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Aerco Benchmark BMK 1000, Operation And Service Manual

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Aerco Benchmark BMK 1000 Operation And Service Manual Download Page 70

BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE

  

SECTION 5 – MAINTENANCE 

Page 

70

 of 

178

 

 

 AERCO International, Inc. 

•

 100 Oritani Dr. 

•

  Blauvelt, NY 10913  

 

OMM-0116_0A

 

03/15/2017

 

 Ph.: 800-526-0288  

 

GF-201 

5.9.1  Low Water Cutoff (LWCO) - Capacitor Electrical Short Test 

This test determines if there is an electrical short between the LWCO capacitor and the heat 
exchanger. Perform the capacitor electrical short test as described below. 

LOW WATER CUTOFF – CAPACITOR ELECTRICAL SHORT TEST Instructions 

1. 

Turn the AC power to the unit to OFF

. 

 WARNING!  

High voltages are used to power these units and so it is required that power applied to 
these units is removed first before performing 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 5-10). 

 

 

 

 

 

 

 

Figure 5-10: Removing Shell Harness Cable from P5 Conn. on C-More Rear Panel 

3.  Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on 

the unit shell as shown on left in Figure 5-11. 

4.  Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed 

from the C-More controller) as shown on right in Figure 5-11. 

 

 

 

Figure 5-11: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable

 

UNPLUG SHELL HARNESS CABLE  
FROM P5 CONNECTOR 
 

CONNECT 2

ND

 LEAD  

TO PIN #6 

 

19-PIN SHELL HARNESS  

CABLE CONNECTOR 

 

LWCO PROBE  

ASSEMBLY CONNECTOR 

 

OHMMETER 

 

CONNECT 1

ST

 LEAD  

TO LWCO TERMINAL 

 

Summary of Contents for Benchmark BMK 1000

Page 1: ...al Fuel Fired Modulating Condensing Boilers Latest Update 03 15 2017 Natural Gas BMK 750 BMK 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 Propane BMK 750P BMK 1000P BMK 1500P BMK 2000P APPLIES TO MODELS Applies to Serial Numbers G 17 0001 and above Dual Fuel NG P BMK 1500DF BMK 2000DF BMK 2500DF BMK 3000DF USER MANUAL 2 of 2 750 1000 1500 2000 2500 and 3000 MBH Boilers SEE ALSO Benchmark Platinum Inst...

Page 2: ...us 24 2 8 3 BMK 2500 3000 COMBUSTION CAL Menus 25 2 9 BST BOILER SEQUENCING TECHNOLOGY MENU 26 2 10 CALIBRATION MENU 29 SECTION 3 MODES OF OPERATION 31 3 1 INTRODUCTION 31 3 2 INDOOR OUTDOOR RESET MODE 31 3 2 1 Reset Ratio 31 3 2 2 Building Reference Temperature 31 3 2 3 Outdoor Air Temperature Sensor Installation 31 3 2 4 Indoor Outdoor Startup 32 3 3 CONSTANT SETPOINT MODE 32 3 3 1 Setting the S...

Page 3: ...ore Test 71 5 10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD 71 5 11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN 71 5 12 SPARK MONITOR AC CURRENT TRANSDUCER 72 SECTION 6 TROUBLESHOOTING GUIDE 73 6 1 INTRODUCTION 73 6 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 85 APPENDIX A BOILER MENU ITEM DESCRIPTIONS 87 TABLE A 1 OPERATING MENU ITEM DESCRIPTIONS 87 TABLE A 2 SETUP MENU IT...

Page 4: ...ION SERVICE and MAINTENANCE GUIDE CONTENTS Page 4 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 APPENDIX J C MORE CONTROL PANEL VIEWS 175 APPENDIX K RECOMMENDED SPARES 177 ...

Page 5: ...0 293 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 function of the unit s firing rate ...

Page 6: ...I 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 or Control Box A control system developed by AERCO and ...

Page 7: ...nnovation and KC1000 Series products IP Internet Protocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 1 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 Op...

Page 8: ... serial full duplex FDX transmission of data based on the RS422 Standard RS485 or EIA 485 A standard for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shield SPDT Single Pole Double Throw a type of switch SSOV Safety Shut Off Valve TEMP Temp Temperature Terminating Resistor A resistor placed at each end of a daisy ...

Page 9: ...t be maintained in legible condition It must be given to the user by the installer and kept in a safe place for future reference WARNING Do not use matches candles flames or other sources of ignition to check for gas leaks Fluids under pressure may cause injury to personnel or damage to equipment when released Be sure to shut off all incoming and outgoing water shutoff valves Carefully decrease al...

Page 10: ...mergency shutdown manual gas valve to operating personnel Figure 1 1 Manual Gas Shutoff Valve 1 3 PROLONGED SHUTDOWN After prolonged shutdown it is recommended that the startup procedures and safety device test procedures described in Section 4 and 5 respectively of the Benchmark 750 3000 Installation and Startup Guide OMM 0115 GF 200 be performed to verify all system operating parameters If there...

Page 11: ...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 p...

Page 12: ... 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 G...

Page 13: ...al 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 120 VAC BMK 750 2000 and 208 or 460 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 14: ...utilize the C More Control Panel 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 Figu...

Page 15: ...r 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 combination...

Page 16: ...ressed 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 17: ... 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 Control Panel will normally be in the Operating menu and the VFD will display the c...

Page 18: ... Only if BST is enabled BST is described in detail in Section 6 of the Benchmark 750 3000 Installation and Startup Guide OMM 0115 GF 200 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 me...

Page 19: ...116 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 Us...

Page 20: ... enter date and time and units of temperature measurements A view only software version display is also provided to indicate the current Control Box 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 21: ...ions 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 2000 MBH 586 1 kW 2500 MBH ...

Page 22: ... 0 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 2...

Page 23: ... 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 the combustion calibra...

Page 24: ... value 9 Set Stdby Volt 0 10 00 V 2 00 V 2 00 V 10 Oxygen Level Displays current value Table 2 7b COMBUSTION CAL Menu BMK 1500 2000 DUAL FUEL Menu Item Display Acceptable Range Defaults NATURAL GAS PROPANE Minimum Maximum BMK 1500 BMK 2000 BMK 1500 BMK 2000 1 CAL Voltage 16 0 25 10 00 1 50 2 10 CAL Voltage 18 0 25 10 00 1 20 2 10 2 CAL Voltage 30 0 25 10 00 2 60 4 50 2 30 3 50 3 CAL Voltage 40 0 2...

Page 25: ...lays current value Table 2 8b COMBUSTION CAL Menu BMK 2500 3000 DUAL FUEL Menu Item Display Acceptable Range Defaults NATURAL GAS PROPANE Minimum Maximum BMK 2500 BMK 3000 BMK 2500 BMK 3000 1 CAL Voltage 14 0 25 10 00 2 40 CAL Voltage 16 0 25 10 00 2 15 CAL Voltage 18 0 25 10 00 2 00 2 30 CAL Voltage 20 0 25 10 00 2 10 CAL Voltage 22 0 25 10 00 2 00 2 CAL Voltage 30 0 25 10 00 3 90 5 40 3 30 4 40 ...

Page 26: ...n 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 keypad Table 2 9 BST Menu MENU ITEM DISPLAY AVAILABLE CHOICE...

Page 27: ...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 55 C 30 F 16 5 C 15 F 8 25 C 33 OPERATE MENU Disabled Enabled Disabled 34 BST Next On VP 16 100 50 35 BST Max Boilers 1 8 8 36 BST On Delay 30 sec 300 sec 60 sec 37 BST On Timeout 15...

Page 28: ...nd Hi 0 25 1 52 BST Deadband Lo 0 25 1 53 Deadband En Time 0 120 Sec 30 Sec 54 BST FR Up Rate 1 120 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 Con...

Page 29: ... 0 sec 60 sec 0 sec 6 FFWD Temp Disply Enabled or Disabled Disabled 7 Outlet Tmp 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 Ex...

Page 30: ...Disabled Disabled 35 Heatr Bkpt Dsp Enabled or Disabled Disabled 36 Stop Level 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 O...

Page 31: ...nce adjusted 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 ...

Page 32: ...to Section 2 3 Control Panel 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 U...

Page 33: ...e 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 the c...

Page 34: ...ield 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 AUT...

Page 35: ...formation 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 signal...

Page 36: ...bus 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 Control Panel Menus for instructions on changing menu options 3 6 1 ACS External Field Wiring Wiring connect...

Page 37: ... 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 pla...

Page 38: ...iler 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 Control Panel Menus for instructions on changing menu options While it is possible to change other temperature related functions for COMBINATION mode th...

Page 39: ...iency and reliability while minimizing emissions It does this by first measuring post combustion oxygen percentages inside the combustion chamber This data is fed through the Electronic Control Unit ECU which is connected to the C More Controller inside the boiler If the oxygen readings are outside of preset or user defined values the blower voltage is changed in small increments until the reading...

Page 40: ... O2 O2 upper range and lower range are at default values but can be changed as needed However you must enable the Adjust O2 Trgts option in the O2 Trim menu before you can change these settings 4 3 OPERATION DETAILS During operation the AERtrim system will adjust the command voltage sent to the combustion air blower within a limited range The amount of voltage trim depends on the error between the...

Page 41: ...or that unit at that fire rate The control will then store this as the new BV calibration setting until changed manually or by another cycle of the AERtrim function NOTE When the O2 sensor is off during the 10 hour O2 Sensor OFF periods shown above Modbus sends an Oxygen Level of 99 rather than 0 to building automation system via ProtoNode Figure 4 3 AERtrim Logic Once the system operational stabi...

Page 42: ... For example if the time and day for an auto calibration passes the controller will wait for the boiler to cycle off and go into standby mode before executing the sensor calibration function If desired a manual calibration can be initiated by the user by enabling the AUTO CAL NOW menu item When sensor calibration occurs the controller starts the O2 Cal Purge for 40 seconds 55 seconds on the BMK 60...

Page 43: ...O2 curve is desired onAER O2 Time Timer to send O2 data periodically to AERCO s onAER or SD card Trim State Displays the current state of a trim function Fire Rate In Displays the input fire rate Fire Rate Out Displays the output fire rate Calc Blower Out Displays the calculated blower voltage adjustment after each O2 trim iteration Blower Voltage Displays the current blower voltage Percent Oxygen...

Page 44: ...ween O2 Upper O2 Lower 18 3 8 5 5 30 3 8 5 5 45 3 8 5 5 60 3 8 5 5 80 3 8 5 5 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 18 2 5 5 5 4 5 30 2 5 5 5 4 5 45 2 5 5 5 4 5 60 2 5 5 5 5 0 80 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper Limit must be at least 1 higher than O2 Lower 18 5 5 8 5 6 5 30 5 5 8 5 6 5 45 5 5 8 5 6 5 60 5 5 8 5 6 0 80 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1...

Page 45: ...ower 18 3 8 5 5 30 3 8 5 5 45 3 8 5 5 60 3 8 5 5 80 3 8 5 5 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 18 2 5 5 5 4 5 30 2 5 5 5 4 5 45 2 5 5 5 5 0 60 2 5 5 5 5 0 80 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper Limit must be at least 1 higher than O2 Lower 18 5 5 8 5 6 5 30 5 5 8 5 6 5 45 5 5 8 5 6 0 60 5 5 8 5 6 0 80 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK 1000 AERtri...

Page 46: ...wer 16 3 8 5 5 30 3 8 6 5 40 3 8 6 5 50 3 8 6 5 70 3 8 6 0 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 16 2 5 5 5 5 0 30 2 5 5 5 5 0 40 2 5 5 5 5 0 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper Limit must be at least 1 higher than O2 Lower 16 5 5 8 5 6 0 30 5 5 8 5 7 0 40 5 5 8 5 7 0 50 5 5 8 5 7 0 70 5 5 8 5 6 5 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK 1500 AERtrim...

Page 47: ... O2 Lower 18 3 8 6 5 30 3 8 6 0 40 3 8 6 0 50 3 8 5 5 70 3 8 5 5 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 18 2 5 5 5 5 0 30 2 5 5 5 5 5 40 2 5 5 5 5 5 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper must be at least 1 higher than O2 Lower 18 5 5 8 5 7 0 30 5 5 8 5 6 5 40 5 5 8 5 6 5 50 5 5 8 5 6 0 70 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK 2000 AERtrim ADJUS...

Page 48: ...r O2 Lower 16 3 8 5 5 30 3 8 6 5 40 3 8 7 0 50 3 8 6 0 70 3 8 6 0 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 16 2 5 5 5 5 0 30 2 5 5 5 4 5 40 2 5 5 5 5 0 50 2 5 5 5 5 5 70 2 5 5 5 5 5 100 2 5 5 5 4 5 O2 Upper must be at least 1 higher than O2 Lower 16 5 5 8 5 6 0 30 5 5 8 5 7 0 40 5 5 8 5 7 5 50 5 5 8 5 6 5 70 5 5 8 5 6 5 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK 2500 AERtrim ADJU...

Page 49: ... O2 Lower 14 3 8 6 5 30 3 8 7 3 40 3 8 7 5 50 3 8 7 0 70 3 8 5 5 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 14 2 5 5 5 5 5 30 2 5 5 5 5 5 40 2 5 5 5 5 5 50 2 5 5 5 5 5 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper must be at least 1 higher than O2 Lower 14 5 5 8 5 7 0 30 5 5 8 5 7 8 40 5 5 8 5 8 0 50 5 5 8 5 7 5 70 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK 3000 AERtrim ADJUS...

Page 50: ...evels fall outside the target range one of the messages listed in Table 4 2 will be displayed when you view the Trim State menu item in the O2 Trim menu Table 4 2 AERtrim GENERAL WARNINGS WARNING CAUSE POSSIBLE SOLUTIONS O2 PERCENTAGE LOW O2 Levels less than 2 for more than 30 seconds auto reset when valve comes back in range Dirty filter or poor combustion calibration recalibrate unit O2 Offset t...

Page 51: ...Err Trim operation exceeds allowable blower voltage limits Check air filter gas regulator combustion calibration BV Lo Err Check sensor calibration it may need to be replaced Max Iter Trim Operation reached maximum iteration Wait and try again Check sensor calibration for inaccuracies Increase gain or iteration attempts Tmp Rng Err Outlet temp is outside of temperature range None Normal Operation ...

Page 52: ...Boiler OPERATION SERVICE and MAINTENANCE GUIDE SECTION 4 AERTRIM OPERATION Page 52 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 This page intentionally blank ...

Page 53: ...P N 58025 01 Therefore only the 24 Month kit is required when performing the waterside fireside inspections Refer to Appendix L for recommended spare parts 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 provided w...

Page 54: ...equired to light the burner the igniter injector also contains a gas injector tube which connects to the staged ignition assembly Figure 5 1a through Figure 5 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 5 1a BMK 750 1000 Burner Assembly Removed from Boiler STAGED IGNITION SOLENOI...

Page 55: ...emoved from Boiler Figure 5 1c BMK 2500 3000 Burner Assembly Removed from Boiler BLOWER BLOWER PLENUM IGNITER INJECTOR ASSEMBLY FLAME DETECTOR BURNER PLENUM FLANGE BURNER TOP PLATE FLAME OBSERVATION PORT AIR FUEL VALVE BLOCKED INLET SWITCH LEAN O2 SENSOR A F VALVE PLENUM BLOWER BLOWER PLENUM IGNITOR INJECTOR ASSEMBLY FLAME DETECTOR BURNER BURNER PLATE FLANGE FLAME OBSERVATION PORT AIR FUEL VALVE B...

Page 56: ...m the four 4 pins in the side panels 3 Disconnect the cable from the igniter injector see Figure 5 1a Figure 5 1c above 4 Referring to Figure 5 2a Figure 5 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 5...

Page 57: ...jector 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 5 3a through 5 3c below Note the recommended injection tube positioning differs for the position...

Page 58: ...5 3a BMK 750 1000 Igniter Injector Orientation Figure 5 3b BMK 1500 2000 Igniter Injector Orientation Figure 5 3c BMK 2500 3000 Igniter Injector Orientation IGNITER INJECTOR INJECTOR TUBE BURNER PLATE BLOWER O2 SENSOR FLAME OBSERVATION PORT FLAME DETECTOR O2 SENSOR IGNITER INJECTOR FLAME OBSERVATION PORT POSITION INJECTOR TUBE INSIDE THIS ARC POSITION INJECTOR TUBE INSIDE THIS ARC INJECTOR TUBE IG...

Page 59: ...cloth 7 Reinstall the flame detector and flame detector gasket 8 Reconnect the flame detector lead wire 9 Reinstall the shroud on the unit 5 4 O2 SENSOR The Lean Oxygen Sensor P N 61026 is located on the burner plate at the top of the unit see Figures 5 1a through 5 1c and 5 2a through 5 2c The sensor may be hot Allow the unit to cool sufficiently before removing or replacing the O2 sensor O2 SENS...

Page 60: ...N The burner assembly is located at the top of the unit s heat exchanger The burner assembly may be hot Therefore allow the unit to cool sufficiently before removing the burner assembly The following parts will be 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 1500 2000...

Page 61: ...t the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit and turn off the gas supply 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 AIR FUEL VALVE BLOCKED INLET SWITCH BURNER GASKET FLAME DETECTOR O2 SENSOR STAGED IGNITION BURNER BLOWER BLOWER PROOF...

Page 62: ...ur 5 16 18 hex head screws securing the blower to the burner plate Figure 5 4b 14 Remove the blower and air fuel valve from the burner plate by lifting straight up Also remove the blower gasket 15 Remove the eight 8 3 8 16 nuts from the burner flange Figure 5 4a using a 9 16 wrench NOTE The burner assembly weighs approximately 25 pounds 11 3 kg 16 Remove the burner assembly from burner flange by p...

Page 63: ...500 2000 Burner Assembly Mounting Details Figure 5 5b BMK 1500 2000 Burner Assembly Mounting Details 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each BLOWER PLENUM AIR FILTER A F VALVE PLENUM BLOWER BURNER PLATE 3 8 16 HEX NUTS 8 each IGNITER INJECTOR ASSEMBLY 1 2 NUTS BOLTS 4 ea 3 8 16 HEX NUTS 8 each 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each A F VALVE PLENUM AIR FILTER AIR FUEL VALVE ...

Page 64: ...tails Figure 5 5d BMK 2500 3000 Burner Assembly Mounting Details 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each BLOWER PLENUM GAS TRAIN AIR FILTER A F VALVE PLENUM BLOWER BURNER PLATE 3 8 16 HEX NUTS 8 each AIR FUEL VALVE FILTER IGNITER INJECTOR ASSEMBLY 1 2 NUTS BOLTS 4 each 3 8 16 HEX NUTS 8 each 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each A F VALVE PLENUM AIR FILTER AIR FUEL VALVE GA...

Page 65: ...niter injector from the burner plate using a 1 open end wrench 9 Loosen and remove the four 5 16 x 1 3 4 bolts washers and nuts from the blower plenum where it attaches to the blower See Figures 5 5a 5 5b BMK 1500 2000 or Figures 5 5c 5 5d BMK 2500 3000 10 You must either rig a support for the blower to hold it in place or remove the blower from the unit and set it aside for later reassembly 11 Re...

Page 66: ...opposite side a third at 90 degrees to the first two and a fourth opposite the third and then repeat this pattern with the remaining four nuts Repeat the entire pattern a second time to partially tighten all eight nuts and then repeat a third time until all eight nuts are fully torqued to 35 ft lbs 47 5 Nm 16 Ensure that the igniter injector and flame detector cutouts in the burner plate are prope...

Page 67: ...ollows 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 5 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 Also insp...

Page 68: ... 2500 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 control panel 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 5 8 ...

Page 69: ...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 5 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 e...

Page 70: ...e performing 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 5 10 Figure 5 10 Removing Shell Harness Cable from P5 Conn on C More Rear Panel 3 Using an ohmmeter connect one ohmmeter probe to the LW...

Page 71: ...owing instructions must be followed SHUTTING BOILER DOWN FOR 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 5 11 PLACING THE BOILER BACK ...

Page 72: ...omatically 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 Installation and Startup Guide OMM 0115 GF 200 for details Figure 5 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 disconnect th...

Page 73: ...as follows to isolate and correct the fault FAULT CORRECTION Instructions 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indication column in Troubleshooting Table 6 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 Perform ...

Page 74: ...iler OPERATION SERVICE and MAINTENANCE GUIDE SECTION 6 TROUBLESHOOTING GUIDE Page 74 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 This page intentionally blank ...

Page 75: ...lace 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 the Blocked Inlet switch If there is an er...

Page 76: ...r including 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 ...

Page 77: ...type 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 78: ...tepper 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 procedures in...

Page 79: ...nged record the current readings then reset them to the default values 3 Using the resistance charts in Appendix C of the Benchmark 750 3000 Installation and Startup Guide OMM 0115 GF 200 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 tempe...

Page 80: ... is 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 ...

Page 81: ...ransformer wiring in AC Power Box against the power 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 Table 5 2 BMK 3000 in section 5 2 of the Benchmark 750 3000 Insta...

Page 82: ... 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 83: ...eck 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 Confi...

Page 84: ...nd 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 ...

Page 85: ...r Injector Figure 5 1a through Figure 5 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...

Page 86: ...SHOOTING GUIDE Page 86 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Figure 8 1 SSOV Actuator With Gas Pressure Adjustment SKP25 BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw DAMPING ORIFICE COVER SCREW ...

Page 87: ... inlet water temperature 4 Air Temp Air Temp is the 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 Flow rate Not Used 7 Valve Position In Desired input valve position This would normally be the sam...

Page 88: ...Ph 800 526 0288 GF 201 TABLE A 1 OPERATING MENU ITEM DESCRIPTIONS MENU OPTIONS DESCRIPTION 19 Spark Current Displays the current going to the ignition transformer 20 Run Cycles Displays the total number of run cycles 21 Run Hours Displays total run time of unit in hours 22 Fault Log Displays information on the last 20 faults 23 Manual Valve Pos Selects valve position Available in Manual mode only ...

Page 89: ...Allows 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 Uploa...

Page 90: ...n 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 Remote Setpoint Direct Drive or Combination Mode 7 Outdoor Sensor Allows outdoor sensor function to be set to Enabled or Disabled 8 Bldg Ref Temp Only...

Page 91: ...e 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 is declared up to 999 seconds 23 Shutoff Dly Temp This feature delays the shutdown of a boiler in order to reduce excessive cycling This specifies the temp...

Page 92: ...erminated 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 Shutdown feature...

Page 93: ...tional 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 94: ...uide OMM 0115 GF 200 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 CAL ...

Page 95: ... Enabled or Disabled 8 Inlet Tmp Dsply Enabled or Disabled 9 Valv Pos Out Dsp Enabled or Disabled 10 Exhaust Tmp Dsp Enabled or Disabled 11 Exhaust Safety 12 Flue Material 13 Exhst Fault Temp 14 Exhst Module Temp 15 Exhst Warn Temp 16 Exhst Tmp VP Adj 17 Exhst Adj Rate 18 VP Change Rate 19 VP Up Rate Allows adjustment of the Valve Position Fire Rate increase rate when raising the Valve Position VP...

Page 96: ...int 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 39 41 embody a feature that allows the user to...

Page 97: ...ither ºF or C 48 Inlet Air Offset Range 20 to 20 either 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 52 24 hr Max Ovrtemp 53 0 10v Out Test 54 Spark Monitor Enables or disables the Spark Monitor function which displays the AC current on the input of the Ignition Transformer 56 Min Spark Amps Allows the adjustment o...

Page 98: ...er OPERATION SERVICE and MAINTENANCE GUIDE APPENDIX A BOILER MENU DESCRIPTIONS Page 98 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 This page intentionally blank ...

Page 99: ...he time 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 du...

Page 100: ...lost within 5 seconds after ignition FLAME LOSS DURING 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 ...

Page 101: ...display Opn indicates sensor is open circuited 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...

Page 102: ...ERATION SERVICE and MAINTENANCE GUIDE APPENDIX B STARTUP STATUS AND FAULT MESSAGES Page 102 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 This page intentionally blank ...

Page 103: ... 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 1337...

Page 104: ...PERATION SERVICE and MAINTENANCE GUIDE APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Page 104 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 This page intentionally blank ...

Page 105: ... 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 of the Benchmark 750 3000 Installation and Startup Guide OMM 0115 GF 200 and the O2 sensor in Section 6 4 of this guide Flue vent stack or intake air duct Monthly Operator Visually inspection condition and c...

Page 106: ...M 0115 GF 200 High and low gas pressure interlocks Monthly Operator See sections 5 2 and 5 3 in the Benchmark 750 3000 Installation and Startup Guide OMM 0115 GF 200 Air Fuel Valve purge position switch Annually Service Technician See section 5 10 in the Benchmark 750 3000 Installation and Startup Guide OMM 0115 GF 200 Air Fuel Valve ignition position switch Annually Service Technician See section...

Page 107: ...0 160 170 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 RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 60 15 6 60 60 60 60 60 60 60 60 60 60 55 12 8 63 64 65 66 67 68 69 70 71 72 50 ...

Page 108: ...97 209 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 RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 70 21 1 70 70 70 70 70 70 70 70 70 70 65 18 3 73 74 75 76 77 78 79 80 81 ...

Page 109: ...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 RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 80 26 7 80 80 80 80 80 80 80 80 80 80 75 23 9 83 84 8...

Page 110: ...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 111: ... 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 CONTROL BOX C MORE 17 1 28317 BMK 750 HEAT EXCHANGER 52 1 69151 PCB ASSY 1 28249 BMK 1000 HEAT EXCHANGER 53 2 124326 RELAY ...

Page 112: ...SION 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 Kit Number Description Item 85 Item 86 Item 87 58037 1 30 PSI 207 kPa Kit Apollo 9 234...

Page 113: ...16_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 113 of 178 GF 201 Ph 800 526 0288 03 15 2017 ITEM 4 FM GAS TRAIN 22140 1 ITEM 4 DBB GAS TRAIN 22140 2 TOP VIEW FRONT 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 ...

Page 114: ...F BENCHMARK 750 1000 PART LISTS Page 114 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 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 115: ...F BENCHMARK 750 1000 PART LISTS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 115 of 178 GF 201 Ph 800 526 0288 03 15 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 116: ...F BENCHMARK 750 1000 PART LISTS Page 116 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 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 ...

Page 117: ... 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 69005 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 30...

Page 118: ...5 VALVE BALL 1 NPT 3 2 92036 VALVE SSOV 1 NPT 18 1 69038 ACTUATOR SSOV W O P O C SWITCH 4 1 69005 ACTUATOR SSOV W REGULATOR 19 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 6 4 12951 2 BUSHING CONTROL BOX 21 1 122774 VALVE VENT 3 4 NPT 7 1 61002 1 LOW PRESSURE SWITCH 2 6 W C FALL N O 23 1 99017 SNUBBER PRESSURE 1 4 8 1 99015 DAMPING ORIFICE SSOV 33 3 92077 1 4 NPT MXF BRASS BALL VALVE 13 2 9 22 PIPE...

Page 119: ... THREADED FLANGE 1 25 NPT 125 24 1 92006 3 VALVE FULL PORT BALL 1 2 NPT BRASS 2 1 92103 VALVE SSOV 1 2 NPT 25 3 92077 1 4 NPT MXF BRASS BALL VALVE 3 1 69005 ACTUATOR SSOV W REGULATOR 29 1 93474 REDUCING COUPLING 1 X 1 2 11 1 93420 UNION NPT FEMALE BLACK MI 31 1 99017 SNUBBER PRESSURE 1 4 12 2 9 22 PIPE PLUG 1 4 NPT STEEL 32 1 97087 20 TUBE FLEXIBLE GAS 20 23 2 12951 2 BUSHING CONTROL BOX 33 1 9901...

Page 120: ...LVE 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 1 60011 4 SWITCH ASSY B...

Page 121: ...URNER RELEASE GASKET 48 1 123449 SENSOR TEMPERATURE 14 1 43090 AIR FUEL VALVE 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 INSULATIO...

Page 122: ...kPa KIT WATTS 92023 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...

Page 123: ...ARK 1500 2000 PART LISTS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 123 of 178 GF 201 Ph 800 526 0288 03 15 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 3 of 9 ...

Page 124: ... International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 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 1500DF 2000 2000DF Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 4 of 9 ...

Page 125: ...ni Dr Blauvelt NY 10913 Page 125 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 1500 2000 Standard FM Gas Train P N 22188 See full part lists below Benchmark 1500 2000 Double Block Bleed Gas Train P N 22199 4 4 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 5 of 9 ...

Page 126: ...DF DUAL FUEL Gas Train P N 22198 consists of 22188 1 NATURAL GAS gas train 22197 PROPANE train Full gas train part lists are shown below PROPANE Gas Train P N 22197 NATURAL GAS Gas Train P N 22188 1 Benchmark 1500DF 2000DF DUAL FUEL Gas Train P N 22198 4 22188 1 NATURAL GAS gas train PARTIALLY EXPLODED VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 01 03...

Page 127: ...Dr Blauvelt NY 10913 Page 127 of 178 GF 201 Ph 800 526 0288 03 15 2017 4 PROPANE Gas Train P N 22200 NATURAL GAS Gas Train P N 22199 1 PARTIALLY EXPLODED VIEW Benchmark 1500DF 2000DF DUAL FUEL DBB Gas Train P N 22201 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 7 of 9 ...

Page 128: ...TS Page 128 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 LEFT SIDE VIEW FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 8 of 9 REAR VIEW TOP VIEW ...

Page 129: ...2000 PART LISTS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 129 of 178 GF 201 Ph 800 526 0288 03 15 2017 PARTIAL FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 01 03 2017 29313 TAB rev E 29337 TAB rev E Sheet 9 of 9 ...

Page 130: ...1 123542 FLANGE 2 125 2 NPT 11 1 97087 20 FLEX HOSE 20 4 1 69005 ACTUATOR SSOV W REGULATOR 14 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 5 2 12951 2 BUSHING CONTROL BOX 23 1 124150 VALVE SSOV 1 1 2 NPT 6 3 92077 1 4 NPT MXF BRASS BALL VALVE 26 1 93382 2 NPT CAP 7 4 9 22 PIPE PLUG 1 4 NPT STEEL 28 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 8 1 99017 SNUBBER PRESSURE 1 4 29 1 9 294 UNION 2 NPT 300 9 1 610...

Page 131: ...SOV W REGULATOR 29 1 122774 VALVE VENT 3 4 NPT 5 4 12951 2 BUSHING CONTROL BOX 33 2 95029 FLANGE SSOV 1 1 2 NPT 6 1 97087 20 TUBING FLEXIBLE 20 34 1 99017 SNUBBER PRESSURE 1 4 19 1 93382 2 NPT CAP 36 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 20 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 37 3 92077 1 4 NPT MXF BRASS BALL VALVE 21 1 9 294 UNION 2 NPT 300 39 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 22 ...

Page 132: ...K 2000 20 1 66026 IGNITOR INJECTOR 24220 3 A F VALVE ASSY BMK 2000 DF 21 1 61026 O2 SENSOR 4 1 46042 BURNER BMK 1500 22 1 81048 GASKET FLAME ROD LOW NOx 46044 BURNER BMK 2000 23 1 66034 FLAME ROD 46044 BURNER BMK 2000 DF 24 1 59104 OBSERVATION PORT 5 1 81057 GASKET BLOWER 25 1 81183 BURNER GASKET UPPER RELEASE 6 1 43095 BLOWER PLENUM 26 1 24277 STAGED IGNITION ASSY 8 1 59138 FILTER AIR 6 27 1 8118...

Page 133: ... FLANGE 2 125 2 NPT 20 1 93382 2 NPT CAP 7 1 69005 ACTUATOR SSOV W REGULATOR 21 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 8 2 12951 2 BUSHING CONTROL BOX 22 1 9 294 UNION 2 NPT 300 9 3 92077 1 4 NPT MXF BRASS BALL VALVE 24 1 9 291 UNION 1 NPT 300 BI 10 3 9 22 PIPE PLUG 1 4 NPT STEEL 29 2 60020 SWITCH DUNGS GAS PRESSURE 2 20 W C 11 1 99017 SNUBBER PRESSURE 1 4 31 1 97087 20 FLEX HOSE 20 18 1 124150 VALV...

Page 134: ...ty Part No Description Item Qty Part No Description 1 1 92036 VALVE SSOV 1 NPT 11 1 99017 SNUBBER PRESSURE 1 4 2 1 69005 ACTUATOR SSOV W REGULATOR 15 1 9 291 UNION 1 NPT 300 BI 3 2 12951 2 BUSHING CONTROL BOX 19 1 93466 CAP 1 NPT M I 4 1 9 22 PIPE PLUG 1 4 NPT STEEL 21 2 60020 SWITCH DUNGS GAS PRESSURE 2 20 W C 8 1 92077 1 4 NPT MXF BRASS BALL VALVE AERCO International Inc Blauvelt NY 10913 Benchm...

Page 135: ... REGULATOR 25 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 8 2 12951 2 BUSHING CONTROL BOX 26 1 69038 ACTUATOR SSOV W O P O C SWITCH 9 4 92077 1 4 NPT MXF BRASS BALL VALVE 27 2 95029 FLANGE SSOV 1 1 2 NPT 10 3 9 22 PIPE PLUG 1 4 NPT STEEL 33 1 124094 UNION 3 4 NPT 150 11 1 99017 SNUBBER PRESSURE 1 4 41 1 122774 VALVE VENT 3 4 NPT 19 1 93382 2 NPT CAP 44 2 60020 SWITCH DUNGS GAS PRESSURE 2 20 W C 20 1 920...

Page 136: ...1 69005 ACTUATOR SSOV W REGULATOR 17 2 92036 VALVE SSOV 1 NPT1 2 2 12951 2 BUSHING CONTROL BOX 20 1 69038 ACTUATOR SSOV W O P O C SWITCH 5 2 9 22 PIPE PLUG 1 4 NPT STEEL 27 1 124094 UNION 3 4 NPT 150 8 2 92077 1 4 NPT MXF BRASS BALL VALVE 28 1 93466 CAP 1 NPT M I 14 1 99017 SNUBBER PRESSURE 1 4 29 1 122774 VALVE VENT 3 4 NPT 16 1 9 291 UNION 1 NPT 300 BI 31 2 60020 SWITCH DUNGS GAS PRESSURE 2 20 W...

Page 137: ...015 1 26015 2 26015 3 BMK 2500 BURNER ASSY 460 VAC BMK 2500 BURNER ASSY 208 VAC BMK 2500DF BURNER ASSY 460 VAC 44 1 38035 I O PANEL COVER 1 26014 1 26014 2 26014 3 BMK 3000 BURNER ASSY 460 VAC BMK 3000 BURNER ASSY 208 VAC BMK 3000DF BURNER ASSY 460 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 1 811...

Page 138: ...Benchmark 2500 3000 2500DF 3000DF Parts List Continued Item Qty Part Description 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 ...

Page 139: ...ARK 2500 3000 PART LISTS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 178 GF 201 Ph 800 526 0288 03 15 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 3 of 9 ...

Page 140: ...ernational Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 2500 3000 Burner Air Fuel Valve Assembly P N 26015 26014 26 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 4 of 9 9 BURNER GASKETS EXPLODED VIEW ...

Page 141: ...dard FM Gas Train P N 22171 See full drawing below Benchmark 3000 Single Fuel Double Block Bleed Gas Train P N 22173 See full drawing below 4 4 Benchmark 2500 Single Fuel Standard FM Gas Train P N 22190 See full drawing below Benchmark 2500 Single Fuel Double Block Bleed Gas Train P N 22211 See full drawing below 4 4 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part ...

Page 142: ... Gas Train P N 22174 See below for full diagram and part list Benchmark 3000 Dual Fuel Double Block Bleed Gas Train P N 22183 See below for full diagram and part list Natural Gas P N 22177 Propane P N 22178 Natural Gas P N 22177 1 Propane P N 22178 1 NATURAL GAS INLET PROPANE INLET NATURAL GAS INLET PROPANE INLET AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part List...

Page 143: ...as Train P N 22210 See below for full diagram and part list Benchmark 2500 Dual Fuel Double Block Bleed Gas Train P N 22209 See below for full diagram and part list Natural Gas P N 22210 1 Propane P N 22210 2 NATURAL GAS INLET PROPANE INLET NATURAL GAS INLET PROPANE INLET Natural Gas P N 22209 1 Propane P N 22209 2 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part Li...

Page 144: ...TS Page 144 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 REAR VIEW TOP VIEW LEFT SIDE VIEW FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 8 of 9 ...

Page 145: ...LISTS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 145 of 178 GF 201 Ph 800 526 0288 03 15 2017 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part List 12 15 2016 28536 TAB rev C 28382 TAB rev D Sheet 9 of 9 PARTIAL FRONT VIEW FRONT PANEL REMOVED ...

Page 146: ...42 FLANGE 2 125 2 NPT 26 1 60020 SWITCH GAS PRESSURE 2 20 W C 5 1 123540 VALVE BALL 2 FULL PORT 27 2 9 22 PIPE PLUG 1 4 NPT STEEL 7 1 99015 DAMPING ORIFICE SSOV 29 1 99017 SNUBBER PRESSURE 1 4 9 1 69005 ACTUATOR SSOV W REGULATOR 31 1 60032 SWITCH GAS PRESSURE 1 20 W C 10 2 12951 2 BUSHING CONTROL BOX 32 2 92143 1 4 BALL VALVE WATTS 12 1 124136 VALVE SSOV 2 NPT 33 1 9 294 UNION 2 NPT 300 18 1 97087...

Page 147: ... SNUBBER PRESSURE 1 4 6 2 95030 FLANGE SSOV 2 NPT 28 2 9 22 PIPE PLUG 1 4 NPT STEEL 7 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 31 1 97087 16 TUBING FLEXIBLE GAS 12 11 1 69005 ACTUATOR SSOV W REGULATOR 35 2 92143 1 4 BALL VALVE WATTS 12 1 69038 ACTUATOR SSOV W O P O C SWITCH 36 1 9 294 UNION 2 NPT 300 13 1 99015 DAMPING ORIFICE SSOV 37 1 60020 SWITCH GAS PRESSURE 2 20 W C 15 1 123769 VALVE SOLENOID N ...

Page 148: ...5 3 92077 1 4 NPT MXF BRASS BALL VALVE 7 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 26 2 9 22 PIPE PLUG 1 4 NPT STEEL 10 1 124150 VALVE SSOV 1 1 2 NPT 28 2 12951 2 BUSHING CONTROL BOX 11 1 69005 ACTUATOR SSOV W REGULATOR 29 1 99017 SNUBBER PRESSURE 1 4 15 1 93382 2 NPT CAP 32 1 99015 DAMPING ORIFICE SSOV 19 1 97087 12 Flex Tubing 12 33 1 9 294 UNION 2 NPT 300 24 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W ...

Page 149: ...9015 DAMPING ORIFICE SSOV 9 1 69005 ACTUATOR SSOV W REGULATOR 30 1 124137 VALVE SSOV DOUBLE BODY 1 1 2 NPT 13 1 93382 2 NPT CAP 31 2 95029 FLANGE SSOV 1 1 2 NPT 17 1 97087 12 Flex Gas Tubing 12 32 1 69038 ACTUATOR SSOV W O P O C SWITCH 21 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 33 1 122774 VALVE VENT 3 4 NPT 22 3 92077 1 4 NPT MXF BRASS BALL VALVE 40 1 124094 UNION 3 4 NPT 150 23 2 9 22 PIPE PL...

Page 150: ...DAMPING ORIFICE SSOV 6 1 123542 FLANGE 2 125 2 NPT 20 1 123540 VALVE BALL 2 FULL PORT 7 1 69005 ACTUATOR SSOV W REGULATOR 21 1 9 294 UNION 2 NPT 300 8 4 12951 2 BUSHING CONTROL BOX 22 2 95030 FLANGE SSOV 2 NPT 9 1 99017 SNUBBER PRESSURE 1 4 25 1 60032 SWITCH GAS PRESSURE 2 20 W C 11 1 69038 ACTUATOR SSOV W O P O C SWITCH 26 1 60020 SWITCH GAS PRESSURE 2 20 W C 12 2 9 22 PIPE PLUG 1 4 NPT STEEL 27 ...

Page 151: ...SSOV DOUBLE BODY 2 NPT 13 4 12951 2 BUSHING CONTROL BOX 2 1 69005 ACTUATOR SSOV W REGULATOR 17 2 95030 FLANGE SSOV 2 NPT 3 1 69038 ACTUATOR SSOV W O P O C SWITCH 23 1 60032 SWITCH GAS PRESSURE 2 20 W C 6 2 9 22 PIPE PLUG 1 4 NPT STEEL 24 1 60020 SWITCH GAS PRESSURE 2 20 W C 8 1 99017 SNUBBER PRESSURE 1 4 25 2 92143 1 4 BALL VALVE WATTS 11 1 93382 2 NPT CAP 1 97087 12 FLEX HOSE 12 12 1 99015 DAMPIN...

Page 152: ...V 4 1 123540 VALVE BALL 2 FULL PORT 19 1 123769 VALVE SOLENOID N O 1 NPT 7 1 123542 FLANGE 2 125 2 NPT 23 1 69005 ACTUATOR SSOV W REGULATOR 8 4 12951 2 BUSHING CONTROL BOX 25 1 9 294 UNION 2 NPT 300 9 1 99017 SNUBBER PRESSURE 1 4 29 2 95030 FLANGE SSOV 2 NPT 11 1 69038 ACTUATOR SSOV W O P O C SWITCH 32 1 60032 SWITCH GAS PRESSURE 2 20 W C 12 2 9 22 PIPE PLUG 1 4 NPT STEEL 33 1 60020 SWITCH GAS PRE...

Page 153: ...E SSOV 2 NPT 2 1 69005 ACTUATOR SSOV W REGULATOR 22 2 92143 1 4 BALL VALVE WATTS 3 1 69038 ACTUATOR SSOV W O P O C SWITCH 24 1 60032 SWITCH GAS PRESSURE 2 20 W C 6 2 9 22 PIPE PLUG 1 4 NPT STEEL 25 1 60020 SWITCH GAS PRESSURE 2 20 W C 8 1 99017 SNUBBER PRESSURE 1 4 29 1 123769 VALVE SOLENOID N O 1 NPT 11 1 93382 2 NPT CAP 32 1 123771 UNION MA x FEM 1 NPT 150 M I 12 1 99015 DAMPING ORIFICE SSOV 1 9...

Page 154: ...E BALL BRASS 1 1 2 NPT 25 2 12951 2 BUSHING CONTROL BOX 9 1 124150 VALVE SSOV 1 1 2 NPT 27 1 99015 DAMPING ORIFICE SSOV 10 1 69005 ACTUATOR SSOV W REGULATOR 29 1 93310 1 1 2 150 BLACK IRON UNION 14 1 93382 2 NPT CAP 30 2 99017 SNUBBER PRESSURE 1 4 17 1 97087 12 TUBING FLEXIBLE GAS 12 32 1 61002 15 HIGH GAS PRESSURE SWITCH 7 0 W C 22 1 61002 21 LOW GAS PRESSURE SWITCH 7 5 W C 33 1 9 294 UNION 2 NPT...

Page 155: ... Item Qty P N Description Item Qty P N Description 5 1 124150 VALVE SSOV 1 1 2 NPT 18 1 9 22 PIPE PLUG 1 4 NPT STEEL 6 1 69005 ACTUATOR SSOV W REGULATOR 19 2 12951 2 BUSHING CONTROL BOX 9 1 93382 2 NPT CAP 21 1 99015 DAMPING ORIFICE SSOV 16 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 23 1 9 294 UNION 2 NPT 300 17 1 92077 1 4 NPT MXF BRASS BALL VALVE AERCO International Inc Blauvelt NY 10913 Benchma...

Page 156: ... SWITCH 9 1 69005 ACTUATOR SSOV W REGULATOR 30 1 122774 VALVE VENT 3 4 NPT 13 1 93382 2 NPT CAP 35 1 124094 UNION 3 4 NPT 150 17 1 97087 12 TUBING FLEXIBLE GAS 12 36 1 9 294 UNION 2 NPT 300 21 1 61002 21 LOW GAS PRESSURE SWITCH 7 5 W C 39 1 93310 1 1 2 150 BLACK IRON UNION 24 2 9 22 PIPE PLUG 1 4 NPT STEEL 41 2 99017 SNUBBER PRESSURE 1 4 25 3 92077 1 4 NPT MXF BRASS BALL VALVE 42 1 61002 15 HIGH G...

Page 157: ...CTUATOR SSOV W REGULATOR 19 1 99015 DAMPING ORIFICE SSOV 10 1 93382 2 NPT CAP 20 1 9 294 UNION 2 NPT 300 15 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 22 1 124137 VALVE SSOV DOUBLE BODY 1 1 2 NPT 16 1 92077 1 4 NPT MXF BRASS BALL VALVE 23 1 69038 ACTUATOR SSOV W O P O C SWITCH 17 1 9 22 PIPE PLUG 1 4 NPT STEEL 24 2 95029 FLANGE SSOV 1 1 2 NPT 18 4 12951 2 BUSHING CONTROL BOX 25 1 122774 VALVE VENT...

Page 158: ...PERATION SERVICE and MAINTENANCE GUIDE APPENDIX H BENCHMARK 2500 3000 PART LISTS Page 158 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 This page intentionally blank ...

Page 159: ... MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 159 of 178 GF 201 Ph 800 526 0288 03 15 2017 Appendix I WIRING DIAGRAMS Benchmark 750 1000 Drawing Number 68038 rev G Sheet 1 of 2 ...

Page 160: ...N SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 160 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 750 1000 Drawing Number 68038 rev G Sheet 2 of 2 ...

Page 161: ...N SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 1500 2000 Drawing Number 68050 rev C page 1 of 2 ...

Page 162: ...N SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 162 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 1500 2000 Drawing Number 68050 rev C page 2 of 2 ...

Page 163: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 163 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 1500 2000 DBB Drawing Number 68071 rev C page 1 of 2 ...

Page 164: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 164 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 1500 2000 DBB Drawing Number 68071 rev C page 2 of 2 ...

Page 165: ...ION SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 3000 208 VAC Diagram 68040 rev F Sheet 1 of 2 ...

Page 166: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 166 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 3000 208 VAC Drawing Number 68040 rev F Sheet 2 of 2 ...

Page 167: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 167 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 3000 460 VAC Drawing Number 68041 rev F Sheet 1 of 2 ...

Page 168: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 168 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 3000 460 VAC Drawing Number 68041 rev E Sheet 2 of 2 ...

Page 169: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 2500 208 VAC Drawing Number 68060 rev C Sheet 1 of 2 ...

Page 170: ...SERVICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 170 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 2500 208 VAC Drawing Number 68060 rev C Sheet 2 of 2 ...

Page 171: ...ICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 2500 3000 208 VAC DBB Drawing Number 68062 rev C Sheet 1 of 2 ...

Page 172: ...ICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 172 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 2500 3000 208 VAC DBB Drawing Number 68062 rev C Sheet 2 of 2 ...

Page 173: ...ICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS OMM 0116_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 178 GF 201 Ph 800 526 0288 03 15 2017 Benchmark 2500 3000 460 VAC DBB Drawing Number 68063 rev B Sheet 1 of 2 ...

Page 174: ...ICE and MAINTENANCE GUIDE APPENDIX I WIRING DIAGRAMS Page 174 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Benchmark 2500 3000 460 VAC DBB Drawing Number 68063 rev B Sheet 2 of 2 ...

Page 175: ...igure J 1 Benchmark Series Control Panel Exploded View ENCLOSURE P N 124951 POWER SUPPLY BOARD P N 124362 IGNITION STEPPER BOARD P N 124361 FISH PAPER INSULATOR P N 124960 V F D DISPLAY MODULE P N 124527 FRONT FACE PLATE BENCHMARK P N 124949 VERTICAL OVERLAY BENCHMARK P N 124718 PUSH BUTTON SWITCHES P N 124954 ROCKER SWITCH P N 124947 GREEN LED P N 124948 DISPLAY BOARD P N 124365 PMC BOARD P N 124...

Page 176: ...lauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 Figure J 2 Benchmark Control Panel Rear View SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX GAS TRAIN HARNESS CONNECTOR 9 PIN SHELL HARNESS CONNECTOR 19 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX ...

Page 177: ...9078 24351 or 24350 SSOV Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of IRI gas train models 64048 69005 69005 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 Kit ...

Page 178: ...NANCE GUIDE Page 178 of 178 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0116_0A 03 15 2017 Ph 800 526 0288 GF 201 AERCO International Inc 2017 CHANGE LOG DATE DESCRIPTION CHANGED BY 03 15 2017 Rev A Initial release Curtis Harvey Chris Blair ...

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