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Benchmark 750-3000 Boiler Operation, Service, Maintenance Guide - KOREA

SECTION 5 – TROUBLESHOOTING GUIDE

Page

68

of

144

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0128_0B

07/17/2017

Ph.: 800-526-0288

TABLE 5-1: Boiler Troubleshooting Procedures

Fault
Indication

Probable Causes

Corrective Action

SSOV RELAY
FAILURE

1.

SSOV relay failed on IGST board.

2.

Floating Neutral.

3.

Hot and Neutral reversed at SSOV.

1.

Press

CLEAR

button and restart unit. If fault persists, replace

Ignition/Stepper (IGST) Board.

2.

The Neutral and Earth Ground are not connected at the source and
therefore there is a voltage measured between the two. Normally this
measurement should be near zero or no more than a few millivolts.

3.

Check SSOV power wiring.

SSOV
SWITCH OPEN

1.

Actuator not allowing for full closure of gas
valve.

2.

SSOV powered when it should not be

3.

Defective switch or Actuator.

4.

Incorrectly wired switch.

1.

Observe operation of the Safety Shut-Off Valve (SSOV) through
indicator on the Valve actuator and ensure that the valve is fully and
not partially closing.

2.

If the SSOV never closes, it may be powered continuously. Close
the gas supply and remove power from the unit. Refer fault to
qualified service personnel.

3.

Remove the electrical cover from the SSOV and check switch
continuity. If the switch does not show continuity with the gas valve
closed, either adjust or replace the switch or actuator.

4.

Ensure that the SSOV Proof of Closure switch is correctly wired.

STEPPER
MOTOR
FAILURE

1.

Air/Fuel Valve out of calibration.

2.

Air/Fuel Valve unplugged.

3.

Loose wiring connection to the stepper motor.

4.

Defective Air/Fuel Valve stepper motor.

5.

Defective Power Supply Board or fuse.

6.

Defective IGST Board.

1.

Refer to the C-More User Manual OMM-0032 (GF-112) and perform
the Stepper Feedback Calibration procedure in Section 6, Section
6.2.1.

2.

Check that the Air/Fuel Valve is connected to the C-More
Controller.

3.

Inspect for loose connections between the Air/Fuel Valve motor and
the wiring harness.

4.

Replace stepper motor.

5.

Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.

6.

Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.

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Summary of Contents for 1000

Page 1: ...RATION SERVICE and MAINTENANCE GUIDE Natural Gas Fired Modulating and Condensing Boilers Latest Update 07 17 2017 USER MANUAL 2 of 2 750 1000 1500 2000 2500 and 3000 MBH Boilers SEE ALSO Benchmark 750 3000 Installation and Startup Guide OMM 0127 GF 205 K Applies to Serial Numbers G 17 1200 and above APPLIES TO MODELS Natural Gas BMK 750 BMK 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 Patent 10 175514...

Page 2: ...STION CAL Menus 22 2 9 BST BOILER SEQUENCING TECHNOLOGY MENU 23 2 10 CALIBRATION MENU 26 SECTION 3 MODES OF OPERATION 29 3 1 INTRODUCTION 29 3 2 INDOOR OUTDOOR RESET MODE 29 3 2 1 Reset Ratio 29 3 2 2 Building Reference Temperature 29 3 2 3 Outdoor Air Temperature Sensor Installation 29 3 2 4 Indoor Outdoor Startup 30 3 3 CONSTANT SETPOINT MODE 30 3 3 1 Setting the Setpoint 31 3 4 REMOTE SETPOINT ...

Page 3: ...ENT TRANSDUCER 56 SECTION 5 TROUBLESHOOTING GUIDE 57 5 1 INTRODUCTION 57 5 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 69 APPENDIX A BOILER MENU ITEM DESCRIPTIONS 71 TABLE A 1 OPERATING MENU ITEM DESCRIPTIONS 71 TABLE A 2 SETUP MENU ITEM DESCRIPTIONS 73 TABLE A 3 CONFIGURATION MENU ITEM DESCRIPTIONS 74 TABLE A 4 TUNING MENU ITEM DESCRIPTIONS 77 TABLE A 5 COMBUSTION CALIBRATION MENU ITEM DE...

Page 4: ...rk 750 3000 Boiler Operation Service Maintenance Guide KOREA CONTENTS Page 4 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 5: ...MK 1000 50 000 14 6 kW 1 000 000 293 kW 48 300 14 15 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 func...

Page 6: ... 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 i...

Page 7: ...s 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 thousandth 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 NOx Nitrogen Oxide NPT ...

Page 8: ...mission 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 i...

Page 9: ...nder 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 operates under a positive press...

Page 10: ...hutdown 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 startup procedures and safety device test procedures described in Section 4 and 5 respectively of the Benchmark 750 3000 Boiler Installation and Startup Guide Guide OMM 0127 GF 205 K be performed to verify all system operating parameters If ...

Page 11: ...l startup by factory trained personnel may void the equipment warranty In addition the following WARNINGS and CAUTIONS must be observed at all times WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 220 VAC BMK 750 2000 and 220 or 380 VAC BMK 2500 3000 and 24 volts AC It must be serviced only by factory certified service technicians DO NOT ATTEMPT TO DRY FIRE THE UNIT Starting the unit without a ...

Page 12: ...tilize the C More Controller shown in Figure 2 1 This panel contains all of the controls indicators and displays necessary to operate adjust and troubleshoot the boiler These operating controls indicators and displays are listed and described in Table 2 1 Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section Figure 2...

Page 13: ...ger display flashes shows header temperature 3 VFD Display Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection BST Messages 4 RS232 Port This port is used only by factory trained personnel to monitor onAER communications in combinati...

Page 14: ...essed and the menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 2 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key ...

Page 15: ...ocessing Procedure Accessing and initiating each menu and option is accomplished using the menu keys shown in Figure 2 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures Menu Navigation and Processing Procedure Instructions 1 The C More Controller will normally be in the Operating menu and the VFD will d...

Page 16: ... BST is enabled BST is described in detail in Section 6 of the Benchmark 750 3000 Boiler Installation and Startup Guide OMM 0127 GF 205 K Figure 2 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer to Appendix A for detailed descriptions of each menu option Refer to Appendix B for a list and descriptions of startup status and error m...

Page 17: ...16 C 2 Outlet Temp 30 F 1 1 C 240 F 116 C Configuration Menu 3 Inlet Temp 30 F 1 1 C 240 F 116 C 4 Air Temp 70 F 56 7 C 245 F 118 C 5 Outdoor Temp 70 F 56 7 C 130 F 54 4 C Configuration Menu 6 Valve Position In 0 100 7 Valve Position Out 0 100 Configuration Menu 8 FFWD Temp 30 F 1 1 C 240 F 115 6 C 9 Exhaust Temp Displays current exhaust temperature 10 Flame Strength 0 100 11 Min Flame Str Not Use...

Page 18: ... date and time and units of temperature measurements A view only software version display is also provided to indicate the current C More Controller software version A full description of each item appears in Appendix A 2 TABLE 2 3 SETUP Menu MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMITS DEFAULT Minimum Maximum 1 Password 0 9999 0 2 Language English English 3 Time 12 00 am 11 59 pm 12 00 4 Date 01...

Page 19: ... normal operating conditions no changes will be required TABLE 2 4 CONFIGURATION Menu MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMITS DEFAULT Minimum Maximum 1 Internal Setpt 40 F 4 4 C 240 F 115 6 C 130 F 54 4 C 2 Unit Type BMK Blr Std BMK Blr Std Dual BMK Blr LN BMK Blr LN Dual BMK Boiler LN 3 Unit Size Only displays sizes available for the unit 750 MBH 220 kW 1000 MBH 293 kW 1500 MBH 439 6 kW 200...

Page 20: ...C 10 F 5 5 C 5 F 2 75 C 22 Network Timeout 5 sec 999 sec 30 sec 23 Shutoff Dly Temp 0 F 0 C 25 F 13 75 C 10 F 5 5 C 24 Demand Offset 0 F 0 C 25 F 13 75 C 10 F 5 5 C 25 Deadband High 0 F 0 C 25 F 13 75 C 5 F 2 75 C 26 Deadband Low 0 F 0 C 25 F 13 75 C 5 F 2 75 C 27 IGST Version Displays current IGST version V2 02 28 IGN Time Setting Displays 4 sec or 7 sec depending on wiring harness installed 29 S...

Page 21: ...tems are used to vary the speed of the unit s blower motor based on air temperature and air density at prescribed Air Fuel Valve positions open This is accomplished by providing a DC drive voltage to the motor which then adjusts the rotational speed of the blower to maximize combustion efficiency and ensure the unit conforms to the Nitrogen Oxide NOx and Carbon Monoxide CO emissions specified in t...

Page 22: ...0 6 40 6 CAL Voltage 100 0 25 10 00 7 90 9 50 7 SET Valve Position 0 100 Variable 8 Blower Output Displays current value 9 Set Stdby Volt 0 10 00 V 2 00 V 2 00 V 10 Oxygen Level Displays current value 2 8 3 BMK 2500 3000 COMBUSTION CAL Menus TABLE 2 8a COMBUSTION CAL Menu BMK 2500 3000 MENU ITEM DISPLAY MINIMUM MAXIMUM DEFAULTS BMK 2500 BMK 3000 1 CAL Voltage 16 0 25 10 00 2 20 CAL Voltage 14 2 80...

Page 23: ... by an asterisk in order to readily identify them within the item list The Items contained in group 1 BST Monitor Items are always displayed within the menu as these items are critical for proper system operation Therefore the BST Monitor Items Header itself is not displayed The Items contained in groups 2 5 are not displayed unless that particular item group has been enabled from the C More keypa...

Page 24: ...to Timer 10 sec 120 sec 30 sec 25 Remote Intlk Use Boiler Shutdown System Shutdown System Shutdown 26 One Boiler Mode Off On Outlet Temp On Avg Temp Off 27 1 Blr Threshold 10 35 25 28 Setpoint Setback Disable Enable Disable 29 Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130 F 54 4 C 30 Setback Start 12 00am 11 59pm 12 00am 31 Setback End 12 00am 11 59pm 12 00am 32 Rate Threshold 1 F 0 5...

Page 25: ... 20 55 BST Bldg Ref Tmp 40 F 4 4 C 230 F 110 C 70 F 21 1 C 56 BST Reset Ratio 0 1 9 9 1 2 57 System Start Tmp 30 F 1 1 C 120 F 48 9 C 60 F 15 6 C 58 BST COMM MENU Disabled Enabled Disabled 59 Comm Address 0 127 0 60 BST Min Addr 1 128 1 61 BST Max Addr 1 128 8 62 SSD Address 0 250 247 63 SSD Poll Control 0 1000 0 64 Err Threshold 1 9 5 65 SSD Temp Format Degrees Points Degrees 66 BST Upld Timer 0 ...

Page 26: ... Dsply Enabled or Disabled Disabled 8 Inlet Tmp Dsply Enabled or Disabled Disabled 9 Valv Pos Out Dsp Enabled or Disabled Enabled 10 Exhaust Tmp Dsp Enabled or Disabled Disabled 11 Exhaust Safety Enabled or Disabled Enabled 12 Flue Material PVC CPVC PolyPro Stainless PVC CPVC 13 Exhst Fault Temp 100 F 500 F 200 F 14 Exhst Module Temp 100 F 500 F 190 F 15 Exhst Warn Temp 100 F 500 F 180 F 16 Exhst ...

Page 27: ...el 0 Start Level 16 37 Start Level Stop Level 40 22 38 Skip Range Cntr 10 95 40 39 Skip Range Span 0 3 0 40 Skip Speed 0 5 2 0 0 5 41 O2 Gain 0 500 1 500 1 000 42 O2 Offset 24 0 2 0 1 0 43 O2 Sensor Enabled or Disabled Depends on unit type size 44 Cal Temp Sensors Off or Start Off 45 FFWD Temp Offset 20 20 0 46 Exhst Tmp Offset 20 20 0 47 Outdr Air Offset 20 20 0 48 Inlet Air Offset 20 20 0 49 Inl...

Page 28: ... 3000 Boiler Operation Service Maintenance Guide KOREA SECTION 2 OPERATION Page 28 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 29: ...justed the supply header temperature will increase by that number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreases the supply header temperature will increase by 1 6 degrees 3 2 2 Building Reference Temperature This is a temperature from 40 F to 230 F 4 4 C to 110 C Once selected it is the...

Page 30: ...ction 2 3 C More Controller Menus above for detailed instructions on navigating the menus 7 Press the CHANGE key The display will begin to flash 8 Use the and arrow keys to select the desired Building Reference Temperature 9 Press ENTER to save any changes 10 Next scroll through the Configuration menu until the display shows RESET RATIO 11 Press the CHANGE key The display will begin to flash 12 Us...

Page 31: ...C The factory default setting for the REMOTE SETPOINT mode is 4 20 mA 1 5 VDC With this setting a 4 to 20 mA 1 to 5 VDC signal sent by an EMS or BAS is used to change the unit s setpoint The 4 mA 1V signal is equal to a 40 F 4 4 C setpoint while a 20 mA 5V signal is equal to a 240 F 115 6 C setpoint When a 0 to 20 mA 0 to 5 VDC signal is used 0 mA is equal to a 40 F 4 4 C setpoint In addition to t...

Page 32: ...d must be connected at the source When driving multiple units each unit s wiring must conform to the above 3 4 2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled no startup instructions are necessary In this mode the REMOTE LED will light when the external signal is present To operate the unit in the MANUAL mode press the AUTO M...

Page 33: ...information 3 5 1 Direct Drive Field Wiring The only wiring connections necessary for DIRECT DRIVE mode are connection of the remote signal leads from the source to the unit s I O Box For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals in the I O Box The sign...

Page 34: ...Modbus network refer to Modbus Communication Manual GF 114 To enable the ACS mode you must set menu items Boiler Mode and Remote Signal in the Configuration menu as follows TABLE 3 4 ACS Mode Settings MENU OPTION SETTING Boiler Mode Direct Drive Remote Signal Network RS485 Refer to Section 2 3 C More Controller Menus for instructions on changing menu options 3 6 1 ACS External Field Wiring Wiring ...

Page 35: ...t containing up to eight combination boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers OPTION 2 When this option is selected the ACS Relay Panel must be used in conjunction with the ACS For this option the ACS controls a boiler pl...

Page 36: ...Mode Remote Signal and Internal Setpt in the Configuration menu as follows TABLE 3 5 Combination Mode Settings MENU OPTION SETTING Boiler Mode Combination Remote Signal Network Internal Setpt 40 F to 190 F 4 4 C to 87 8 C Refer to Section 2 3 C More Controller Menus for instructions on changing menu options While it is possible to change other temperature related functions for COMBINATION mode the...

Page 37: ... except clean Air Filter 2500 3000 58025 10 24 Month Water Fireside 58025 01 plus Burner LWCO Air Filter replacement 58025 18 Same as 58025 10 except clean Air Filter WARNING Prior to servicing ensure that the following guidelines are strictly observed Disconnect the AC power supply by turning off the service switch and AC supply circuit breaker Shut off the gas supply at the manual shut off valve...

Page 38: ...spark required to light the burner the igniter injector also contains a gas injector tube which connects to the staged ignition assembly Figure 4 1a through Figure 4 1c shows the complete burner assembly removed from the boiler and indicates the location of the igniter injector flame detector and other related components Figure 4 1a BMK 750 1000 Burner Assembly BLOWER PROOF SWITCH BLOCKED INLET SW...

Page 39: ...2000 Burner Assembly Figure 4 1c BMK 2500 3000 Burner Assembly A F VALVE PLENUM LEAN O2 SENSOR BLOCKED INLET SWITCH BURNER PLENUM FLANGE BURNER TOP PLATE FLAME OBSERVATION PORT FLAME DETECTOR AIR FUEL VALVE IGNITER INJECTOR ASSEMBLY BLOWER BLOWER PLENUM LEAN O2 SENSOR FLAME OBSERVATION PORT BURNER FLAME DETECTOR BLOCKED INLET SWITCH IGNITOR INJECTOR ASSEMBLY BURNER PLATE FLANGE BLOWER PLENUM AIR F...

Page 40: ... the four 4 pins in the side panels 3 Disconnect the cable from the igniter injector see Figure 4 1a Figure 4 1c above 4 Referring to Figure 4 2a Figure 4 2c below use a 7 16 open end wrench to disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly Disconnect the staged ignition assembly from the igniter injector Figure 4 ...

Page 41: ...gniter injector apply a high temperature conductive anti seize compound to the threads 8 Reinstall the igniter injector in the burner plate using 1 to 3 indexing washers as needed so that when the igniter injector is tightened its injector tube will be positioned within the approximately 120 arc shown in Figure 4 3a through 4 3c below Note the recommended injection tube positioning differs for the...

Page 42: ...a BMK 750 1000 Igniter Injector Orientation Figure 4 3b BMK 1500 2000 Igniter Injector Orientation Figure 4 3c BMK 2500 3000 Igniter Injector Orientation POSITION INJECTOR TUBE INSIDE THIS ARC IGNITER INJECTOR BURNER PLATE INJECTOR TUBE BLOWER POSITION INJECTOR TUBE INSIDE THIS ARC INJECTOR TUBE IGNITER INJECTOR O2 SENSOR FLAME DETECTOR FLAME OBSERVATION PORT POSITION INJECTOR TUBE INSIDE THIS ARC...

Page 43: ...roded the detector should be replaced Otherwise clean the detector with a fine emery cloth 7 Reinstall the flame detector and flame detector gasket 8 Reconnect the flame detector lead wire 9 Reinstall the shroud on the unit 4 4 O2 SENSOR The Lean Oxygen Sensor P N 61026 is located on the burner plate at the top of the unit see Figure 4 1a through 4 1c and 4 2a through 5 2c below The sensor may be ...

Page 44: ...SPECTION The following parts are required for reassembly after burner inspection BMK 750 1000 Burner Inspection Parts Part No Description 81143 Burner Gasket 81048 Flame Detector Gasket 81064 Blower Gasket BMK 750 1000 Burner Inspection Instructions 1 Set the ON OFF switch on the C More Controller to the OFF position Disconnect AC power from the unit and turn off the gas supply 2 Remove the top sh...

Page 45: ... Burner Assembly Exploded View 8 Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench 9 Disconnect the unit wiring harness connectors from the air fuel valve and blower motor FRONT REAR 1 2 BOLTS NUTS 4 GAS TRAIN to A F VALVE IGNITER INJECTOR 3 16 16 HEX NUTS 8 BURNER PLATE BLOWER BLOWER PROOF SWITCH BLOCKED INLET SWITCH AIR FILTER STAGED IGNITION ASSEMBLY BL...

Page 46: ...lling straight up 17 Remove and replace the burner gasket NOTE During reassembly apply a light coating of high temperature anti seize lubricant to the threads of the igniter injector and grounding screw Also ensure that the igniter injector is properly positioned as indicated in Figure 4 3a Torque the igniter injector to 14 15 ft lbs 19 0 20 3 Nm 18 Beginning with the burner assembly removed in st...

Page 47: ...tion Burner Inspection Parts Description Part No BMK 1500 2000 BMK 2500 3000 Burner Upper Release Gasket 81183 81173 Burner Middle Gasket 81166 81180 Burner Lower Release Gasket 81186 81185 Flame Detector Gasket 1 each 81048 81048 BMK 1500 3000 Burner Inspection Instructions Figure 4 5a BMK 1500 2000 Burner Assembly Mounting Details IGNITER INJECTOR ASSEMBLY 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK ...

Page 48: ...Details Figure 4 5c BMK 2500 3000 Burner Assembly Mounting Details BLOWER PLENUM GAS INLET PIPE MANUAL SHUT OFF VALVE 3 8 16 HEX NUTS 8 each A F VALVE PLENUM AIR FUEL VALVE BLOCKED INLET SWITCH 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each AIR FILTER BLOWER PROOF SWITCH BLOWER A F VALVE PLENUM AIR FUEL VALVE FILTER 1 2 NUTS BOLTS 4 each AIR FILTER IGNITER INJECTOR ASSEMBLY GAS TRAIN BURNER PL...

Page 49: ...o the plate The flame detector is secured to the burner plate with one 1 10 32 screw and one 1 8 32 screw 5 Remove the flame detector and gasket from the burner plate 6 Disconnect the cable from the igniter injector 7 Using a 7 16 open end wrench disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly see Figure 4 2b BMK 15...

Page 50: ...RELEASE GASKET has tabs which the others do not NOTE During reassembly apply a light coating of high temperature anti seize lubricant to the threads of the igniter injector and grounding screw Also ensure that the igniter injector is properly positioned as indicated in Figure 4 3b or Figure 4 3c Torque the igniter injector to 14 15 ft lbs 19 0 20 3 Nm Figure 4 6 Bare Burner and Replacement Gaskets...

Page 51: ...ceed as follows Condensate Drain Trap Maintenance Instructions 1 Disconnect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap see Figure 4 7 2 Loosen the four 4 thumbscrews securing the trap s cover and then remove the cover and the O ring from under the cover 3 Remove the float and then thoroughly clean the trap and float ...

Page 52: ... 3000 88014 To inspect replace the air filter proceed as follows Air Filter Cleaning and Replacement Instructions 1 Set the ON OFF switch on the C More Controller to the OFF position Disconnect AC power from the unit 2 Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels 3 Refer to Figure 4 8 a...

Page 53: ...e clamp with a flat tip screwdriver or 5 16 nut driver 7 Replace the top shroud on the unit and return boiler to service use 4 9 WATER CUTOFF LWCO CAPACITOR INTEGRITY TEST The LWCO capacitor should be tested for electrical shorts every 12 months and replaced then tested every 24 months The LWCO capacitor integrity test consists of two parts as described in the next two sections The first procedure...

Page 54: ...erforming the procedure described in this instruction Serious personal injury or death may occur if this warning is not observed 2 Remove the Shell Harness Cable male connector from the P 5 female connector on the rear panel of the C More Controller see Figure 4 10 Figure 4 10 Removing Shell Harness Cable from P5 Conn on C More Rear Panel 3 Using an ohmmeter connect one ohmmeter probe to the LWCO ...

Page 55: ...An Extended Period Instructions 1 Set ON OFF switch on the front panel to the OFF position to shut down the boiler s operating controls 2 Disconnect AC power from the unit 3 Close the water supply and return valves to isolate boiler 4 Close external gas supply valve 5 Open relief valve to vent water pressure 4 11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutd...

Page 56: ...shuts down The monitor s wires are connected to the I O board s Spark Signal terminals see Section 2 11 4 in the Benchmark 750 3000 Boiler Installation and Startup Guide Guide OMM 0127 GF 205 K for details Figure 4 12 Spark Detector Sensor AC Current Transducer P N 61034 If the spark monitor needs to be replaced open the monitor s orifice by pulling on the tab at the side remove Wire 140 disconnec...

Page 57: ...s follows to isolate and correct the fault Fault Correction Instructions 1 Observe the fault messages displayed in the C More Controller display 2 Refer to the Fault Indication column in Troubleshooting Table 5 1 which follows and locate the Fault that best describes the existing conditions 3 Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication 4 Per...

Page 58: ...Boiler Operation Service Maintenance Guide KOREA SECTION 5 TROUBLESHOOTING GUIDE Page 58 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 59: ...nspect for signs of blockage clean or replace as necessary 4 Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary 5 Check the continuity of the Blower Proof switch with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 6 Turn off unit and check the continuity of t...

Page 60: ...ncluding any ductwork leading up to the combustion blower for signs of blockage 5 During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified service personnel 6 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current ove...

Page 61: ...ype voltage or current 1 Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check wiring continuity between source and unit 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration menu FLAME LOSS ...

Page 62: ...gnition Stepper IGST board failed to activate when commanded 2 Relay is activated when not in Demand 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Poor combustion calibration 2 Carboned heat exchanger due to incorrect combustion calibration 1 Check combustion calibration using proc...

Page 63: ... details If the settings have been changed record the current readings then reset them to the default values 3 Using the resistance charts in Appendix C measure the resistance of Shell sensor and BTU sensor at a known water temperature 4 If unit is in MANUAL mode switch to AUTO mode 5 Check setpoint of unit and setpoint of Temperature switch Ensure that the temperature switch is set higher than th...

Page 64: ... wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not replace IGST Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 2 D...

Page 65: ...ower box transformer wiring diagram to ensure it is wired correctly LOW GAS PRESSURE 1 Incorrect supply gas pressure 2 Defective Low Gas Pressure switch 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing Ensure it is above the values in Table 5 1 BMK 750 2500 or or above the value calculated in step 4 in section 5 2 BMK 3000 of the Benchmark 750 3000 Boiler Installation an...

Page 66: ... the switch is wired correctly correct wire numbers on the normally open terminals 3 If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not replace IGST Board PRG SWTCH OPEN DURING PURGE 1 Defective Purge switch 2 No voltage pre...

Page 67: ...1 Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check continuity of wiring between source and unit 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in item 6 of the Configuration menu see Section 2 6 C...

Page 68: ...ure that the valve is fully and not partially closing 2 If the SSOV never closes it may be powered continuously Close the gas supply and remove power from the unit Refer fault to qualified service personnel 3 Remove the electrical cover from the SSOV and check switch continuity If the switch does not show continuity with the gas valve closed either adjust or replace the switch or actuator 4 Ensure...

Page 69: ...jector Figure 4 1a through Figure 4 1c and inspect Gas Injector to ensure it is not clogged or damaged 2 Close the Manual Shutoff Valve Attempt to start the unit and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged Ignition Solenoid Fluctuating Gas Pressure 1 Gas pressure going into uni...

Page 70: ...UBLESHOOTING GUIDE Page 70 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Figure 5 1 SSOV Actuator With Gas Pressure Adjustment SKP25 COVER SCREW DAMPING ORIFICE BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw ...

Page 71: ... air temperature at the input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed 5 Outdoor Temp Outdoor temperature is displayed in ºF or ºC only if outdoor temperature sensor is installed and enabled 6 Valve Position In Desired input valve position This would normally be the same as the fire valve position shown on the bar graph valve position out w...

Page 72: ...3 OMM 0128_0B 07 17 2017 Ph 800 526 0288 TABLE A 1 OPERATING Menu Item Descriptions MENU OPTIONS DESCRIPTION 19 Fault Log Displays information on the last 20 faults An additional parameter associated with the Operating menu Manual Valve Pos Min 0 Max 100 does not appear in this menu but can be displayed by pushing the Auto Man button on the C More Control Panel s front face ...

Page 73: ...lows user to set the date from 01 01 00 to 12 31 99 5 Unit of Temp Permits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C 6 Comm Address For RS 485 communications RS232 should have its own programmable password 7 Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 8 onAER Mode Allows selection of either Ethernet or SD Card 9 Min Upload ...

Page 74: ...MBH 732 6 kW 3000 MBH 879 2 kW 4 Fuel Type Allows selection of Natural Gas or Propane 5 Boiler Mode Only available if Unit Type Boiler Allows selection of Constant Setpoint Remote Setpoint Direct Drive Combination or Outdoor Reset Mode 6 Remote Signal Only available if Mode Remote Setpoint Direct Drive or Combination Used to set the type of external signal which will be used when operating in the ...

Page 75: ...ANGE from its default value 19 Lo Fire Timer Specifies how long from 2 to 600 seconds to remain in the low fire position after ignition before going to the desired output 20 Setpt Limiting Setpoint Limiting can be Enabled or Disabled 21 Setpt Limit Band The Setpoint Limit Band can be set from 0 F to 10 F 0 C to 5 5 C 22 Network Timeout Specifies the timeout value in seconds before a Modbus fault i...

Page 76: ... will be terminated and the PID LOOP will again attempt Valve Position corrections Setting range is 0 F 0 C to 25 F 13 75 C Default is 5 F 2 75 C for both Deadband High and Deadband Low 27 IGST Version Displays the version of the IGST Board installed 28 IGN Time Setting Displays the MAX Ignition time of 4 Seconds or 7 Seconds as set in the Safety String Harness 29 Slow Shutdown Set the Slow Shutdo...

Page 77: ...rtional band setting the fire rate will be 100 2 Integral Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 1 0 3 Derivative Time This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output...

Page 78: ...e Guide OMM 0127 GF 205 K TABLE A 5 COMBUSTION CAL Menu Item Descriptions MENU OPTION DESCRIPTION 1 CAL Voltage BMK 750 18 BMK 1000 18 BMK 1500 16 BMK 2000 18 BMK 2500 16 BMK 3000 14 Displays the default DC drive voltage provided to the blower at each Air Fuel Valve position Items 1 6 This drive voltage adjusts the rotational speed of the blower to maximize combustion efficiency 2 CAL Voltage 30 3...

Page 79: ...st Tmp Dsp Enabled or Disabled 11 Exhaust Safety Enabled or Disabled 12 Flue Material Select flue material PVC Polypropylene or stainless 13 Exhst Fault Temp Fault threshold temperature 14 Exhst Module Temp Decreases Valve Position to lower exhaust temperature 15 Exhst Warn Temp Flue temperature high warning 16 Exhst Tmp VP Adj VP adjust value 17 Exhst Adj Rate VP adjust rate 18 VP Change Rate 19 ...

Page 80: ... Display to be Enabled or Disabled When Enabled Breakpoints can be viewed and or changed 36 Stop Level Allows the Stop Level to be set to a valve position ranging from 0 to the presently set Start Level 37 Start Level Allows the Start Level to be set to a valve position ranging from the presently set Stop Level to a maximum of 40 SKIP FEATURE Items 38 40 embody a feature that allows the user to de...

Page 81: ... ºF or C 49 Inlet Wtr Offset Range 20 to 20 either ºF or C 50 Outlet Wtr Offset Range 20 to 20 either ºF or C 51 24 hr Max Cycles Maximum cycles in 24 hour period 52 24 hr Max Ovrtemp Maximum over temp in 24 hour period 53 0 10v Out Test Set the blower voltage at 0 10v for testing 54 Spark Monitor Enables or disables the Spark Monitor function which displays the AC current on the input of the Igni...

Page 82: ...iler Operation Service Maintenance Guide KOREA APPENDIX A BOILER MENU DESCRIPTIONS Page 82 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 83: ...ime am or pm and date that the unit was disabled FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed during...

Page 84: ...NG RUN The Flame signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The Exhaust Temperature has exceeded 200 F 93 3 C GAS PRESSURE FAULT The High Gas Pressure Limit switch is open or the Low Gas Pressure Limit switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceed...

Page 85: ...ted PRG SWTCH CLOSED DURING IGNITION The Purge Position Limit switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during standby SSOV SWITCH OPEN...

Page 86: ...Operation Service Maintenance Guide KOREA APPENDIX B STARTUP STATUS AND FAULT MESSAGES Page 86 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 87: ...0 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 40 34 4 28 9 23 3 17 2 12 2 6 7 1 1 4 4 10 15 5 21 1 26 7 32 2 37 8 43 3 48 9 54 4 60 65 6 71 1 76 7 82 2 87 8 93 3 98 9 104 4 110 115 6 121 1 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 133...

Page 88: ... Operation Service Maintenance Guide KOREA APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Page 88 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 89: ...r log Instrument and equipment settings Daily Operator Visual check against factory recommended specifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Technician Verify factory settings Annually Service Technician Check with combustion calibration test equipment see Section 4 3 of the Benchmark 750 3000 Boiler Installation and Startup Guide Guide OMM 0127 ...

Page 90: ...Section 2 2 Low air flow Monthly Operator See Section 5 8 in the Benchmark 750 3000 Boiler Installation and Startup Guide Guide OMM 0127 GF 205 K High and low gas pressure interlocks Monthly Operator See Sections 5 2 and 5 3 in the Benchmark 750 3000 Boiler Installation and Startup Guide Guide OMM 0127 GF 205 K Air Fuel Valve purge position switch Annually Service Technician See Section 5 10 in th...

Page 91: ...50 160 170 5 20 6 83 94 105 116 127 138 149 160 171 182 10 23 3 86 98 110 122 134 146 158 170 182 194 15 26 1 89 102 115 128 141 154 167 180 193 206 20 28 9 92 106 120 134 148 162 176 190 204 218 Header Temperature for a Building Reference Temperature 60 F 15 6 C AIR TEMP RESET RATIO F C 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 60 15 6 60 60 60 60 60 60 60 60 60 60 55 12 8 63 64 65 66 67 68 69 70 7...

Page 92: ...09 0 17 8 104 117 130 143 156 169 182 195 208 5 20 6 107 121 135 149 163 177 191 205 219 10 23 3 110 125 140 155 170 185 200 215 15 26 1 113 129 145 161 177 193 209 20 28 9 116 133 150 167 201 218 Header Temperature for a Building Reference Temperature 70 F 21 1 C AIR TEMP RESET RATIO F C 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 70 21 1 70 70 70 70 70 70 70 70 70 70 65 18 3 73 74 75 76 77 78 79 80 ...

Page 93: ... 219 10 12 2 114 127 140 153 166 179 192 205 218 5 15 0 117 131 145 159 173 187 201 215 0 17 8 120 135 150 165 180 195 210 5 20 6 123 139 155 171 187 203 219 10 23 3 126 143 160 177 194 211 15 26 1 129 147 165 183 201 219 Header Temperature for a Building Reference Temperature 80 F 26 7 C AIR TEMP RESET RATIO F C 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 80 26 7 80 80 80 80 80 80 80 80 80 80 75 23 9...

Page 94: ...06 108 110 112 114 75 23 9 99 102 105 108 111 114 117 120 123 126 70 21 1 102 106 110 114 118 122 126 130 134 138 65 18 3 105 110 115 120 125 130 135 140 145 150 60 15 6 108 114 120 126 132 138 144 150 156 162 55 12 8 111 118 125 132 139 146 153 160 167 174 50 10 0 114 122 130 138 146 154 162 170 178 186 45 7 2 117 126 135 144 153 162 171 180 189 198 40 4 4 120 130 140 150 160 170 180 190 200 210 ...

Page 95: ...ARK PUMP RELAY 1 24367 2 BMK 750 A F Valve FRU kit 47 2 124512 FUSE 4 AMP 13 1 24277 STAGED IGNITION ASSY 48 1 123449 SENSOR TEMPERATURE 14 1 81143 GASKET BURNER 49 1 44146 THERMOWELL 15 1 59171 REFLECTOR SIGHT GLASS 50 1 33137 ELECTRICAL PANEL 16 1 59104 OBSERVATION PORT 51 1 181197 C MORE CONTROLLER 17 1 28317 BMK 750 HEAT EXCHANGER 52 1 69151 PCB ASSY 1 28249 BMK 1000 HEAT EXCHANGER 53 2 124326...

Page 96: ...RESSION 78 1 50010 LATCH DRAW 93 1 24441 COND TRAP ASSEMBLY 79 1 50011 KEEPER DRAW LATCH 94 1 59178 VENT AIR 1 8 NPT 80 1 74039 BENCHMARK BOILER LOGO 100 1 92084 6 MOTORIZED SEQUENCING ISOLATION VALVE OPTIONAL 82 1 39217 ADAPTER AIR INLET 6 PVC 101 1 63150 HARNESS FLAME ROD NOTES NOT SHOWN ON DRAWINGS BELOW TABLE A Spare Parts Kit Kit Number Description Item 85 Item 86 Item 87 58037 1 30 PSI 207 k...

Page 97: ...28_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 97 of 144 GF 206 K Ph 800 526 0288 07 17 2017 ITEM 4 FM GAS TRAIN 22140 3 TOP VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 01 25 2017 28321 TAB rev D 28253 TAB rev D Sheet 3 of 6 FRONT VIEW ITEM 4 FM GAS TRAIN 22140 1 ...

Page 98: ...NDIX F BENCHMARK 750 1000 PART LISTS Page 98 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 01 25 2017 28321 TAB rev D 28253 TAB rev D Sheet 4 of 6 ...

Page 99: ...F BENCHMARK 750 1000 PART LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 99 of 144 GF 206 K Ph 800 526 0288 07 17 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 01 25 2017 28321 TAB rev D 28253 TAB rev D Sheet 5 of 6 ...

Page 100: ...LISTS Page 100 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 TOP VIEW REAR VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 01 25 2017 28321 TAB rev D 28253 TAB rev D Sheet 6 of 6 FRONT VIEW RIGHT SIDE VIEW LEFT SIDE VIEW ...

Page 101: ...5 NPT 125 THREADED FLANGE 16 1 92006 5 VALVE BALL 1 NPT 3 1 92036 VALVE SSOV 1 NPT 23 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 4 1 64048 ACTUATOR SSOV W REGULATOR 25 3 92077 1 4 NPT MXF BRASS BALL VALVE 6 2 12951 2 BUSHING CONTROL BOX 27 1 99017 SNUBBER PRESSURE 1 4 7 1 61002 1 LOW PRESSURE SWITCH 2 6 W C FALL N O 29 1 97087 20 TUBE FLEXIBLE GAS 20 50 8 cm LG 13 2 9 22 PIPE PLUG 1 4 NPT STEEL 3...

Page 102: ...ER 15 1 See Table A F VALVE ASSY 4 1 24111 BLOWER AMETEK 8 9 17 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 5 1 59104 OBSERVATION PORT 18 1 59171 REFLECTOR SIGHT GLASS 6 1 24277 STAGED IGNITION ASSY 19 1 61026 O2 SENSOR 7 1 66034 FLAME ROD 20 1 61024 AIR INLET TEMPERATURE SENSOR 8 1 88004 O RING 2 244 BUNA N 24 1 66026 IGNITOR INJECTOR 9 1 81048 GASKET FLAME ROD LOW NOx 25 1 9 21 PLUG HEX HD 1 8 NPT 11...

Page 103: ...VE PLENUM 49 1 58132 THERMOWELL KIT 15 1 24311 3 AIR FUEL VALVE ASSY BMK 1500 50 1 63105 I O SENSOR COMM HARNESS 1 24311 10 AIR FUEL VALVE ASSY BMK 2000 51 1 63104 I O INTERLOCK HARNESS 15a 1 93230 ORIFICE SNUBBER FOR BLOWER PROOF SWITCH 52 1 63090 HARNESS TEMP LIMIT CONTROL 53 1 63150 FLAME DETECTOR HARNESS HOSES INSULATION 54 1 33170 MOUNTING PANEL 16 1 97087 72 FLEX GAS TUBE 72 1 83 m 55 1 1243...

Page 104: ...2023 9 123675 5 58087 9 40 PSI 276 kPa 92015 45 123675 5 58088 W60 60 PSI 414 kPa KIT WATTS 92023 10 123675 6 58088 W75 75 PSI 517 kPa KIT WATTS 92023 11 123675 6 58088 W100 100 PSI 689 kPa KIT WATTS 92023 12 123675 6 58088 W125 125 PSI 862 kPa KIT WATTS 92023 13 123675 6 58088 W150 150 PSI 1034 kPa KIT WATTS 92023 14 123675 7 58088 K160 160 PSI 1103 kPa KIT KUNKLE 92023 15 123675 7 Benchmark 1500...

Page 105: ... BENCHMARK 1500 2000 PART LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 105 of 144 GF 206 K Ph 800 526 0288 07 17 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 3 of 7 ...

Page 106: ...f 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 1500 2000 Burner Air Fuel Valve Assembly P N 24378 24388 See full part lists below AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 4 of 7 ...

Page 107: ...RT LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 107 of 144 GF 206 K Ph 800 526 0288 07 17 2017 REAR VIEW TOP VIEW FRONT VIEW LEFT SIDE VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 5 of 7 ...

Page 108: ...IX G BENCHMARK 1500 2000 PART LISTS Page 108 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 6 of 7 ...

Page 109: ... a fixed value indicating the failure of the Actuator or leakage in the gas line it triggers the shutdown of the boiler Once the problem has been diagnosed and corrected the Valve Proving device must be reset by pressing the red Reset switch before the unit is restarted PARTIAL FRONT VIEW YELLOW RUN LIGHT OFF during normal operation ON during valve proving operation ON when unit is not running RED...

Page 110: ... VALVE BALL BRASS 1 1 2 NPT 5 3 12951 2 BUSHING CONTROL BOX 34 1 9 294 UNION 2 NPT 300 8 1 93382 2 NPT CAP 35 2 95029 FLANGE SSOV 1 1 2 NPT 10 1 99017 SNUBBER PRESSURE 1 4 39 1 124138 ACTUATOR SSOV 11 2 9 22 PIPE PLUG 1 4 NPT STEEL 41 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 14 1 67007 GAGE LOW PRESSURE 0 15 in H2O 42 1 64048 ACTUATOR SSOV W REGULATOR 15 1 64083 REGULATOR GAS PRESSURE WITH VENT...

Page 111: ...DIX G BENCHMARK 1500 2000 PART LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 111 of 144 GF 206 K Ph 800 526 0288 07 17 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Gas Train Korea 03 17 2017 P N 22240 rev C Sheet 2 of 2 ...

Page 112: ... 24220 10 A F VALVE ASSY BMK 2000 20 1 66026 IGNITOR INJECTOR 4 1 46042 BURNER BMK 1500 21 1 61026 O2 SENSOR 46044 BURNER BMK 2000 22 1 81048 GASKET FLAME ROD LOW NOx 5 1 81057 GASKET BLOWER 23 1 66034 FLAME ROD 6 1 43095 BLOWER PLENUM 24 1 59104 OBSERVATION PORT 8 1 59138 FILTER AIR 6 25 1 81183 BURNER GASKET UPPER RELEASE 9 5 9 21 PLUG HEX HD 1 8 NPT 26 1 24277 STAGED IGNITION ASSY 12 1 61024 AI...

Page 113: ...NER ASSY 208 VAC 44 1 38035 I O PANEL COVER 1 26014 1 26014 2 BMK 3000 BURNER ASSY 460 VAC BMK 3000 BURNER ASSY 208 VAC 45 1 38036 POWER PANEL COVER 10 1 24277 STAGED IGNITION ASSY 46 1 65128 3 POLE 20A BREAKER 11 1 81180 BURNER GASKET 47 2 124512 FUSE 4 AMP 12 1 81173 RELEASE GASKET 48 2 123449 SENSOR TEMPERATURE 13 1 81185 LOWER RELEASE GASKET 49 1 58132 THERMOWELL KIT 14 1 43090 AIR FUEL VALVE ...

Page 114: ... Item Qty Part Description 67 1 63111 HARNESS CONTROL OTHER ACCESSORIES PARTS 68 1 63004 HARNESS 460V TRANSFORMER 87 1 SEE TABLE A PRESSURE TEMP GAUGE 69 1 63090 HARNESS TEMP LIM CONTROL 88 1 SEE TABLE A PRESSURE RELIEF VALVE KIT 70 1 61034 SPARK MONITOR 89 1 123540 EXT MANUAL SHUT OFF VALVE SHEET METAL PANEL ASSEMBLY 90 1 69126 LOW WATER CUTOFF CAPACITOR ASSY 71 2 59179 HANDLE CONCEALED PULL 72 1...

Page 115: ... BENCHMARK 2500 3000 PART LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 115 of 144 GF 206 K Ph 800 526 0288 07 17 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 3 of 7 ...

Page 116: ...4 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 9 BURNER GASKETS EXPLODED VIEW 26 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 4 of 7 Benchmark 2500 3000 Burner Air Fuel Valve Assembly P N 26015 26014 ...

Page 117: ...RT LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 117 of 144 GF 206 K Ph 800 526 0288 07 17 2017 REAR VIEW TOP VIEW LEFT SIDE VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 5 of 7 FRONT VIEW ...

Page 118: ... 3000 PART LISTS Page 118 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 PARTIAL FRONT VIEW FRONT PANEL REMOVED AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 6 of 7 ...

Page 119: ...alls below a fixed value indicating the failure of the Actuator or leakage in the gas line it triggers the shutdown of the boiler Once the problem has been diagnosed and corrected the Valve Proving device must be reset by pressing the red Reset switch before the unit is restarted PARTIAL FRONT VIEW YELLOW RUN LIGHT OFF during normal operation ON during valve proving operation ON when unit is not r...

Page 120: ...5029 FLANGE SSOV 1 1 2 NPT 8 1 93382 2 NPT CAP 37 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 10 1 99017 SNUBBER PRESSURE 1 4 39 1 124138 ACTUATOR SSOV 11 1 9 22 PIPE PLUG 1 4 NPT STEEL 40 1 124137 VALVE SSOV DOUBLE BODY 1 1 2 NPT 14 1 67007 GAGE LOW PRESSURE 0 15 in H2O 45 1 61002 22 HIGH GAS PRESSURE SWITCH 3 0 W C 15 1 64083 REGULATOR GAS PRESSURE WITH VENT LIMITING ORIFICE 46 1 24629 2 VALVE PR...

Page 121: ...ENDIX H BENCHMARK 2500 3000 PART LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 121 of 144 GF 206 K Ph 800 526 0288 07 17 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 Gas Train Korea 04 17 2017 P N 22244 rev F Sheet 2 of 2 ...

Page 122: ... NPT 31 1 63063 RELAY 10 1 99015 DAMPING ORIFICE SSOV 34 1 124138 ACTUATOR SSOV 12 3 12951 2 BUSHING CONTROL BOX 35 1 9 294 UNION 2 NPT 300 15 1 93382 2 NPT CAP 37 1 64048 ACTUATOR SSOV W REGULATOR 17 1 99017 SNUBBER PRESSURE 1 4 39 1 60032 SWITCH GAS PRESSURE 2 20 W C 18 1 9 22 PIPE PLUG 1 4 NPT STEEL 44 1 24629 2 VALVE PROVING SYSTEM ASSEMBLY 22 1 67007 GAGE LOW PRESSURE 0 15 in H2O 45 1 97087 1...

Page 123: ...ENDIX H BENCHMARK 2500 3000 PART LISTS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 123 of 144 GF 206 K Ph 800 526 0288 07 17 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 3000 Gas Train Korea 04 17 2017 P N 22215 rev H Sheet 2 of 2 ...

Page 124: ... Operation Service Maintenance Guide KOREA APPENDIX H BENCHMARK 2500 3000 PART LISTS Page 124 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 This page intentionally blank ...

Page 125: ...nance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 125 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Appendix I WIRING DIAGRAMS Benchmark 750 1000 Drawing Number 68038 rev G Sheet 1 of 2 ...

Page 126: ...ion Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 126 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 750 1000 Drawing Number 68038 rev G Sheet 2 of 2 ...

Page 127: ...Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 127 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 1500 2000 Drawing Number 68050 rev C page 1 of 2 ...

Page 128: ...ion Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 128 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 1500 2000 Drawing Number 68050 rev C page 2 of 2 ...

Page 129: ...rvice Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 129 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 1500 2000 DBB Drawing Number 68071 rev C page 1 of 2 ...

Page 130: ...n Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 130 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 1500 2000 DBB Drawing Number 68071 rev C page 2 of 2 ...

Page 131: ... Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 131 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 3000 208 VAC Diagram 68040 rev F Sheet 1 of 2 ...

Page 132: ...n Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 132 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 3000 208 VAC Drawing Number 68040 rev F Sheet 2 of 2 ...

Page 133: ...rvice Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 133 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 3000 460 VAC Drawing Number 68041 rev F Sheet 1 of 2 ...

Page 134: ...n Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 134 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 3000 460 VAC Drawing Number 68041 rev E Sheet 2 of 2 ...

Page 135: ...rvice Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 135 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 2500 208 VAC Drawing Number 68060 rev C Sheet 1 of 2 ...

Page 136: ...n Service Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 136 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 2500 208 VAC Drawing Number 68060 rev C Sheet 2 of 2 ...

Page 137: ... Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 137 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 2500 3000 208 VAC DBB Drawing Number 68062 rev C Sheet 1 of 2 ...

Page 138: ...rvice Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 138 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 2500 3000 208 VAC DBB Drawing Number 68062 rev C Sheet 2 of 2 ...

Page 139: ... Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS OMM 0128_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 144 GF 206 K Ph 800 526 0288 07 17 2017 Benchmark 2500 3000 460 VAC DBB Drawing Number 68063 rev B Sheet 1 of 2 ...

Page 140: ...rvice Maintenance Guide KOREA APPENDIX I WIRING DIAGRAMS Page 140 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Benchmark 2500 3000 460 VAC DBB Drawing Number 68063 rev B Sheet 2 of 2 ...

Page 141: ...EWS Figure J 1 C More Controller Exploded View FISH PAPER INSULATOR P N 124960 FRONT FACE PLATE BENCHMARK P N 124949 V F D DISPLAY MODULE P N 124527 CONNECTOR BOARD P N 124366 LOW WATER CUTOFF BOARD P N 124363 PMC BOARD P N 124364 DISPLAY BOARD P N 124365 GREEN LED P N 124948 ROCKER SWITCH P N 124947 PUSH BUTTON SWITCHES P N 124954 IGNITION STEPPER BOARD P N 124361 POWER SUPPLY BOARD P N 124362 EN...

Page 142: ...i Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Figure J 2 C More Controller Rear View INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX A F VALVE HARNESS CONNECTOR 16 PIN SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN SENSOR HARNESS CONNECTOR 7 PIN ...

Page 143: ... 69078 24351 or 24350 SSOV Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of IRI gas train models 64048 64048 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 69038 69038 Temperature Switch Manual Reset 123552 123552 123552 TABLE K 2 Recommended Spare Parts For Maintenance DESCRIPTION PART NUMBER Annual Maintenance Ki...

Page 144: ...l Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0128_0B 07 17 2017 Ph 800 526 0288 Change Log Date Description Changed By 06 15 2017 Rev A Initial release Chris Blair 07 17 2017 DIR 17 050 Corrected part numbers kit numbers and figure numbers in Section 4 Maintenance Chris Blair AERCO International Inc 2017 ...

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