Instruction Manual

ManualsBrandsAERCO ManualsEquipmentBMK 1000

Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual

OMM-0082_0J AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 192

GF-130 Ph.: 800-526-0288 05/21/2014

TABLE OF CONTENTS

FOREWORD ................................................................................................................. 7

CHAPTER 1. SAFETY PRECAUTIONS ..................................................................... 11

1.1 WARNINGS & CAUTIONS ................................................................................................................... 11

1.2 EMERGENCY SHUTDOWN ................................................................................................................. 12

1.3 PROLONGED SHUTDOWN ................................................................................................................. 13

CHAPTER 2. INSTALLATION .................................................................................... 15

2.1 INTRODUCTION ................................................................................................................................. 15

2.2 RECEIVING THE UNIT ......................................................................................................................... 15

2.3 UNPACKING ....................................................................................................................................... 15

2.4 SITE PREPARATION ............................................................................................................................ 16

2.4.1 Installation Clearances ................................................................................................................ 16

2.4.2 Setting the Unit ........................................................................................................................... 17

2.5 SUPPLY AND RETURN PIPING ............................................................................................................ 19

2.6 PRESSURE RELIEF VALVE INSTALLATION ........................................................................................... 19

2.7 CONDENSATE DRAIN & PIPING ......................................................................................................... 20

2.8 GAS SUPPLY PIPING ........................................................................................................................... 22

2.8.1 Gas Supply Specifications ........................................................................................................... 22

2.8.2 Manual Gas Shutoff Valve .......................................................................................................... 23

2.8.3 External Gas Supply Regulator .................................................................................................... 23

2.8.3.1 Massachusetts Installations Only ......................................................................................... 23

2.8.3.2 All Installations (Except Massachusetts) .............................................................................. 23

2.9 AC ELECTRICAL POWER WIRING ........................................................................................................ 24

2.9.1 Electrical Power Requirements ................................................................................................... 25

2.10 FIELD CONTROL WIRING .................................................................................................................. 26

2.10.1 OUTDOOR AIR IN Terminals...................................................................................................... 28

2.10.2 COMBUSTION AIR Terminal ...................................................................................................... 29

2.10.3 O

SENSOR Terminals ................................................................................................................ 29

2.10.4 SPARK SIGNAL Terminals .......................................................................................................... 29

2.10.5 ANALOG IN Terminals ............................................................................................................... 29

2.10.6 B.M.S. (PWM) IN Terminals ...................................................................................................... 29

2.10.7 SHIELD Terminals ...................................................................................................................... 29

2.10.8 ANALOG OUT Terminals ........................................................................................................... 30

2.10.9 RS-485 Comm Terminals ........................................................................................................... 30

2.10.10 RS-232 Comm Terminals ......................................................................................................... 30

2.10.11 VFD/Blower (0-10 & AGND) .................................................................................................... 30

2.10.12 Interlocks ................................................................................................................................ 30

2.10.12.1 REMOTE INTL’K Terminals................................................................................................ 30

2.10.12.2 DELAYED INTL’K Terminals (OUT & IN) ............................................................................ 30

2.10.13 FAULT RELAY (NC, COM, & NO) Terminals ............................................................................. 31

2.10.14 AUX RELAY CONTACTS (NC, COM, & NO) Terminals .............................................................. 31

2.11 FLUE GAS VENT INSTALLATION ....................................................................................................... 31

2.12 COMBUSTION AIR ............................................................................................................................ 32

2.12.1 Combustion From Outside the Building ................................................................................... 32