Benchmark 750-3000 Boiler Installation & Startup Manual
CONTENTS
OMM-0121_D • GF-205 • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 2 of 122
TABLE OF CONTENTS
FOREWORD ...................................................................................................... 5
SECTION 1: SAFETY PRECAUTIONS ................................................................... 9
1.1 WARNINGS & CAUTIONS ................................................................................................... 9
1.2 EMERGENCY SHUTDOWN ...............................................................................................10
1.3 PROLONGED SHUTDOWN ...............................................................................................10
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ...............................................11
SECTION 2: INSTALLATION ............................................................................. 13
2.1 INTRODUCTION.................................................................................................................13
2.2 RECEIVING THE UNIT .......................................................................................................13
2.3 UNPACKING .......................................................................................................................13
2.4 SITE PREPARATION .........................................................................................................14
2.4.1 Installation Clearances ................................................................................................................... 14
2.4.2 Setting the Unit .............................................................................................................................. 17
2.5 LIFTING PROVISIONS .......................................................................................................19
2.5.1 BMK 750 – 1000 lifting Provisions .................................................................................................. 19
2.5.2 BMK 1500 – 3000 Lifting Provisions ............................................................................................... 20
2.6 SUPPLY AND RETURN PIPING .........................................................................................21
2.6.1 BMK 750 – 1000 Supply and Return Piping .................................................................................... 21
2.6.2 BMK 1500 – 3000 Supply and Return Piping .................................................................................. 21
2.7 PRESSURE RELIEF VALVE INSTALLATION ....................................................................23
2.8 CONDENSATE DRAIN AND PIPING ..................................................................................24
2.9 GAS SUPPLY PIPING ........................................................................................................26
2.9.1 Gas Supply Specifications ............................................................................................................... 27
2.9.2 Manual Gas Shutoff Valve
......................................................................................................... 27
2.9.3 External Gas Supply Regulator ................................................................................................. 28
2.10 AC ELECTRICAL POWER WIRING ..................................................................................30
2.10.1 Electrical Power Requirements .................................................................................................... 30
2.10.2 Power Box Locations .................................................................................................................... 31
2.10.3 Electrical Power Box Internal Components .................................................................................. 32
2.11 FIELD CONTROL WIRING ...............................................................................................34
2.11.1 Outdoor Air & Air Sensor Common .............................................................................................. 35
2.11.2 AIR TEMP SENSOR ........................................................................................................................ 36
2.11.3 O
2
SENSOR (+ & –) ........................................................................................................................ 36
2.11.4 SPARK SIGNAL (+ & –) ................................................................................................................... 36
2.11.5 ANALOG IN ................................................................................................................................... 36
2.11.6 VALVE FEEDBACK .......................................................................................................................... 36
2.11.7 SHIELD (SHLD & SHLD) .................................................................................................................. 37
2.11.8 ANALOG OUT ................................................................................................................................ 37
2.11.9 RS485 Comm (+, GND, & -) ........................................................................................................... 37
2.11.10 RS232 Comm (TxD & RxD) .......................................................................................................... 37
2.11.11 VFD/Blower (0-10 & AGND) ....................................................................................................... 37
2.11.12 Interlocks .................................................................................................................................... 38
2.11.13 Fault Relay (NC, COM, & NO) ..................................................................................................... 38
2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) ................................................................................ 38
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