Watts Aerco Benchmark Series, Installation And Start-Up Manual

Page 1: ...uct include OMM 0137 GF 211 Operation Service Manual OMM 0138 GF 212 Reference Manual OMM 0139 GF 213 Edge Controller Manual TAG 0019 GF 2070 Boiler Application Guide TAG 0022 GF 2050 Vent Combustion...

Page 2: ...1 2 6 SUPPLY AND RETURN PIPING 22 2 6 1 BMK750 1000 Supply and Return Piping 22 2 6 2 BMK1500 4000 Supply and Return Piping 23 2 6 3 BMK5000 6000 Supply and Return Piping 24 2 6 4 Dual Inlet Return Pi...

Page 3: ...12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 3 of 57 3 1 INTRODUCTION 45 3 1 1 Connecting the Ethernet Cable 45 3 1 2 Confirming the Ethernet Connection 46 3 1 3 Confirm Ethern...

Page 4: ...Benchmark Platinum Edge ii Installation Manual CONTENTS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 4 of 57 This page intentionally blank...

Page 5: ...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 58 6 kW 3 000 000 879 kW 1...

Page 6: ...less each symbol is 1 bit long BMK Benchmark AERCO s Benchmark series boilers BMS or BMS II AERCO Boiler Management Systems BLDG Bldg Building BST AERCO on board Boiler Sequencing Technology BTU Briti...

Page 7: ...net Protocol 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 1...

Page 8: ...rd 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 SPDT Single Pole Double Thro...

Page 9: ...fe place for future reference WARNING Do not 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 w...

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

Page 11: ...n the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm...

Page 12: ...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 ins...

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

Page 14: ...2 1d 2 4 1 Installation Clearances All Benchmark models are the same height but vary in depth by model The unit must be installed with the prescribed clearances for service as shown in Figure 2 1a thr...

Page 15: ...age 15 of 57 Section 6 6 Combination Control System of the Benchmark Platinum Edge OPERATION SERVICE Manual GF 211 Figure 2 1a BMK750 1000 Clearances Figure 2 1b BMK1500 2000 Clearances NOTE Ensure th...

Page 16: ...port 800 526 0288 Mon Fri 8 am 5 pm EST Page 16 of 57 Figure 2 1c BMK2500 3000 Clearances Figure 2 1d BMK4000 Clearances Housekeeping Pad NOTE Ensure that condensate assembly is not located over the h...

Page 17: ...nd flammable vapors or liquids FOR MASSACHUSETTS ONLY For Massachusetts installations the unit must be installed by a plumber or gas fitter licensed within the Commonwealth of Massachusetts In additio...

Page 18: ...stallation Manual SECTION 2 INSTALLATION OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 18 of 57 Figure 2 2a BMK750 1000 Anchor Bolt Locations Figure 2 2b BMK150...

Page 19: ...INSTALLATION OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 19 of 57 Figure 2 2c BMK2500 3000 Anchor Bolt Locations Figure 2 2d BMK4000 Anchor Bolt Locations Fi...

Page 20: ...elow WARNING When using the lifting tab and bar ensure there is no load placed on the gas train or blower Attaching the Lifting Bar BMK750 1000 Instructions 1 Remove the lifting bar from its shipping...

Page 21: ...visions BMK1500 2000 Shown 2 5 3 BMK5000 6000 Lifting Provisions 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...

Page 22: ...MK750 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...

Page 23: ...eturn piping connections They also include an optional second 4 10 2 cm 150 flange for the water INLET as shown in Figure 2 4b Figure 2 4b BMK1500 4000 Supply and Return Locations Benchmark Platinum 4...

Page 24: ...turn temperature zone or AERCO SmartPlate thermal efficiency can improve by up to 6 based on an 80 F 26 7 C minimum return water temperature at full fire Lower return temperatures are possible which w...

Page 25: ...e used on the threaded connections Any excess should be wiped off to avoid getting any joint compound into the valve body The relief valve must be piped to within 12 inches 30 5 cm of the floor to pre...

Page 26: ...O recommends that 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 dra...

Page 27: ...OBE PORT 3 4 NPT NIPPLE HOSE CLAMP CONDENSATE TRAP P N 24441 1 DIAM HOSE 3 4 NPT NIPPLES UNION EXHAUST MANIFOLD TO CONDENSATE NEUTRALIZER TRAP INLET INTEGRAL ADAPTOR AND THUMBSCREW TOP COVER THUMB SCR...

Page 28: ...LGP in back of unit 1 1 2 inch 3 81 cm on top of unit Prior to installation all pipes should be de burred and internally cleared of any scale metal chips or other foreign particles Do NOT install any...

Page 29: ...rmation On all Benchmark models it is strongly recommended that the pressure regulator be installed a minimum distance of 10 pipe diameters between the pressure regulator and the nearest downstream fi...

Page 30: ...2 7c BMK1500 4000 Gas Regulator and Manual Shut Off Valve Dual Fuel GAS INLET GAS PRESSURE REGULATOR MANUAL SHUT OFF VALVE NATURAL GAS INLET NATURAL GAS INLET NATURAL GAS PRESSURE REGULATOR PROPANE MA...

Page 31: ...Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 31 of 57 Figure 2 7d BMK5000 6000 Manual Gas Shut Off Valve Location Dual Fuel NATURAL GAS SUPPLY 2 MANUAL GAS SHUT OFF VALVE NATURAL GAS PRES...

Page 32: ...7d 2 10 AC ELECTRICAL POWER WIRING AERCO s Benchmark Electrical Power Guide TAG 0048 GF 2060 must be consulted prior to connecting any AC power wiring to the unit 2 10 1 Electrical Power Requirements...

Page 33: ...ch must be installed on the electrical supply line external to the unit in an easily accessible location to quickly and safely disconnect electrical service DO NOT attach the switch to sheet metal enc...

Page 34: ...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 accord...

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

Page 36: ...aximum gauge of wires connecting to the I O board is 14 J24 SPARK MONITOR FROM SHELL HARNESS 63216 2 CONNECTOR J9 VALVE HARNESS INTERLOCK FROM SHELL HARNESS 63216 2 J6 PINS 3 4 DUAL FUEL SWITCH HARNES...

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

Page 38: ...g V1 feedback Swing V2 Feedback VS Pump Feedback Variable Speed Pump Feedback Remote Setpoint 2 DHW VSP Fdbk To assign program its function go to the Controller s Main Menu Advanced Setup Ancillary De...

Page 39: ...u Advanced Setup Ancillary Devices Relays then set the Relay to Spare 2 Relay and the Name to one of the above devices 2 Spare 2 Relay Com 3 DHW Pump Relay N O Connection to a DHW Pump enable disable...

Page 40: ...Unit Settings 2 Find the Vent Type parameter 3 Set the value of this parameter to match your vent material PVC Polypro or Stainless Steel This sets the exhaust temperature limits Note PVC is not allow...

Page 41: ...g is designed or installed Air supply is a direct requirement of ANSI 223 1 NFPA 54 CSA B149 1 and local codes These codes should be consulted before a permanent design is determined The combustion ai...

Page 42: ...boiler designated the Manager manage the other boilers at the site designated as Clients in such a way that the efficiency of the entire boiler array is maximized When operated with the BST system th...

Page 43: ...oard and to a power supply Figure 2 14 Sequencing Isolation Valve Molex Connector and Jumper Wire Isolation Valve Harness Wire Color Signal 1236 Black 24V Common 1237 Red 24V Hot 1238 White Valve anal...

Page 44: ...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 pilo...

Page 45: ...ections below provide instructions for implementing only the first option enabling communication through an Ethernet cable connected to the site s network If you ordered a Benchmark Platinum boiler wi...

Page 46: ...Ethernet Connection Refer to Figure 3 2 below and complete the following instructions to confirm that the Ethernet cable connection is working Confirming the Ethernet Connection Instructions 1 Powered...

Page 47: ...t DHCP Configuration Instructions 1 Connect your computer to the network jack that will be used by the Edge Controller Your computer should be configured to automatically get a network address Boot or...

Page 48: ...Benchmark Platinum Edge ii Installation Manual SECTION 3 ONAER SETUP OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 48 of 57 This page intentionally blank...

Page 49: ...ual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 49 of 57 Appendix A Dimensional and Clearance Drawings Benchmark...

Page 50: ...Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 50 of 57 Benchmark 750 1000 Single Unit Clearan...

Page 51: ...i Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 51 of 57 Benchmark 750 1000 Zero Side Clearanc...

Page 52: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 52 of 57 Benchmark 1500 2000 Dimension Drawin...

Page 53: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 53 of 57 Benchmark 1500 2000 Clearance Drawin...

Page 54: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 54 of 57 Benchmark 2500 3000 Dimension Drawin...

Page 55: ...ii Installation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 55 of 57 Benchmark 2500 3000 Clearance Drawin...

Page 56: ...nstallation Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 136_E GF 210 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 56 of 57 Benchmark 4000 Clearance Dimensional Dra...

Page 57: ...ntractors in Massachusetts Section 2 12 1 DIR 19 03 Added International option to Section 2 10 AC Electrical Power Wiring DIR 19 04 Added additional requirements to Section 1 2 Emergency Shutdown DIR...