ii]: Installation Manual FORWARD The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration. AERCO Technical Terminology Meanings TERMINOLOGY MEANING A (Amp) Ampere AERCO Control System, AERCO’s boiler management systems ADDR Address AGND...
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Benchmark Platinum-Edge [ii]: Installation Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Ground Header Hexadecimal Number (0 – 9, A – F) Horse Power Heat Exchanger Hertz (Cycles Per Second) I.D. Inside Diameter Ignition IGST Board Ignition/Stepper Board, contained in the Controller INTLK (INTL’K) Interlock Input/Output...
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Benchmark Platinum-Edge [ii]: Installation Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Point-to-Point (usually over RS232 networks) P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref) Reference RES.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 1 – SAFETY PRECAUTIONS SECTION 1: SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 1 – SAFETY PRECAUTIONS 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.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 1 – SAFETY PRECAUTIONS 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS Requirements for 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.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 1 – SAFETY PRECAUTIONS Requirements for Massachusetts Installations 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.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION SECTION 2: INSTALLATION 2.1 INTRODUCTION This section provides the descriptions and procedures necessary to unpack, inspect and install AERCO Benchmark Platinum Boilers. 2.2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for these BMK models is approximately as follows: •...
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION • A 1”, 1-1/2” or 2” Natural Gas Supply Shutoff Valve, and a Propane Shutoff Valve on Propane and Dual Fuel units When optional accessories are ordered, they may be packed within the unit’s shipping container, factory installed on the unit, or packed and shipped in a separate container.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION Section 6.6: Combination Control System of the Benchmark Platinum-Edge: OPERATION- SERVICE Manual (GF-211). NOTE: Ensure that condensate assembly is not located over the housekeeping pad. 4” High Pad Figure 2-1a: BMK750/1000 Clearances NOTE: Ensure that condensate...
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION NOTE: Ensure that condensate assembly is not located over the housekeeping pad. Housekeeping Pad. Figure 2-1c: BMK2500/3000 Clearances NOTE: Ensure that condensate assembly is not located over the housekeeping pad. Housekeeping Pad. Figure 2-1d: BMK4000 Clearances OMM-136_E •...
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION Figure 2-1e: Benchmark Model 5000 & 6000 Clearances WARNING! Keep the unit area clear and free from all combustible materials and flammable vapors or liquids FOR MASSACHUSETTS ONLY: For Massachusetts installations, the unit must be installed by a plumber or gas-fitter licensed within the Commonwealth of Massachusetts.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.5 LIFTING PROVISIONS WARNING! When lifting or moving the boiler, DO NOT attempt to manipulate the boiler using the gas train or blower. 2.5.1 BMK750 – 1000 Lifting Provisions Unpack and inspect the unit, then remove the four (4) lag screws securing the boiler to the shipping pallet.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.5.2 BMK1500 – 4000 Lifting Provisions Three lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-3b. Remove the front top panel from the unit to provide access to the lifting lugs. Remove the four (4) lag screws securing the unit to the shipping skid.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION LIFTING LUGS NOTE: The front top panel must be removed to access the front lifting lug. Figure 2-3c: Lifting Lug Locations – BMK5000 & 6000 2.6 SUPPLY AND RETURN PIPING When connecting the hot water outlet and cold-water inlet to building piping, first make sure the mating surfaces are thoroughly clean.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.6.2 BMK1500 – 4000 Supply and Return Piping Benchmark Platinum 1500 – 3000 units have one 4” (10.2 cm) 150# flange for the water INLET (supply) and one 4” (10.2 cm) 150# flange for the hot water OUTLET (return) piping connections.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.6.3 BMK5000 – 6000 Supply and Return Piping Benchmark 5000 and 6000 Platinum boilers utilizes 6” (15.24 cm) 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 2-4c.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.7 PRESSURE RELIEF VALVE INSTALLATION An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler (BMK5000 and 6000 boilers are supplied with one or more valves, depending on the pressure required). The pressure rating for the relief valve must be specified on the sales order.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.8 CONDENSATE DRAIN and 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. See below for information on the condensate drain and piping for the various models.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION TOP COVER THUMB TRAP INLET SCREWS (4 each) INTEGRAL ADAPTOR AND THUMBSCREW CONDENSATE TRAP COMBUSTION ANALYZER (P/N 24441) PROBE PORT 3/4” NPT NIPPLE UNION EXHAUST MANIFOLD HOSE CLAMP 1” DIAM. HOSE 4”...
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.9 GAS SUPPLY PIPING AERCO’s Benchmark Gas Components and Supply Design Guide, TAG-0047 (GF-2030) must be consulted prior to designing or installing any gas supply piping. WARNING! Never use matches, candles, flames or other sources of ignition to check for gas leaks CAUTION! Many of the soaps used for gas pipe leak testing are corrosive to metals.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION NOTE: It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above. However, AERCO offers for sale an appropriate regulator, which may be ordered at the time of unit purchase or separately. Contact your AERCO sales representative for more information.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION GAS PRESSURE REGULATOR NATURAL GAS INLET GAS INLET MANUAL SHUT-OFF VALVE Figure 2-7b: BMK1500-4000 Gas Regulator and Manual Shut-Off Valve NATURAL GAS MANUAL SHUT-OFF VALVE NATURAL GAS NATURAL GAS PRESSURE REGULATOR SUPPLY PROPANE SUPPLY...
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION PROPANE SUPPLY 1-1/2” MANUAL GAS SHUT-OFF VALVE PROPANE PRESSURE REGULATOR DRIP NATURAL GAS PRESSURE REGULATOR 2” MANUAL GAS SHUT-OFF VALVE NATURAL GAS SUPPLY Figure 2-7d: BMK5000/6000 Manual Gas Shut-Off Valve Location – Dual Fuel OMM-136_E •...
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.9.2.1 Massachusetts Installations Only For Massachusetts installations, a mandatory external gas 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 venting of the supply gas regulator.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.10.2 Power Panel Locations External AC power connection is made inside the Power Panel, located on the front of the unit, behind the unit’s removable front panel. SECONDARY MAIN POWER POWER PANEL PANEL (with cover) (with cover)
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.10.3 Electrical Power Panel Internal Components Remove the front panel to access the Power Panel. Run the electrical service through the opening above the Power Panel and make the connections to the Power Breaker in accordance to the Power Panel cover label.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION WIRE CONDUITS FUSE BLOCK FUSE BLOCK POWER BREAKER 12V POWER SUPPLY TERMINAL BLOCKS Figure 2-9b: BMK2500 – 6000 Power Panel Internal Components NOTES: • The 115V to 24V transformer provides power for the Edge Controller and the Sequencing Isolation Valve.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION OXYGEN SENSOR FLOW SENSOR AIR PUMP 4-20mA OUT (AIR EDUCTOR ON BMK5000 & 6000 ONLY) PUMP RELAY BLOWER RELAY BLOCKED FLUE SWITCH Figure 2-11: Secondary Power Panel Terminals I/O BOARD POWER SPARK MONITOR HARNESS 63232 FROM SHELL...
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION NOTE: To facilitate making the connections, these strip can be lifted off the I/O board. The entire strip is then remounted on the I/O board after all connections have been made. If a connector strip is removed, it must be re-mounted in its original orientation (connecting wires arranged around the outside perimeter of the I/O board).
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION Connector Strip J4 Terminals Pin # Name Description Connection to the Supply Header temperature sensor (2 wire sensor P/N 24410, or 4 wire sensor P/N 61058) for: • Main Loop (in a Variable-Primary application) •...
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION Connector Strip J6 Terminals Pin # Name Description Remote Interlock Out Connection to an auxiliary device interlock, such as louver open feedback or flow sensor. Remote Interlock Return Delayed Interlock 1 Out Connection to an auxiliary device interlock that requires a delay before the plant starts firing.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION Connector Strip J14 Terminals Pin # Name Description BACnet MSTP). For IP network, use the Ethernet port. BAS RS485 - RS485 Local + RS4585 Ground Reserved for internal use only RS485 Local - 2.12 FLUE GAS VENT INSTALLATION AERCO’s Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) must be consulted before any flue or combustion air venting is designed or installed.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.12.1 MASSACHUSETTS INSTALLATIONS For Massachusetts installations, the following companies provide vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts. Contact information is as follows: Selkirk Corporation - Heatfab Division Watertown Supply 130 Industrial Blvd.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION 2.13.1 DUCTED COMBUSTION AIR For ducted combustion air installations, the air ductwork must be attached directly to the air inlet connection on the sheet metal enclosure. Consult the Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) when designing combustion air ducting.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 2 – INSTALLATION Sequencing Isolation Valve Installation Instructions AERCO SEQUENCING ISOLATION VALVE HOT WATER OUTLET Figure 2-13: Sequencing Isolation Valve Installed 2. Find the grey cable inside the unit’s enclosure with the unused Molex connector with a cap containing a jumper wire inserted in it (the jumper wire allows units that do not have a sequencing isolation valve to operate normally).
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 3 – ONAER SETUP 2.15 BOILER PUMP RELAY Figure 2-15: Boiler Pump Relay The Benchmark 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.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 3 – ONAER SETUP SECTION 3: onAER SETUP 3.1 INTRODUCTION AERCO has developed new connectivity capabilities to make its IoT offering, onAER, easier for its broad customer base to implement. The onAER feature lets AERCO boilers be monitored remotely.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 3 – ONAER SETUP Connecting the Ethernet Cable Instructions ETHERNET JACK Figure 3-1: Edge Controller – Left Side View 3.1.2 Confirming the Ethernet Connection Refer to Figure 3-2, below, and complete the following instructions to confirm that the Ethernet cable connection is working.
Benchmark Platinum-Edge [ii]: Installation Manual SECTION 3 – ONAER SETUP 3.1.3 Confirm Ethernet DHCP Configuration Once you have confirmed that the Ethernet connection is working, complete the following steps to confirm that the connection is active. Confirming Ethernet DHCP Configuration Instructions 1.
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Benchmark Platinum-Edge [ii]: Installation Manual SECTION 3 – ONAER SETUP (This page intentionally blank) OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 48 of 57...
Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix A: Dimensional and Clearance Drawings Benchmark 750/1000 Dimension Drawing AP-A-891 rev J OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 49 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Single Unit Clearance Drawing SD-A-871 rev C OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 50 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Zero Side Clearance Drawing SD-A-872 rev C OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 51 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Dimension Drawing Number: AP-A-1036 rev B OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 52 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Clearance Drawing Number: SD-A-995 rev B OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 53 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Dimension Drawing Number: AP-A-915 rev E OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 54 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Clearance Drawing Number: SD-A-898 rev E OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 55 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 4000 Clearance & Dimensional Drawing Number: AP-A-1191 rev A OMM-136_E • GF-210 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 56 of 57...
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Benchmark Platinum-Edge [ii]: Installation Manual Change Log: Changed Date Description Rev D: Minor corrections, plus: DIR 18-38: Added new vendor to vent systems contractors in Massachusetts, Section 2.12.1. DIR 19-03: Added “International” option to Section 2.10 AC Electrical Power Wiring. 7/16/2019 Chris Blair DIR 19-04: Added additional requirements to Section 1.2:...