Watts Aerco Benchmark OMM-0116 Installation And Start-Up Manual
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Watts Aerco Benchmark OMM-0116 Installation And Start-Up Manual

Natural gas, propane gas and dual fuel fired modulating & condensing boilers
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Installation and Startup Manual
Benchmark
Natural Gas, Propane Gas and Dual Fuel Fired
Modulating & Condensing Boilers
Models 750 through 3000
Other documents for this product include:
OMM-0116, GF-201 Operation-Service Manual
TAG-0019, GF-2070 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-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 of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or consequential
damages occurring in connection with the furnishing, performance, or use of
these materials
OMM-115_D • GF-200 • 5/9/2019
Boilers
®

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Summary of Contents for Watts Aerco Benchmark OMM-0116

  • Page 1 Installation and Startup Manual Benchmark Boilers ® Natural Gas, Propane Gas and Dual Fuel Fired Modulating & Condensing Boilers Models 750 through 3000 Other documents for this product include: OMM-0116, GF-201 Operation-Service Manual TAG-0019, GF-2070 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:...

  • Page 2: Table Of Contents

    Benchmark 750-3000 Installation & Startup Manual CONTENTS TABLE OF CONTENTS FOREWORD ...................... 5 SECTION 1: SAFETY PRECAUTIONS ..............9 1.1 WARNINGS & CAUTIONS ..................... 9 1.2 EMERGENCY SHUTDOWN ....................10 1.3 PROLONGED SHUTDOWN ....................10 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ..........11 SECTION 2: INSTALLATION ................
  • Page 3 Benchmark 750-3000 Installation & Startup Manual CONTENTS 2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) ................39 2.12 FLUE GAS VENT INSTALLATION ..................39 2.12.1 MASSACHUSETTS INSTALLATIONS ....................39 2.13 COMBUSTION AIR ......................40 2.13.1 DUCTED COMBUSTION AIR ......................40 2.14 BENCHMARK PUMP RELAY .....................
  • Page 4 Benchmark 750-3000 Installation & Startup Manual CONTENTS 5.6.2 Delayed Interlock Test ........................89 5.7 FLAME FAULT TEST ......................90 5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES ....91 5.8.1 Blower Proof Switch Test ....................... 91 5.8.2 Blocked Inlet Switch Test .......................

  • Page 5: Foreword

    Benchmark 750-3000 Installation & Startup Manual FORWARD FOREWORD The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 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.
  • Page 6 Benchmark 750-3000 Installation & Startup 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...
  • Page 7 Benchmark 750-3000 Installation & Startup Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING GF-xxxx Gas Fired (an AERCO document numbering system) Ground Header Hexadecimal Number (0 – 9, A – F) Horse Power Heat Exchanger Hertz (Cycles Per Second) I.D. Inside Diameter Ignition IGST Board...
  • Page 8 Benchmark 750-3000 Installation & Startup Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) 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)

  • Page 9: Section 1: Safety Precautions

    Benchmark 750-3000 Installation & Startup 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.

  • Page 10: Emergency Shutdown

    Benchmark 750-3000 Installation & Startup 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.

  • Page 11: Important - For Massachusetts Installations

    Benchmark 750-3000 Installation & Startup 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.
  • Page 12 Benchmark 750-3000 Installation & Startup 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.

  • Page 13: Section 2: Installation

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION SECTION 2: INSTALLATION 2.1 INTRODUCTION This Section provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark Boilers, models 750, 1000, 1500, 2000, 2500 and 3000. 2.2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit.

  • Page 14: Site Preparation

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 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. Any standard or optional accessories shipped loose should be identified and stored in a safe place until ready for installation or use.
  • Page 15 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION NOTE: Ensure that condensate assembly is not located over the housekeeping pad. 4” High Pad Figure 2-1a: BMK 750/1000 Clearances NOTE: Ensure that condensate assembly is not located over the housekeeping pad.
  • Page 16 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION REAR NOTE: Ensure that condensate assembly is not located over the housekeeping pad. Housekeeping Pad. FRONT Figure 2-1c: BMK 2500/3000 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...

  • Page 17: Setting The Unit

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.4.2 Setting the Unit All Benchmark Boilers must be installed on a level housekeeping pad to ensure proper condensate drainage. The pad thickness must be: • BMK 750 – 1000 – 4 to 6 inch (10.2 to 15.2 cm) •...
  • Page 18 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION FRONT REAR NOTES: • All holes are flush with the bottom surface of the frame • All dimensions shown are in inches [millimeters] Figure 2-2c: BMK 2500/3000 Anchor Bolt Locations •...

  • Page 19: Lifting Provisions

    Benchmark 750-3000 Installation & Startup 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 BMK 750 – 1000 lifting Provisions Unpack and inspect the unit, then remove the four (4) lag screws securing the boiler to the shipping pallet.

  • Page 20: Bmk 1500 - 3000 Lifting Provisions

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.5.2 BMK 1500 – 3000 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.

  • Page 21: Supply And Return Piping

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.6 SUPPLY AND RETURN PIPING 2.6.1 BMK 750 – 1000 Supply and Return Piping Benchmark 750 and 1000 Boiler utilizes 3” (7.62cm) 150# flanges for the water system supply and return piping connections. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-4a.

  • Page 22: Dual Inlet Return Piping

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2” NATURAL GAS OR 1” PROPANE INLET HOT WATER OUTLET (SUPPLY) BMK 1500/2000 BMK 2500/3000 AIR INLET SECONDARY WATER INLET (WARMER WATER RETURN) PRIMARY WATER INLET (COOLER WATER RETURN) EXHAUST MANIFOLD CONDENSATE DRAIN Figure 2-4b: BMK 1500/2000 and BMK 2500/3000 Supply and Return Locations 2.6.3 Dual Inlet Return Piping...

  • Page 23: Pressure Relief Valve Installation

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.7 PRESSURE RELIEF VALVE INSTALLATION An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler. The 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).

  • Page 24: Condensate Drain And Piping

    Benchmark 750-3000 Installation & Startup 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.
  • Page 25 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION TOP COVER THUMB TRAP INLET SCREWS (4 each) INTEGRAL ADAPTOR AND THUMBSCREW CONDENSATE TRAP COMBUSTION (P/N 24441) ANALYZER PROBE PORT 3/4” NPT NIPPLE UNION EXHAUST MANIFOLD HOSE CLAMP 1” DIAM. HOSE 4”...

  • Page 26: Gas Supply Piping

    Benchmark 750-3000 Installation & Startup 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.

  • Page 27: Gas Supply Specifications

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.9.1 Gas Supply Specifications The gas supply input specifications to the unit are as follows: The maximum static pressure to the unit must not exceed the following: TABLE 2-1: Maximum Static Gas Pressure Model Natural gas Propane...

  • Page 28: External Gas Supply Regulator

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.9.3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions (see, below). Regulators must conform to the specifications shown in the tables below. The external natural gas regulator must be capable of regulating the following BTU per hour while maintaining the minimum gas pressure listed below: TABLE 2-3a: NATURAL GAS Regulator Capacity...
  • Page 29 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 1” MANUAL SHUTOFF VALVE GAS INLET DIRT TRAP GAS PRESSURE REGULATOR Figure 2-7a: BMK 750/1000 Manual Gas Shut-Off Valve and Gas Regulator GAS PRESSURE REGULATOR NATURAL GAS INLET GAS INLET MANUAL SHUT-OFF VALVE...

  • Page 30: Ac Electrical Power Wiring

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION NATURAL GAS MANUAL SHUT-OFF VALVE NATURAL GAS NATURAL GAS PRESSURE REGULATOR SUPPLY PROPANE NATURAL GAS INLET SUPPLY PROPANE MANUAL SHUT- PROPANE INLET OFF VALVE PROPANE PRESSURE REGULATOR NOTE In propane-only units, the natural gas piping and components shown...

  • Page 31: Power Box Locations

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.10.2 Power Box Locations External AC power connections are made to the unit inside the Power Box on the front of the unit. Remove the front panel to access the Power Box, which is mounted in the upper part of the unit as shown in Figure 2-8a and 2-8b.

  • Page 32: Electrical Power Box Internal Components

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.10.3 Electrical Power Box Internal Components WARNING! The power breaker shown in Figure 2-9a, 2-9b and 2-9c does NOT remove power from the terminal blocks. FUSE BLOCKS (2) POWER BREAKER 12V POWER SUPPLY TERMINAL BLOCKS...
  • Page 33 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION WIRE CONDUITS POWER BREAKER TRANSFORMER 24V POWER SUPPLY 12V POWER SUPPLY TERMINAL BLOCKS FUSE BLOCKS (2) Figure 2-9c: BMK 2500/3000 Power Box Internal Components NOTES: • With the exception of the transformer shown in Figure 2-9a 2-9b, and 2-9c, all of the components in the Power Box are mounted on a DIN rail.

  • Page 34: Field Control Wiring

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.11 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 Controller used with all Benchmark units does allow for some additional control and monitoring features.

  • Page 35: Outdoor Air & Air Sensor Common

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION Outdoor Air Remote Intl’k OUT Air Sensor Common Remote Intl’k IN Air Temp Sensor O2 Sensor – NOT USED Not Used Delayed Intl’k OUT Spark Signal + Delayed Intl’k IN Spark Signal –...

  • Page 36: Air Temp Sensor

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 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 from direct sunlight as well as impingement by the elements.

  • Page 37: Valve Feedback

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.11.6 VALVE FEEDBACK The two VALVE FEEDBACK terminals (+ and –) are used when the Sequencing Isolation Valve Feedback option is selected. The Valve Feedback signal is connected to the “Valve Fdbk” terminals and is used to confirm that the valve has properly opened or closed.

  • Page 38: Interlocks

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.11.12 Interlocks The unit has two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps, louvers or other accessories. These interlocks are called the Remote Interlock and Delayed Interlock (REMOTE INTL’K IN and DELAYED INTL’K IN in Figure 2-11).

  • Page 39: Auxiliary Relay Contacts (Nc, Com, & No)

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) Each unit is equipped with a single pole double throw (SPDT) relay that is energized when there is a demand for heat and de-energized after the demand for heat is satisfied. The relay is provided for the control of auxiliary equipment, such as pumps and louvers, or can be used as a unit status indictor (firing or not firing).

  • Page 40: Combustion Air

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.13 COMBUSTION AIR The Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) MUST be consulted before any inlet air venting is designed or installed. Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes.

  • Page 41: Benchmark Pump Relay

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION 2.14 BENCHMARK PUMP RELAY All Benchmark models ship with a pump relay (P/N 69102-2 for BMK750/1000, 69102-3 for BMK1500-3000) as standard equipment. The pump relay allows the user to turn a pump on/off and open/close a motorized valve as the boiler cycles on and off on demand.

  • Page 42: Sequencing Isolation Valve Installation

    Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION See Figures 2-13 and 2-14 for wiring details. (Orange) – N/O The Benchmark pump relay (SPDT) contact is rated for: (Yellow) - COM • 10 A Resistive @ 277 VAC/28 VDC Pump Relay Terminals •...
  • Page 43 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION NOTE: When the Sequencing Isolation Valve is used, the AUX START ON DLY in the Configuration menu must be set to 120 seconds (see Section 2.6: CONFIGURATION Menu, item 16, in the Benchmark 750 –...
  • Page 44 Benchmark 750-3000 Installation & Startup Manual SECTION 2 – INSTALLATION (This page intentionally blank) • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 44 of...

  • Page 45: Section 3: Start Sequence

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE SECTION 3: START SEQUENCE 3.1 INTRODUCTION The information in this Section provides a guide to starting the Benchmark Boiler using the C- More Controller mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • Page 46 Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE When there is a demand for heat, the following events will occur: Start Sequence: 1. The DEMAND LED status indicator will light. 2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed.
  • Page 47 Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE Start Sequence: NATURAL GAS INLET SSOV AIR/FUEL LOW GAS VALVE MANUAL PRESSURE SHUT-OFF SWITCH VALVE Figure 3-1c: BMK 2500: SSOV Location (P/N 22190 shown) NATURAL GAS INLET AIR/FUEL SSOV VALVE MANUAL LOW GAS...
  • Page 48 Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE Start Sequence: STEPPER MOTOR AIR INLET BLOWER Figure 3-2a: BMK 750 & 1000 Air/Fuel Valve in Purge Position TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN Figure 3-2b: BMK 1500 –...
  • Page 49 Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE Start Sequence: BLOWER PROOF SWITCH BLOCKED INLET SWITCH Figure 3-3a: BMK 750 & 1000 Blower Proof Switch AIR/FUEL VALVE OUTLET TO BLOWER BLOWER PROOF SWITCH AIR/FUEL VALVE INLET FROM GAS TRAIN BLOCKED INLET...
  • Page 50 Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE Start Sequence: b) The “Spark Cycle Time” item in the Factory menu can be set to either 0 Sec, 2 Sec or 7 Sec to define the duration of the Spark Element Cleaning Cycle. This cycle turns on the spark transformer to produce a spark (with no gas flowing) to clean the spark element of moisture or carbon buildup.

  • Page 51: Start/Stop Levels

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE 3.3 START/STOP LEVELS The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows: TABLE 3-1a: Start/Stop Levels –...

  • Page 52: Start/Stop Levels - Air/Fuel & Energy Input

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE 3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT The Tables below show the relationship between the energy input and Air/Fuel Valve position for the BMK models covered in this document. 3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input TABLE 3-2a: BMK 750/1000 Air/Fuel Valve Position –...

  • Page 53: Bmk 1500 Air/Fuel Valve Position And Energy Input

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE 3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input TABLE 3-3a: BMK 1500 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 16% (Stop Level)

  • Page 54: Bmk 2000 Air/Fuel Valve Position And Energy Input

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE 3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input TABLE 3-4a: BMK 2000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 18% (Stop Level)

  • Page 55: Bmk 2500 Air/Fuel Valve Position And Energy Input

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE 3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input TABLE 3-5a: BMK 2500 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 16% (Stop Level)

  • Page 56: Bmk 3000 Air/Fuel Valve Position And Energy Input

    Benchmark 750-3000 Installation & Startup Manual SECTION 3 - START SEQUENCE 3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input TABLE 3-6a: BMK 3000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 14% (Stop Level)

  • Page 57: Section 4: Initial Start-Up

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP SECTION 4: INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark boiler consists of the following: • Complete the installation (Section 2: Installation) •...

  • Page 58: Installing Gas Supply Manometer

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.2.2 Installing Gas Supply Manometer The gas supply manometer (or gauge) is used to monitor the gas pressure on the downstream side of the SSOV during the Combustion Calibration procedures described in Section 4.4.1: Natural Gas Combustion Calibration or Section 4.4.2: Propane Gas Combustion Calibration The gas supply manometer is installed at the upstream and/or downstream location shown in Figure 4-1a through 4-1d.
  • Page 59 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP NATURAL GAS INLET HIGH GAS PRESSURE SWITCH AIR/FUEL VALVE MANUAL SHUT-OFF VALVE LOW GAS SSOV PRESSURE SWITCH 1/4” NPT PLUG (Install manometer here for Combustion Calibration) LEAK DETECTION BALL VALVE Figure 4-1b: BMK 1500 &...

  • Page 60: Accessing The Analyzer Probe Port

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP NATURAL GAS INLET SSOV AIR/FUEL VALVE LOW GAS MANUAL PRESSURE SHUT-OFF SWITCH VALVE HIGH GAS PRESSURE SWITCH LEAK DETECTION 1/4” NPT PLUG BALL VALVE (Install manometer here for Combustion Calibration) Figure 4-1d: BMK 3000 1/4 Inch Gas Plug Location (P/N 22171 shown)

  • Page 61: Fuel Types And Combustion Calibration

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP Analyzer Probe Port Access Instructions PRIMARY HOT WATER INLET ANALYZER PROBE EXHAUST MANIFOLD PORT CONDENSATE DRAIN Figure 4-2a: BMK 750 & 1000 Analyzer Probe Port Location DRAIN VALVE PRIMARY HOT WATER INLET EXHAUST MANIFOLD ANALYZER PROBE...

  • Page 62: Combustion Calibration

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.4 COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated with either standard combustion or Ultra-Low (on the BMK 750/1000 only) at the factory, whichever was ordered, prior to shipping. This gas pressure must be within the ranges shown in Table 4-1 for each model of boiler at full fire.

  • Page 63: Natural Gas Combustion Calibration

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.4.1 NATURAL GAS Combustion Calibration NATURAL GAS Combustion Calibration Instructions These instructions apply only to units running on NATURAL GAS. Instructions for doing combustion calibration on a unit running PROPANE appear in the next section, 4.4.2. Open the water supply and return valves to the unit and ensure that the system pumps are running.
  • Page 64 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP NATURAL GAS Combustion Calibration Instructions On Benchmark 3000 units only, once the manifold gas pressure is within the range in table 4-1, record this value; it will be used later, in Section 5.2.2: Low Pressure Gas Test, and Section 5.3.2: High Pressure Gas Test.
  • Page 65 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP NATURAL GAS Combustion Calibration Instructions With the valve position at 100%, if the oxygen level is still not within the required tolerance after adjusting the blower voltage, then the gas pressure on the downstream side of the SSOV must be adjusted using the gas pressure adjustment screw on the SSOV (Figure 4- 3).
  • Page 66 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP NATURAL GAS Combustion Calibration Instructions TABLE 4-3c: NATURAL GAS Final Valve Positions: BMK 1500DF-2000DF BMK 1500 Dual Fuel Units Valve % ≤20 ppm 6.0% ± 0.2% <100 ppm ≤20 ppm 6.3% ±...

  • Page 67: Propane Gas Combustion Calibration

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.4.2 PROPANE GAS COMBUSTION CALIBRATION PROPANE Combustion Calibration Instructions These instructions apply only to units running PROPANE gas. Instructions for doing combustion calibration on a unit running Natural Gas appear in the previous section, 4.4.1. Open the water supply and return valves to the unit and ensure that the system pumps are running.
  • Page 68 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions Press the Down▼ arrow key until SET Valve Position appears on the display, then press CHANGE. Press the Up ▲ arrow key until the SET Valve Position reads 100%, then press ENTER. With the valve position at 100%, insert the combustion analyzer probe into the exhaust manifold probe opening (see Figure 4-2a or 4-2b in Section 4.2.3) and allow enough time for the combustion analyzer reading to stabilize.
  • Page 69 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions Use the Down ▼arrow key to lower the valve position to one of the following: • BMK 750P & 1000P: 80% • BMK 1500/2000/2500 DF & P: 70% •...
  • Page 70 Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions BMK 3000 5.2% ± 0.2% <100 ppm <150 ppm 5.4% ± 0.2% <100 ppm <150 ppm 6.0% ± 0.2% <100 ppm <150 ppm 6.4% ± 0.2% <100 ppm <100 ppm 6.4% ±...

  • Page 71: Reassembly

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.5 REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation. Reassembly Instructions 1. Set the ON/OFF switch in the OFF position. 2.

  • Page 72: Switchover From Natural Gas To Propane

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.6.1 Switchover from NATURAL GAS to PROPANE Switchover from NATURAL GAS to PROPANE Instructions 1. Set the ON/OFF switch on the C-More Controller to the OFF position. 2. Close the external Natural Gas supply valves. 3.

  • Page 73: Switchover From Propane To Natural Gas

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.6.2 Switchover from PROPANE to NATURAL GAS Switchover from PROPANE to NATURAL GAS Instructions 1. Set the ON/OFF switch on the C-More Controller to the OFF position. 2. Close the external Propane Gas supply valves. 3.

  • Page 74: Over-Temperature Limit Switches

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.7 OVER-TEMPERATURE LIMIT SWITCHES The unit contains three (3) types of over-temperature limit controls. These controls consist of a Manual Reset button, a rotary adjustable Temperature Limit switch and a digital Over- Temperature Alarm button.

  • Page 75: Digital Alarm Switch Checks And Adjustments

    Benchmark 750-3000 Installation & Startup Manual SECTION 4 – INITIAL START-UP 4.7.1 Digital Alarm Switch Checks and Adjustments The Over-Temperature Alarm switch settings can be checked or adjusted using the controls and display on the front panel of the switch illustrated and described in Figure 4-7 and Table 4-9.
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  • Page 77: Section 5: Safety Device Testing

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING SECTION 5: SAFETY DEVICE TESTING 5.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion- related safety devices before, during and after the start sequence.

  • Page 78: Low Gas Pressure Test

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.2 LOW GAS PRESSURE TEST Complete the instructions in Section 5.2.1 for BMK 750 – 2500 units, or in Section 5.2.2 for BMK 3000 units, which have different Low and High Gas Pressure switches. 5.2.1 LOW GAS PRESSURE TEST: BMK 750 –...
  • Page 79 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK 750 – 2500 TO AIR/FUEL (P/N 22140-1 shown) VALVE MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH SSOV GAS INLET 1/4”...

  • Page 80: Low Gas Pressure Test: Bmk 3000 Only

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK 750 – 2500 NATURAL HIGH GAS PRESSURE GAS INLET SWITCH (P/N 22190 shown) SSOV LOW GAS PRESSURE AIR/FUEL VALVE SWITCH MANUAL SHUT-OFF VALVE 1/4”...
  • Page 81 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK 3000 Only 7. Press the MENU key on the front panel of the C-More Controller and access the Setup menu, enter the password 6817 and then press the ENTER key. 8.

  • Page 82: High Gas Pressure Test

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.3 HIGH GAS PRESSURE TEST Complete the instructions in Section 5.3.1 for BMK 750 – 2500 units, or in Section 5.3.2 for BMK 3000 units, which have different High Gas Pressure switches. 5.3.1 HIGH GAS PRESSURE TEST: BMK 750 –...
  • Page 83 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 750 – 2500 11. Press the CLEAR button on the C-More Controller to clear the fault. 12. The fault message should clear and the FAULT indicator should go off. The unit should restart (if in MANUAL mode).

  • Page 84: High Gas Pressure Test: Bmk 3000 Only

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 750 – 2500 HIGH GAS NATURAL PRESSURE GAS INLET SWITCH 1/4” NPT PLUG (install manometer here for HIGH SSOV PRESSURE FAULT TEST) HIGH GAS LOW GAS BALL VALVE...
  • Page 85 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 3000 ONLY to 100%. 8. Slowly increase the manifold gas supply pressure by turning the Gas Pressure Adjustment Screw in the Downstream SSOV (Figure 4-3) while reading the CO level on the combustion analyzer.

  • Page 86: Low Water Level Fault Test

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: LOW Water Fault Test Instructions 1. Set the ON/OFF switch to the OFF position 2.

  • Page 87: Water Temperature Fault Test

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the automatic Over-Temperature switch. This switch is accessible from the front of the unit as shown in Figure 5-5a and 5-5b. Water Temperature Fault Test Instructions 1.
  • Page 88 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING Water Temperature Fault Test Instructions Manual Reset button for Digital Over- Temperature Temperature Manual Limit Controller Limit Switch Temperature Limit Switch Adjustable Temperature Limit switch (auto-rest) Figure 5-5b: Temperature Limit Switch Location – BMK 750-1000 •...

  • Page 89: Interlock Tests

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (shown in Figure 2- 11) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.

  • Page 90: Flame Fault Test

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.7 FLAME FAULT TEST Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: Flame Fault Test Instructions 1.

  • Page 91: Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5-6a and 5-6b.
  • Page 92 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING BLOCKED INLET SWITCH BLOWER PROOF SWITCH AIR/FUEL VALVE Figure 5-6b: Bare Boiler – Partial View – BMK 750/13000 Shown Blower Proof Switch Test Instructions 1. Set the Controller’s On/Off switch to Off. 2.

  • Page 93: Blocked Inlet Switch Test

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.8.2 Blocked Inlet Switch Test This test will be run in simulated fire mode, with the Blocked Inlet switch isolated from the rest of the control circuitry. Blocked Inlet Switch Test Instructions 1.

  • Page 94: Ssov Proof Of Closure Switch Check

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.9 SSOV PROOF OF CLOSURE SWITCH CHECK The SSOV, shown in Figure 5-9, contains the Proof of Closure switch. The Proof of Closure switch circuit is checked as follows: SSOV Proof Of Closure Switch Check Instructions 1.
  • Page 95 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING Purge Switch Open During Purge Check Instructions 6. The unit should begin its start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE. 7. Replace the wire on the Purge switch and depress the CLEAR button. The unit should restart.
  • Page 96 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING Purge Switch Open During Purge Check Instructions TO BLOWER Ignition Position Switch VALVE POSITION DIAL AIR/FUEL VALVE SWITCH WIRING BREAKOUT Purge Position Switch AIR IN Figure 5-11a: Air/Fuel Purge and Ignition Locations– BMK 1500 – 3000 Ignition Position Switch Purge Position Switch TO BLOWER...

  • Page 97: Ignition Switch Open During Ignition

    Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING 5.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Ignition Switch Open During Ignition Check Instructions 1.
  • Page 98 Benchmark 750-3000 Installation & Startup Manual SECTION 5 – SAFETY DEVICE TESTING (This page intentionally blank) • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 98 of...

  • Page 99: Section 6: Boiler Sequencing Technology

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.1 INTRODUCTION The Boiler Sequencing Technology system (BST) is built into the C-More Controller. BST is an integrated 8 boiler control system. It has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 8 boilers while achieving maximum operational efficiency.

  • Page 100: Installation Notes

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.1.1 INSTALLATION NOTES If you are installing a BST system that also includes a ProtoNode SSD (Client-Client Device), you must adhere to the procedure listed below. Failure to complete these steps can result in the failure of the BST system.

  • Page 101: Bst Implementation Instruction

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3 BST Implementation Instruction 6.3.1 OPTION 1 - CONSTANT SETPOINT WITH DIRECT WIRED HEADER SENSOR OPTION 1 - Constant Setpoint With Direct Wired Header Sensor Instructions Step 1: Direct Wired Header Sensor Wiring 1.

  • Page 102: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.2 OPTION 2 - CONSTANT SETPOINT WITH MODBUS WIRED HEADER SENSOR OPTION 2 - Constant Setpoint With Modbus Wired Header Sensor Instructions Step 1: Modbus Header Sensor Wiring 1.

  • Page 103: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.3 OPTION 3 - OUTDOOR RESET WITH DIRECT WIRED HEADER SENSOR AND DIRECT WIRED OUTDOOR SENSOR OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor Instructions NOTE: Both Header Sensor AND Outdoor Sensor must be wired.
  • Page 104 Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor Instructions 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.

  • Page 105: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.4 OPTION 4 - OUTDOOR RESET WITH MODBUS HEADER SENSOR AND MODBUS OUTDOOR SENSOR OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor Instructions NOTE: Both Header Sensor AND Outdoor Sensor must be wired.
  • Page 106 Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor Instructions NOTES: • Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD”...

  • Page 107: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.5 OPTION 5 - REMOTE SETPOINT WITH DIRECT WIRED HEADER SENSOR AND 4-20MA SETPOINT DRIVE OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4- 20ma Setpoint Drive Instructions NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired.
  • Page 108 Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4- 20ma Setpoint Drive Instructions 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.

  • Page 109: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.6 OPTION 6 - REMOTE SETPOINT WITH DIRECT WIRED HEADER SENSOR AND MODBUS SETPOINT DRIVE OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive Instructions NOTE: Both Header Sensor AND Outdoor Sensor must be wired.
  • Page 110 Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive Instructions NOTES: • Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD”...

  • Page 111: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.7 OPTION 7 - REMOTE SETPOINT WITH MODBUS HEADER SENSOR AND 4-20MA SETPOINT DRIVE OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4- 20ma Setpoint Drive Instructions NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired.
  • Page 112 Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4- 20ma Setpoint Drive Instructions 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.

  • Page 113: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY 6.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive Instructions NOTE: Both Header Sensor AND ProtoNode SSD Device must be wired.
  • Page 114 Benchmark 750-3000 Installation & Startup Manual SECTION 6 – BOILER SEQUENCING TECHNOLOGY OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive Instructions 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.

  • Page 115: Section 7: Onaer Setup

    Benchmark 750-3000 Installation & Startup Manual SECTION 7 – ONAER SETUP SECTION 7: onAER SETUP 7.1 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 you monitor your AERCO boilers and water heaters remotely.
  • Page 116 Benchmark 750-3000 Installation & Startup Manual SECTION 7 – ONAER SETUP Connecting The Ethernet Cable Instructions I/O Box enclosure with I/O PCB and Ethernet PCB. Ethernet cable enters through I/O enclosure grommet here. Ethernet cable plugs into Ethernet PCB here. Figure 7-1: I/O Box Interior Showing Ethernet Cable &...

  • Page 117: Confirming The Ethernet Connection

    Benchmark 750-3000 Installation & Startup Manual SECTION 7 – ONAER SETUP 7.1.2 Confirming the Ethernet Connection Refer to Figure 7-2, below, and complete the following instructions to confirm that the Ethernet cable connection is working. Confirming The Ethernet Connection Instructions 1.
  • Page 118 Benchmark 750-3000 Installation & Startup Manual SECTION 7 – ONAER SETUP (This page intentionally blank) • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 118 of...

  • Page 119: Appendix A: Dimensional And Clearance Drawings

    Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix A: Dimensional and Clearance Drawings Benchmark 750/1000 Dimension Drawing AP-A-891 rev J • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019...
  • Page 120 Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Single Unit Clearance Drawing SD-A-871 rev C • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 120 of...
  • Page 121 Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 750/1000 Zero Side Clearance Drawing SD-A-872 rev C • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 121 of...
  • Page 122 Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Dimension Drawing Number: AP-A-1036 rev B • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 122 of...
  • Page 123 Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 1500/2000 Clearance Drawing Number: SD-A-995 rev B • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 123 of...
  • Page 124 Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Dimension Drawing Number: AP-A-915 rev E • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 124 of...
  • Page 125 Benchmark 750-3000 Installation & Startup Manual APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS Benchmark 2500/3000 Clearance Drawing Number: SD-A-898 rev E • • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST OMM-115_D GF-200 5/9/2019 Page 125 of...
  • Page 126 Benchmark 750-3000 Installation & Startup Manual NOTES Change Log: Date Description Changed By Rev C: DIR 17-065: Changed minimum gas pressure for BMK 1500/2000 to 4’ W.C. in Table 2-2, section 2.9.1 11/29/2017 Chris Blair DIR 17-080: Verified part numbers throughout the manual, standardized C-More Controller naming convention.

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