AER Benchmark 2.0 LN User manual

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
OMM-0046_0J AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1of 168
GF-123 Ph.: 800-526-0288 06/18/2015
USER MANUAL
Installation, Operation and Maintenance
Natural Gas Fired
Modulating, Condensing,
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Applicable to Serial Numbers
G-12-0800 and above
Latest Update: DRAFT
Benchmark 2.0LN
Low NOx Boiler

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
Page 2 of 168 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0046_0J
06/18/2015 Phone: [phone] GF-123
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
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. Nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of this
material.

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TABLE OF CONTENTS
CHAPTER 1. SAFETY PRECAUTIONS ..................................................................................................9
1.1 WARNINGS & CAUTIONS..................................................................................................................9
1.2 EMERGENCY SHUTDOWN.............................................................................................................10
1.3 PROLONGED SHUTDOWN.............................................................................................................10
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 ......................................................................................................18
2.6 CONDENSATE DRAIN AND PIPING ...............................................................................................19
2.6.1 Exhaust Manifold Condensate Drain..........................................................................................20
2.7 GAS SUPPLY PIPING.......................................................................................................................21
2.7.1 Gas Supply Specifications..........................................................................................................22
2.7.2 Manual Gas Shutoff Valve..........................................................................................................22
2.7.3 External Gas Supply Regulator ..................................................................................................22
2.7.4 IRI Gas Train Kit .........................................................................................................................23
2.8 AC ELECTRICAL POWER WIRING.................................................................................................23
2.8.1 Electrical Power Requirements...................................................................................................23
2.9 MODES OF OPERATION AND FIELD CONTROL WIRING............................................................24
2.9.1 Constant Setpoint Mode .............................................................................................................25
2.9.2 Indoor/Outdoor Reset Mode .......................................................................................................25
2.9.3 Boiler Management System Mode..............................................................................................25
2.9.4 Remote Setpoint and Direct Drive Modes ..................................................................................25
2.9.5 Combination Mode......................................................................................................................26
2.10 I/O BOX CONNECTIONS ...............................................................................................................26
2.10.1 Outdoor Sensor In (1) .............................................................................................................27
2.10.2 Air temp. Sensor (2)................................................................................................................27
2.10.3 Analog In (3)............................................................................................................................27
2.10.4 B.M.S. (PWM) IN (4)...............................................................................................................28
2.10.5 Shield (5).................................................................................................................................28
2.10.6 mA Out (6)...............................................................................................................................28
2.10.7 RS-485 COMM (7)..................................................................................................................28
2.10.8 TxD, RxD (8)...........................................................................................................................28
2.10.9 VFD/Blower (9) .......................................................................................................................28
2.10.10 Exhaust Switch In (11)..........................................................................................................28
2.10.11 Interlocks (10, 12)................................................................................................................28
2.10.11.1 Remote Interlock In (10)..............................................................................29
2.10.11.2 Delayed Interlock In (12)............................................................................29
2.10.12 Fault Relay (13).....................................................................................................................29
2.10.13 Auxiliary Relay Contacts (14)................................................................................................29
2.11 FLUE GAS VENT INSTALLATION .................................................................................................29
2.12 COMBUSTION AIR.........................................................................................................................30
2.12.1 Combustion Air From Outside the Building ..............................................................................30
2.12.2 Combustion Air From Inside The Building................................................................................30
2.12.3 Sealed Combustion ..................................................................................................................30
2.12.4 Ducted Combustion Air.............................................................................................................31
2.12.5 Temporary Combustion Air Filtering During Construction........................................................31
2.13 BENCHMARK PUMP RELAY OPTION ..........................................................................................32

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CHAPTER 3. OPERATION ....................................................................................................................35
3.1 introduction........................................................................................................................................35
3.2 CONTROL PANEL DESCRIPTION ..................................................................................................35
3.3 CONTROL PANEL MENUS..............................................................................................................39
3.3.1 Menu Processing Procedure ......................................................................................................39
3.4 OPERATING MENU..........................................................................................................................40
3.5 SETUP MENU...................................................................................................................................41
3.6 CONFIGURATION MENU.................................................................................................................42
3.7 TUNING MENU .................................................................................................................................44
3.8 COMBUSTION CAL MENU ..............................................................................................................44
3.9 START SEQUENCE..........................................................................................................................45
3.10 START/STOP LEVELS ...................................................................................................................48
CHAPTER 4. INITIAL START-UP..........................................................................................................51
4.1 INITIAL START-UP REQUIREMENTS.............................................................................................51
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION.......................................51
4.2.1 Required Tools & Instrumentation..............................................................................................52
4.2.2 Installing Gas Supply Manometer...............................................................................................52
4.2.3 Accessing the Analyzer Probe Port............................................................................................53
4.3 COMBUSTION CALIBRATION.........................................................................................................54
4.4 UNIT REASSEMBLY.........................................................................................................................58
4.5 OVER-TEMPERATURE LIMIT SWITCHES......................................................................................59
4.5.1 Digital Alarm Switch Checks and Adjustments...........................................................................60
CHAPTER 5. MODE OF OPERATION ..................................................................................................63
5.1 INTRODUCTION...............................................................................................................................63
5.2 INDOOR/OUTDOOR RESET MODE................................................................................................63
5.2.1 Reset Ratio.................................................................................................................................63
5.2.2 Building Reference Temperature................................................................................................63
5.2.3 Outdoor Air Temperature Sensor Installation.............................................................................63
5.2.4 Indoor/ Outdoor Startup..............................................................................................................63
5.3 CONSTANT SETPOINT MODE........................................................................................................64
5.3.1 Setting the Setpoint ....................................................................................................................64
5.4 REMOTE SETPOINT MODES..........................................................................................................65
5.4.1 Remote Setpoint Field Wiring.....................................................................................................65
5.4.2 Remote Setpoint Startup ............................................................................................................66
5.5 DIRECT DRIVE MODES...................................................................................................................66
5.5.1 Direct Drive Field Wiring.............................................................................................................67
5.5.2 Direct Drive Startup ....................................................................................................................67
5.6 BOILER MANAGEMENT SYSTEM (BMS) .......................................................................................67
5.6.1 BMS External Field Wiring..........................................................................................................68
5.6.2 BMS Setup and Startup..............................................................................................................68
5.7 COMBINATION CONTROL SYSTEM (CCS)....................................................................................68
5.7.1 Combination Control System Field Wiring..................................................................................69
5.7.2 Combination Control System Setup and Startup........................................................................69
CHAPTER 6. SAFETY DEVICE TESTING ............................................................................................71
6.1 TESTING OF SAFETY DEVICES.....................................................................................................71
6.2 LOW GAS PRESSURE FAULT TEST..............................................................................................71
6.3 HIGH GAS PRESSURE TEST..........................................................................................................72
6.4 LOW WATER LEVEL FAULT TEST .................................................................................................73
6.5 WATER TEMPERATURE FAULT TEST...........................................................................................73
6.6 INTERLOCK TESTS .........................................................................................................................74
6.6.1 REMOTE INTERLOCK...............................................................................................................75
6.6.2 DELAYED INTERLOCK .............................................................................................................75
6.7 FLAME FAULT TESTS......................................................................................................................75
6.8 AIR FLOW FAULT TESTS................................................................................................................76
6.9 SSOV PROOF OF CLOSURE SWITCH...........................................................................................77
6.10 PURGE SWITCH OPEN DURING PURGE....................................................................................78

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
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6.11 IGNITION SWITCH OPEN DURING IGNITION..............................................................................78
6.12 SAFETY PRESSURE RELIEF VALVE TEST.................................................................................80
CHAPTER 7. MAINTENANCE...............................................................................................................81
7.1 MAINTENANCE SCHEDULE............................................................................................................81
7.2 IGNITION MAINTENANCE ...............................................................................................................82
7.3 FLAME DETECTOR..........................................................................................................................84
7.4 COMBUSTION CALIBRATION.........................................................................................................85
7.5 SAFETY DEVICE TESTING .............................................................................................................85
7.6 BURNER ASSEMBLY INSPECTION................................................................................................85
7.7 CONDENSATE DRAIN TRAP...........................................................................................................88
7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ...................................89
7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN.....................89
CHAPTER 8. TROUBLESHOOTING GUIDE.........................................................................................91
8.1 INTRODUCTION...............................................................................................................................91
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ........................................104
CHAPTER 9. RS232 COMMUNICATION ............................................................................................107
9.1 INTRODUCTION.............................................................................................................................107
9.1.1 Aquiring the PuTTY Application................................................................................................107
9.1.2 Logging on to a Remote Machine Using PuTTY......................................................................107
9.1.3 Running a Command on a Remote Machine Using PuTTY.....................................................108
9.2 RS232 COMMUNICATION SETUP ................................................................................................109
9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION......................................................109
9.4 DATA LOGGING.............................................................................................................................110
9.4.1 Fault Log...................................................................................................................................110
9.4.2 Operation Time Log..................................................................................................................110
9.4.3 Sensor Log................................................................................................................................111
APPENDIX A – BOILER MENU ITEM DESCRIPTIONS ...................................................................................113
APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES...........................................................................121
APPENDIX C – SENSOR TEMPERATURE RESISTANCE .................................................................................125
APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ........................................................................127
APPENDIX E – BOILER DEFAULT SETTINGS ................................................................................................131
APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS ..............................................................................135
APPENDIX G – PIPING DRAWINGS .............................................................................................................149
APPENDIX H – WIRING SCHEMATICS .........................................................................................................153
APPENDIX I – RECOMMENDED PERIODIC TESTING CHECK LIST ................................................................163
APPENDIX J – BENCHMARK CONTROL PANEL FEATURES ..........................................................................165
APPENDIX K – RECOMMENDED SPARE PARTS LISTS .................................................................................167

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Benchmark 2.0 LN Installation, Operation & Maintenance Manual
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Foreword
The AERCO Benchmark 2.0 Low NOx (LN) Boiler is a modulating unit. It represents 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. The Benchmark 2.0LN, with
its 20:1 turn down ratio and condensing capability, provides extremely high efficiencies and
makes it ideally suited for modern low temperature, as well as, conventional heating systems.
The boiler operates at inputs ranging from 100,000 BTU/hr. to 2,000,000 BTU/hr. The output of
the boiler is a function of the unit’s firing rate and return water temperature. Output ranges from
99,000 BTU/hr. to 1,933,000 BTU/hr., depending on operating conditions.
When installed and operated on natural gas in accordance with this Instruction Manual, the
Benchmark 2.0LN Boiler complies with the NOx emission standards outlined in:
•South Coast Air Quality Management District (SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the Benchmark 2.0LN offers the maximum
flexibility in venting with minimum installation space requirements. The Benchmark's advanced
electronics are available in several selectable modes of operation offering the most efficient
operating methods and energy management system integration.
For service or parts, contact your local sales representative or AERCO INTERNATIONAL.
NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
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Benchmark 2.0 LN Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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CHAPTER 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).
Where ASME CSD-1 is required by local jurisdiction, the installation must conform to CSD-1.
Where applicable, the equipment shall be installed in accordance with the current Installation
Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial
regulations for the class; which should be carefully followed in all cases. Authorities having
jurisdiction should be consulted before installations are made.
IMPORTANT
This Instruction 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
WARNINGS MUST BE OBSERVED TO PREVENT SERIOUS INJURY.
WARNING
BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE
UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.
WARNING
THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A
POSITIVE PRESSURE AND THERE-FORE MUST BE COMPLETELY
SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO
LIVING SPACES.
WARNING
A DOUBLE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNIT. THE SWITCH MUST BE INSTALLED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY DIS-
CONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO UNIT
SHEET METAL ENCLOSURES.
WARNING
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.

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WARNING
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.
WARNING
ELECTRICAL VOLTAGES UP TO 120 VAC 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.
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.
CAUTION!
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.
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.
IMPORTANT
The Installer must identify and indicate the location of the
emergency shutdown manual gas valve to operating personnel.
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of this manual be performed, 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.

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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MANUAL GAS SHUTOFF
VALVE
VALVE OPEN VALVE CLOSED
Figure 1-1: Manual Gas Shutoff Valve
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY
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.
•Prior to unit operation, the complete gas train and all connections must be leak tested
using a non-corrosive soap.
•If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed
upstream of the Fill/Makeup Valve.
•The vent termination must be located a minimum of 4 feet above grade level.
•If side-wall venting is used, the installation must conform to the following requirements
extracted from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
building or structure used in whole or in part for residential purposes, including those owned or
operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation
of the side wall horizontal vented gas fueled equipment, the installing plumber or
gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and
battery back-up is installed on 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 is installed on each additional level
of the dwelling, building or structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to secure the services of
qualified licensed professionals for the installation of hard wired carbon monoxide
detectors.

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a. In the event that the side wall horizontally vented gas fueled equipment is
installed in a crawl space or an attic, the hard wired carbon monoxide detector
with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the
time of completion of installation, the owner shall have a period of thirty (30) days
to comply with the above requirements; provided, however, that during said thirty
(30) day period, a battery operated carbon monoxide detector with an alarm shall
be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector
as required in accordance with the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the
exterior of the building at a minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than one-half (1/2) inch in size,
"GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
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.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented"
in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a
room or structure separate from the dwelling, building or structure used in whole or in
part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM
PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas
equipment provides a venting system design 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 installation of the venting system design or the venting
system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT
PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the flue gases, but identifies "special
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the
appliance or equipment installation instructions, and

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2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for the Product Approved side wall horizontally vented
gas fueled equipment and all the venting instructions, parts lists and/or design instructions for
the venting system shall remain with the appliance or equipment at the completion of the
installation.
End of Extracted Information From 248 CMR 5.08 (2)

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Benchmark 2.0 LN Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
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CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
the AERCO Benchmark 2.0LN Boiler. Brief descriptions are also provided for each available mode
of operation. Detailed procedures for implementing these modes are provided in Chapter 5.
2.2 RECEIVING THE UNIT
Each Benchmark 2.0LN System is shipped as a single crated unit. The shipping weight is
approximately 1600 pounds. 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.
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
A close inspection of the unit should be made to ensure that there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
IMPORTANT
After unpacking, take off the unit top panel and remove the strap and packing
material at the top of the heat exchanger. The packing material is located in
the area of the igniter and staged ignition solenoid on the burner assembly.
The following accessories come standard with each unit and are either packed separately within
the unit’s packing container or are factory installed on the boiler:
•Pressure/Temperature Gauge
•ASME Pressure Relief Valve
•Condensate Drain Trap
•2” Gas Supply Shutoff Valve
When ordered, optional accessories may be packed separately, packed within the boiler shipping
container, or may be installed on the boiler. Any standard or optional accessories shipped loose
should be identified and stored in a safe place until ready for installation or use.

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2.4 SITE PREPARATION.
Ensure that the site selected for installation of the Benchmark 2.0LN Boiler includes:
•Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20A
•Access to line at a Minimum supply gas pressure of 4" W.C. (2000 cfh for Natural Gas).
2.4.1 Installation Clearances
The unit must be installed with the prescribed clearances for service as shown in Figure 2-1. The
minimum clearance dimensions, required by AERCO, are listed below. However, if Local Building
Codes require additional clearances, these codes shall supersede AERCO’s requirements.
Minimum acceptable clearances required are:
•Sides: 24 inches
•Front : 24 inches
•Rear: 30 inches
•Top: 18 inches
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.
44.5" 18"
79"
101"
4" HIGH PAD*
24"
24"
30" 24"
REAR FRONT
*(SEE NOTE IN PARAGRAPH 2.4.2)
Figure 2-1: Benchmark 2.0LN Boiler Clearances
WARNING
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
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CAUTION
While packaged in the shipping container, the boiler must be moved by pallet
jack or forklift from the FRONT ONLY.
FOR MASSACHUSSETTS ONLY
For Massachusetts installations, the boiler must be installed by a plumber or
gas fitter who is licensed within the Commonwealth of Massachusetts. In
addition, the installation must comply with all requirements specified in
Chapter 1 (Safety Precautions).
2.4.2 Setting the Unit
The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate
drainage (see NOTE below). If anchoring the unit, refer to the dimensional drawings in Appendix F
for anchor locations. Two lifting tabs are provided at the top of the heat exchanger. Figure 2-2
shows the location of the tab on the top-left side. The second tab is located on the top-right side of
the heat exchanger. USE THESE TWO TABS TO LIFT AND MOVE THE UNIT. Remove the top
panel from the unit to provide access to the lifting tabs. 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 6 inch
housekeeping concrete pad (required) in the desired location.
NOTE
When using the AERCO Condensate Neutralizer Tank for proper condensate
drainage, the Neutralizer Tank must be stored in a pit, OR the boiler and
AERCO Condensate Trap must be elevated higher than 4” above the floor.
See Condensate Tank instructions in TID-0074 for details.
WARNING
WHEN LIFTING OR MOVING THE BOILER:
•DO NOT MANIPULATE THE BOILER USING THE GAS TRAIN OR
BLOWER
•WHEN USING THE LIFTING TABS, ENSURE THERE IS NO LOAD
PLACED ON THE GAS TRAIN OR BLOWER

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LIFTING
TABS (2)
Figure 2-2: Partial Top View Showing Lifting Tab Location
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.
If installing a Combination Control Panel (CCP) system, it is important to identify the Combination
Mode Boilers in advance and place them in the proper physical location. Refer to Chapter 5 for
information on Combination Mode Boilers.
2.5 SUPPLY AND RETURN PIPING
The Benchmark 2.0LN Boiler utilizes 4” 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 2-3. Refer to Appendix F, Drawing AP-A-798 for additional dimensional
data.

Benchmark 2.0 LN Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
OMM-0046_0J AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 19 of 168
GF-123 Ph.: 800-526-0288 06/18/2015
2" GAS INLET
CONNECTION
BOILER RETURN
4" – 150# FLANGE
CONNECTION
BOILER SUPPLY
4" – 150# FLANGE
CONNECTION
EXHAUST
MANIFOLD
SHELL
DRAIN
VALVE
REAR VIEW
Figure 2-3: Supply and Return Locations
2.6 CONDENSATE DRAIN AND PIPING
The Benchmark 2.0LN Boiler is designed to condense water vapor from the flue products.
Therefore, the installation must have provisions for suitable condensate drainage or collection.
The condensate drain pipe located on the exhaust manifold (Figure 2-4) must be connected to a
condensate trap which is packed separately within the unit’s shipping container.
The procedure to install and connect the condensate drain is provided in paragraph 2.6.1.

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CHAPTER 2 – INSTALLATION
Page 20 of 168 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0046_0J
06/18/2015 Phone: [phone] GF-123
EXHAUST
MANIFOLD
1/2” NPT
CONDENSATE
DRAIN
CONNECTION
HOUSE-
KEEPING
PAD
BOILER
RETURN
Figure 2-4: Condensate Drain Connection Location
2.6.1 Exhaust Manifold Condensate Drain
A condensate drain trap (part no. 24060) is shipped loose and must be installed at the rear of the
unit. The trap inlet and outlet contain tapped 3/4” NPT ports. The actual installation details for the
condensate trap will depend on the available clearances, housekeeping pad height/dimensions
and other prevailing conditions at the site. However, the following guidelines must be observed to
ensure proper condensate trap operation:
•The condensate trap inlet (Figure 2-5) must be level with, or lower than the exhaust manifold
drain port.
•The condensate trap must be supported to ensure that its base is level (horizontal).
•The trap must be removable for routine maintenance. AERCO recommends that a union be
utilized between the exhaust manifold condensate drain port and the trap inlet port.
While observing the above guidelines, connect the condensate trap inlet to the exhaust manifold
drain connection using the appropriate piping components (nipples, reducers, elbows, etc.) for the
boiler installation site. Connect as follows:
Condensate Trap Installation
1. At the condensate trap outlet, install a 3/4” NPT nipple.
2. Connect a length of 1” I.D polypropylene hose to the trap outlet and secure with a hose clamp.
3. Route the hose on the trap outlet to a nearby floor drain.
4. If a floor drain is not available, a condensate pump can be used to remove the condensate to
drain. The maximum condensate flow rate is 20 GPH. The condensate drain trap, associated
fittings and drain line must be removable for routine maintenance.