AER 750 Installation manual

Benchmark 750-3000 Installation & Startup Guide - KOREA
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
GF-205-K
INSTALLATION and STARTUP GUIDE
®
Natural Gas Fired, Modulating and Condensing Boilers
Latest Update: 07/17/2017
750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers
USER MANUAL (1 of 2)
SEE ALSO:
Benchmark 750-3000 Boiler
Operation and Maintenance
Guide OMM-0128 (GF-206-K)
APPLIES TO MODELS:
Natural Gas:
•BMK 750
•BMK 1000
•BMK 1500
•BMK 2000
•BMK 2500
•BMK 3000
This Manual Applies to Serial Number:
G-17-1200 and above.
Patent # 10-1755141

Benchmark 750-3000 Installation & Startup Guide - KOREA
CONTENTS
Page 2of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
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
SECTION 2: INSTALLATION .............................................................................11
2.1 INTRODUCTION.................................................................................................................11
2.2 RECEIVING THE UNIT.......................................................................................................11
2.3 UNPACKING.......................................................................................................................11
2.4 SITE PREPARATION .........................................................................................................12
2.4.1 Installation Clearances ...................................................................................................................12
2.4.2 Setting the Unit ..............................................................................................................................15
2.5 LIFTING PROVISIONS.......................................................................................................17
2.5.1 BMK 750 – 1000 lifting Provisions..................................................................................................17
2.5.2 BMK 1500 – 2000 Lifting Provisions ...............................................................................................18
2.6 SUPPLY AND RETURN PIPING.........................................................................................19
2.6.1 BMK 750 – 1000 Supply and Return Piping.................................................................................... 19
2.6.2 BMK 1500 – 3000 Supply and Return Piping.................................................................................. 19
2.7 PRESSURE RELIEF VALVE INSTALLATION ....................................................................21
2.8 CONDENSATE DRAIN AND PIPING..................................................................................22
2.9 GAS SUPPLY PIPING ........................................................................................................24
2.9.1 Gas Supply Specifications ............................................................................................................... 25
2.9.2 Manual Gas Shutoff Valve .............................................................................................................. 25
2.9.3 External Gas Supply Regulator ....................................................................................................... 26
2.10 AC ELECTRICAL POWER WIRING..................................................................................28
2.10.1 Electrical Power Requirements ....................................................................................................28
2.10.2 Power Box Locations ....................................................................................................................30
2.10.3 Electrical Power Box Internal Components.................................................................................. 30
2.11 FIELD CONTROL WIRING ...............................................................................................33
2.11.1 Outdoor Air & Air Sensor Common.............................................................................................. 34
2.11.2 AIR TEMP SENSOR ........................................................................................................................35
2.11.3 O2SENSOR (+ & –) ........................................................................................................................35
2.11.4 SPARK SIGNAL (+ & –)................................................................................................................... 35
2.11.5 ANALOG IN ................................................................................................................................... 35
2.11.6 VALVE FEEDBACK.......................................................................................................................... 36
2.11.7 SHIELD (SHLD & SHLD).................................................................................................................. 36
2.11.8 ANALOG OUT................................................................................................................................ 36
2.11.9 RS485 Comm (+, GND, & -)........................................................................................................... 36
2.11.10 RS232 Comm (TxD & RxD)..........................................................................................................36
2.11.11 VFD/Blower (0-10 & AGND) .......................................................................................................36
2.11.12 Interlocks.................................................................................................................................... 37
2.11.13 Fault Relay (NC, COM, & NO) ..................................................................................................... 37
2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) ................................................................................ 37

Benchmark 750-3000 Installation & Startup Guide - KOREA
CONTENTS
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 3of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
2.12 FLUE GAS VENT INSTALLATION....................................................................................38
2.13 COMBUSTION AIR...........................................................................................................39
2.13.1 DUCTED COMBUSTION AIR ..........................................................................................................39
2.14 BENCHMARK PUMP RELAY ...........................................................................................40
2.15 SEQUENCING ISOLATION VALVE INSTALLATION........................................................41
SECTION 3: START SEQUENCE ........................................................................43
3.1 INTRODUCTION.................................................................................................................43
3.2 START SEQUENCE ...........................................................................................................43
3.3 START/STOP LEVELS.......................................................................................................49
3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT.....................................................50
SECTION 4: INITIAL START-UP ........................................................................53
4.1 INITIAL START-UP REQUIREMENTS................................................................................53
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION........................................53
4.2.1 Required Tools & Instrumentation................................................................................................. 53
4.2.2 Installing Gas Supply Manometer – BMK 750 & 1000 ONLY.......................................................... 54
4.2.3 Gas Supply Gauge – BMK 1500 – 3000 ONLY ................................................................................ 55
4.2.4 Accessing the Analyzer Probe Port................................................................................................. 57
4.3 COMBUSTION CALIBRATION...........................................................................................58
4.4 REASSEMBLY....................................................................................................................63
4.5 OVER-TEMPERATURE LIMIT SWITCHES........................................................................64
4.5.1 Digital Alarm Switch Checks and Adjustments............................................................................... 65
SECTION 5: SAFETY DEVICE TESTING ..............................................................67
5.1 TESTING OF SAFETY DEVICES.......................................................................................67
5.2 LOW GAS PRESSURE TEST.............................................................................................68
5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500 .................................................................................. 68
5.2.2 LOW GAS PRESSURE TEST: BMK 3000 Only....................................................................................70
5.3 HIGH GAS PRESSURE TEST............................................................................................72
5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500 ................................................................................. 72
5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 Only ...................................................................................74
5.4 LOW WATER LEVEL FAULT TEST....................................................................................76
5.5 WATER TEMPERATURE FAULT TEST.............................................................................77
5.6 INTERLOCK TESTS...........................................................................................................79
5.6.1 Remote Interlock Test ....................................................................................................................79
5.6.2 Delayed Interlock Test....................................................................................................................79
5.7 FLAME FAULT TEST..........................................................................................................80
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES ..............81
5.8.1 Blower Proof Switch Test ............................................................................................................... 81
5.8.2 Blocked Inlet Switch Test................................................................................................................83
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK................................................................84
5.10 PURGE SWITCH OPEN DURING PURGE.......................................................................84
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................87
5.12 SAFETY PRESSURE RELIEF VALVE TEST....................................................................87
SECTION 6: BOILER SEQUENCING TECHNOLOGY ............................................89

Benchmark 750-3000 Installation & Startup Guide - KOREA
CONTENTS
Page 4of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
6.1 INTRODUCTION.................................................................................................................89
6.1.1 Installation Notes ...........................................................................................................................90
6.2 AERCO BST QUICK START CHART .................................................................................90
6.3 BST IMPLEMENTATION INSTRUCTION ...........................................................................91
6.3.1 OPTION 1 - Constant Setpoint With Direct Wired Header Sensor .................................................91
6.3.2 OPTION 2 - Constant Setpoint With Modbus Wired Header Sensor .............................................92
6.3.3 OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor93
6.3.4 OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor.............. 95
6.3.5 OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma Setpoint Drive ......97
6.3.6 OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive .....99
6.3.7 OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma Setpoint Drive ........... 101
6.3.8 OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive ..........103
SECTION 7: ONAER SETUP............................................................................105
7.1 INTRODUCTION...............................................................................................................105
7.1.1 Connecting the Ethernet Cable .................................................................................................... 105
7.1.2 Confirming the Ethernet Connection ........................................................................................... 107
7.1.3 Confirm Ethernet DHCP Configuration.........................................................................................107
APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS .............................109

Benchmark 750-3000 Installation & Startup Guide - KOREA
FORWARD
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 5of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
FOREWORD
The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas 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. These BMK models provide extremely high efficiency operation and
are ideally suited for modern low temperature, as well as, conventional heating systems.
The Benchmark models operate within the input and output ranges listed below.
Benchmark Boiler Intake And Output Ranges
MODEL
INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.)
MINIMUM MAXIMUM MINIMUM MAXIMUM
BMK 750 50,000 (14.6 kW) 750,000 (220 kW) 47,750 (14.0 kW) 716,250 (210 kW)
BMK 1000 50,000 (14.6 kW) 1,000,000 (293 kW) 48,300 (14.2 kW) 968,000 (284 kW)
BMK 1500 75,000 (22 kW) 1,500,000 (440 kW) 64,500 (18.9 kW) 1,395,000 (409 kW)
BMK 2000 100,000 (29.3 kW) 2,000,000 (586 kW) 86,000 (25.2 kW) 1,860,000 (545 kW)
BMK 2500 167,000 (48.9 kW) 2,500,000 (732 kW) 144,000 (42.2 kW) 2,395,000 (702 kW)
BMK 3000 200,000 (58.6 kW) 3,000,000 (879 kW) 174,000 (51.0 kW) 2,874,000 (842 kW)
The output of the boiler is a function of the unit’s firing rate (valve position) and return water
temperature.
Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting
flexibility with minimum installation space requirements. These boilers are Category II and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:
•Room Combustion Air:
oVertical Discharge
oHorizontal Discharge
•Ducted Combustion Air:
oVertical Discharge
oHorizontal Discharge
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In
addition, the BMK 750 & 1000 models are also approved for PVC and CPVC, vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.

Benchmark 750-3000 Installation & Startup Guide - KOREA
FORWARD
Page 6of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
A (Amp) Ampere
ACS
AERCO Control System, AERCO’s boiler management systems
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ANSI American National Standards Institute,
ASME American Society of Mechanical Engineers
AUX Auxiliary
BAS
Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate Symbol
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 series boilers
BMS or BMS II AERCO Boiler Management Systems
BLDG (Bldg) Building
BST AERCO on-board Boiler Sequencing Technology
BTU British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)
BTU/HR BTUs per Hour (1 BTU/hr = 0.29 W)
CCP Combination Control Panel
CCS Combination Control System
C-More Controller
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CFH Cubic Feet per Hour (1 CFH = 0.028 m
3
/hr)
CO Carbon Monoxide
COMM (Comm) Communication
Cal. Calibration
CNTL Control
CPU Central Processing Unit
DBB
Double Block and Bleed, a gas trains containing 2 Safety Shutoff
Valves (SSOVs) and a solenoid operated vent valve.
DIP Dual In-Line Package, a type of switch
ECU Electronic Control Unit (O2 sensor)
EMS Energy Management System; often used interchangeably with BAS
FM Factory Mutual. Used to define boiler gas trains.
GF-xxxx Gas Fired (an AERCO document numbering system)
GND Ground

Benchmark 750-3000 Installation & Startup Guide - KOREA
FORWARD
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 7of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
HDR Header
Hex
Hexadecimal Number (0 – 9, A – F)
HP
Horse Power
HX
Heat Exchanger
Hz
Hertz (Cycles Per Second)
I.D. Inside Diameter
IGN Ignition
IGST Board Ignition/Stepper Board, contained in C-More Controller
INTLK (INTL’K) Interlock
I/O Input/Output
I/O Box Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
IP
Internet 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 thousand
th
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
NOxNitrogen Oxide
NPT National Pipe Thread
O2Oxygen
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 C-More
Controller
P/N Part Number
POC
Proof of Closure
PPM Parts per Million
PSI Pounds per Square Inch (1 PSI = 6.89 kPa)

Benchmark 750-3000 Installation & Startup Guide - KOREA
FORWARD
Page 8of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
PTP Point-to-Point (usually over RS232 networks)
P&T
Pressure and Temperature
ProtoNode
Hardware interface between BAS and a boiler or water heater
PVC
Poly Vinyl Chloride, a common synthetic plastic
PWM
Pulse Width Modulation
REF (Ref) Reference
RES. Resistive
RS232
(or EIA-232) A standard for serial, full-duplex (FDX) transmission of data based on the RS232 Standard
RS422
(or EIA-422) A standard for serial, full-duplex (FDX) transmission of data based on the RS422 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)
Shield
SPDT Single Pole Double Throw, a type of switch
SSOV Safety Shut Off Valve
TEMP (Temp) Temperature
Terminating Resistor A resistor placed at each end of a daisy-chain or multi-drop network
in order to prevent
reflections that may cause invalid data in the
communication
Tip-N-Tell A device that indicates if a package was tipped during shipping
UL A business that tests and validates products
VAC Volts, Alternating Current
VDC Volts, Direct Current
VFD Vacuum Fluorescent Display, also Variable Frequency Drive
W Watt
W.C. Water Column, a unit of pressure (1 inch W.C. = 249 Pa)
µA Micro amp (1 million
th
of an ampere)

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 1 – SAFETY PRECAUTIONS
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 9of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
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. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers. Authorities having jurisdiction should be consulted before installations are
made.
IMPORTANT!
This manual is an integral part of the product and must be maintained in legible condition. It
must be given to the user by the installer and kept in a safe 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 when
released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully
decrease all trapped pressures to zero before performing maintenance.
•Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
•The exhaust vent pipe of the unit may operate under a positive pressure and therefore must
be completely sealed to prevent leakage of combustion products into living spaces.
•Electrical voltages up to 220 VAC (BMK 750 – 2000) or 220 or 380 VAC (BMK 2500/3000)
may be used in this equipment. Therefore the cover on the unit’s power box (located behind
the front panel door) must be installed at all times, except during maintenance and servicing.
•A cut-off switch must be installed on the electrical supply line to the unit. The switch must be
installed in an easily accessible position to quickly and safely disconnect electrical service.
Do not affix switch to unit sheet metal enclosures.
CAUTION!
•Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
•DO NOT use this boiler if any part has been under water. Call a qualified service technician
to inspect and replace any part that has been under water.

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 1 – SAFETY PRECAUTIONS
Page 10 of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
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.
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the initial startup procedures in Section 4 and
the safety device test procedures in Section 5, to verify all system-operating parameters. If
there is an emergency, turn off the electrical power supply to the AERCO boiler and close the
manual gas valve located upstream the unit. The installer must identify the emergency shut-off
device.
VALVE
OPEN
VALVE
CLOSED
MANUAL GAS SHUT-OFF VALVE

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 11 of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
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 is shipped as a single crated unit. The shipping weight for these BMK
models is approximately as follows:
•BMK 750: 1100 lbs. (499 kg)
•BMK 1000: 1200 lbs. (544 kg)
•BMK 1500/2000: 1800 lbs. (817 kg).
•BMK 2500/3000: 2200 lbs. (1000 kg)
The unit must be moved with the proper rigging equipment for safety and to avoid equipment
damage. The unit should be completely inspected for evidence of shipping damage and
shipment completeness at the time of receipt from the carrier and before the bill of lading is
signed.
CAUTION!
While packaged in the shipping 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 crate. This indicates if the unit has been turned on its side during shipment. If
the Tip-N-Tell indicator is tripped, do not sign for the shipment. Note the information on the
carrier’s paperwork and request a freight claim and inspection by a claims adjuster before
proceeding. Any other visual damage to the packaging materials should also be made clear to
the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, make a close inspection of the unit to ensure that there is no evidence of
damage not indicated by the Tip-N-Tell indicator. The freight carrier should be notified
immediately if any damage is detected.
The following accessories come standard with each unit and are either packed separately within
the unit’s shipping container or are factory installed on the unit:
•Pressure/Temperature Gauge
•ASME Pressure Relief Valve
•Condensate Drain Trap (P/N 24441)
•A 1 “ or 2” Natural Gas Supply Shutoff Valve

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
Page 12 of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
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.
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark Boiler includes:
•Access to AC input power specified in Section 2.10.1.
•Access to a natural gas supply line with minimum pressure specified in Section 2.9.1.
2.4.1 Installation Clearances
All Benchmark models are the same height, but vary in depth according to model pairs;
750/1000, 1500/2000, and 2500/3000. The unit must be installed with the prescribed clearances
for service as shown in Figure 2-1a, 2-1b and 2-1c. The minimum clearance dimensions,
required by AERCO, are listed below for all models. However, if Local Building Codes require
additional clearances, these codes shall supersede AERCO’s requirements. The minimum
acceptable clearances required are as follows:
•Sides: 24 inches (61 cm)
•Front: 24 inches (61 cm)
•Rear: 24 inches (61 cm)
•Top: 18 inches (45.7 cm)
All gas piping, water piping and electrical conduit or cable must be arranged so that they do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient
space for piping connections and future service/maintenance requirements must also be taken
into consideration. All piping must include ample provisions for expansion.
NOTE:
Benchmark 750 – 3000 units may be installed with zero side clearances in pairs only. The
perimeter clearances still apply. See drawings in Appendix A: Dimensions and Clearance
Drawings.
If installing a Combination (CCP) system using an ACS panel, it is important to identify the
Combination Mode Boilers in advance and place them in the proper physical location. For
information on Combination Mode Boilers refer to Section 3.7 of the Benchmark 750-3000 Boiler
Operation and Maintenance Guide,OMM-0128 (GF-206-K).

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 13 of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
Figure 2-1a: BMK 750/1000 Clearances
Figure 2-1b: BMK 1500/2000 Clearances
NOTE:
Ensure that
condensate
assembly is
not located
over the
housekeeping
NOTE:
Ensure that
condensate
assembly is
not located
over the
housekeeping
pad.

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
Page 14 of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
Figure 2-1c: BMK 2500/3000 Clearances
WARNING!
Keep the unit area clear and free from all combustible materials and flammable vapors or
liquids.
Housekeeping Pad.
FRONT
REAR
NOTE:
Ensure that
condensate
assembly is
not located
over the
housekeeping

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 15 of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
2.4.2 Setting the Unit
BMK 750/1000 units must be installed on a 4 to 6 inch (10.2 to 15.2 cm) while BMK 1500 –
3000 units must be installed on a 4 to 8 inch (10.2 to 20.3 cm) housekeeping pad to ensure
proper condensate drainage. If anchoring the unit, refer to Figure 2-2a, 2-2b and 2-2c for anchor
locations.
•All holes are flush with the bottom surface of the frame.
•All dimensions shown are in inches [millimeters]
Figure 2-2a: BMK 750/1000 Anchor Bolt Locations
Figure 2-2b: BMK 1500/2000 Anchor Bolt Locations

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
Page 16 of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
NOTES:
1) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME
2) ALL DIMENSIONS SHOWN ARE IN INCHES [MILLIMETERS]
Figure 2-2c: BMK 2500/3000 Anchor Bolt Locations
FRONT
REAR

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 17 of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
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. The boiler can be lifted and moved by inserting forklift tines in the front slots
provided in the base of the unit, or it can be lifted by attaching a lifting bar to the unit’s heat
exchanger. A lifting bar (P/N 59174), with attaching hardware, is supplied with each unit. When
shipped, this bar is attached to the rear of the unit as shown in Figure 2-3a (View A). One (1)
lifting tab is provided at the top of the unit’s heat exchanger as shown. This tab is used to attach
the lifting bar to the unit, as described below.
WARNING!
When using the lifting tab and bar, ensure there is no load placed on the gas train or blower.
Attaching The Lifting Bar: BMK 750/1000 Instructions
1. Remove the lifting bar from its shipping location at the rear of the unit (Figure 2-3a, View
A). Retain the two (2) hex head cap screws, hex nuts and flat washers.
2. Remove the top shroud from the boiler and locate the lifting tab at the top-rear of the heat
exchanger.
3. Attach the lifting bar to the heat exchanger lifting tab using the hardware removed in step 1
(Fig. 2-3a, View B). The upper end of the lifting bar containing the oval cutout should be
positioned over the top of the heat exchanger as shown.
4. Using proper rigging equipment capable of lifting 1200 lbs. (544 kg), lift the boi
ler and
position it on the housekeeping pad.
5. After the boiler is properly set on the pad, detach the lifting bar and replace the shroud on
the top of the unit, but retain the lifting bar for possible reuse at the installation site.
Figure 2-3a: BMK 750/1000 Boiler Lifting Provisions
LIFTING BAR
IN LIFTING
POSITION
LIFTING
BAR IN
SHIPPING
POSITION
LIFTING
TAB
VIEW B - LIFTING POSITION
VIEW A - SHIPPING POSITION

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
Page 18 of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
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. Lift the unit off the shipping skid and
position it on the 4 inch to 8 inch (10.2 cm to 20.3 cm) housekeeping concrete pad (required)
in the desired location.
Figure 2-3b: Boiler Lifting Provisions – BMK 1500/2000 Shown
LIFTING LUGS (3 POSITIONS)
YELLOW ARROWS
2” NATURAL
GAS

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
OMM-0127_0B AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 19 of 116
GF-205-K Ph.: 800-526-0288 07/17/2017
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. Refer to Appendix A for dimensional data.
When connecting the hot water outlet and cold water inlet to building piping, first make sure the
mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the
mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
Figure 2-4a: BMK 750/1000 Supply and Return Locations
2.6.2 BMK 1500 – 3000 Supply and Return Piping
All Benchmark 1500, 2000, 2500 and 3000 units have one 4” (10.2 cm) 150# flanges for the
water INLET (supply) and one 4” (10.2 cm) 150# flanges for the hot water OUTLET (return)
piping connections. Refer to Appendix A for dimensional data.
When connecting the hot water outlet and cold water inlet to building piping, first make sure the
mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the
mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
1” (2.54cm) NATURAL GAS INLET
1/4” ANALYZER
NPT PORT
3” HOT WATER OUTLET
(SUPPLY)
CONDENSATE DRAIN
AIR INLET
3” WATER INLET
DRAIN VALVE
EXHAUST
MANIFOLD

Benchmark 750-3000 Installation & Startup Guide - KOREA
SECTION 2 – INSTALLATION
Page 20 of 116 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-127_0B
07/17/2017 Ph.: 800-526-0288 GF-205-K
Figure 2-4b: BMK 1500/2000 and BMK 2500/3000 Supply and Return Locations
CONDENSATE DRAIN
EXHAUST MANIFOLD
BMK 1500/2000
BMK 2500/3000
2” NATURAL GAS
AIR INLET
HOT WATER
OUTLET
(SUPPLY)
WATER INLET
(RETURN)