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Watts Aerco Benchmark 1000, Reference Manual

The Watts Aerco Benchmark 1000 is a high-efficiency boiler that ensures optimal performance. Access its Reference Manual for detailed instructions on installation, operation, and maintenance. Download the manual for free from manualshive.com and get the most out of your heating system.

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Benchmark with Edge [I] Controller: Reference Manual

 

CHANGE LOG  

 

 

OMM-

0146_A   •   GF-219  •   5/25/2020          Technical Support  •  (800) 526-0288  •  Mon-Fri, 8 am - 5 pm EST          Page 

76

  of 

76

 

 

Change Log:

 

Date

 

 

Description 

Changed By 

5/25/2020 

Rev A: 

Initial release

. 

 

 

 

 

 

 

 

 

© AERCO International, Inc., 2020 

Summary of Contents for Aerco Benchmark 1000

Page 1: ...TAG 0022 GF 2050 Vent Combustion Air Guide TAG 0047 GF 2030 Benchmark Gas Guide TAG 0048 GF 2060 Benchmark Power Guide Applies to serial numbers G 20 0100 and above BMK 750 5000N N 20 0050 and above...

Page 2: ...BLE OF CONTENTS 2 SECTION 1 SAFETY PRECAUTIONS 3 1 1 WARNINGS CAUTIONS 3 1 2 EMERGENCY SHUTDOWN 4 1 3 PROLONGED SHUTDOWN 4 SECTION 2 BENCHMARK 750 1000 PART LIST 5 SECTION 3 BENCHMARK 1500 2000 PART L...

Page 3: ...r gas leaks Fluids under pressure may cause injury to personnel or damage to equipment when released Be sure to shut off all incoming and outgoing water shutoff valves Carefully decrease all trapped p...

Page 4: ...r circuit breaker marked for easy identification at a location readily accessible in the event of boiler mis operation Design the system so activation of the emergency shutdown switch or circuit break...

Page 5: ...XCHANGER 5 1 58179 1 BMK 750 Heat Exchanger 58179 2 BMK 1000 Heat Exchanger 6 1 80080 Insulation Shell 7 1 123692 Plug 1 1 2 NPT CONTROLS 8 2 123449 Temperature Sensor 9 1 93360 3 4 Plug NPT 10 1 6103...

Page 6: ...SEMBLIES See full diagrams below 21 1 22140 1 BMK 750 1000 FM Gas Train 22140 2 BMK 750 1000 DBB Gas Train 22140 3 1 BMK 750 Propane Gas Train 22140 3 2 BMK 1000 Propane Gas Train CONTROLS 22 1 24356...

Page 7: ...rame Assembly 3 1 37155 Left Rear Panel 4 1 37156 Right Rear Panel 5 1 39217 Air Inlet Adapter 6 6 2 59179 Handle Concealed Pull 7 1 25085 3 Front Panel Assembly 8 2 59133 Latch Compression 9 1 59174...

Page 8: ...er 20A 7 3 65122 Terminal Ground Block DIN Mounted 8 2 65120 Terminal Block Black 9 1 65156 Amplifier Flame Rod Signal 10 1 65162 24V Power Supply Sequencing Valve 11 1 65011 Transformer 115 24V 100VA...

Page 9: ...alve 1 92015 484 Pressure Relief Valve 1 92015 361 Pressure Relief Valve 1 123659 Pressure Relief Valve 1 9 234 3 4 Close Nipple 1 1 1 1 1 1 1 Wiring Harnesses not shown in figures below Part Descript...

Page 10: ...26 Flange 1 25 NPT 125 Threaded 16 1 92006 5 Ball Valve 1 NPT 3 1 92036 Valve SSOV 1 NPT 24 1 61002 12 High Gas Pressure Switch 4 7 W C 4 1 64048 Actuator SSOV w Regulator 26 2 92077 Ball Valve 1 4 NP...

Page 11: ...Ball Valve 1 NPT 3 2 92036 Valve SSOV 1 NPT 18 1 27086 1 Actuator SSOV w o P O C Switch 4 1 64048 Actuator SSOV w Regulator 19 1 61002 12 High Gas Pressure Switch 4 7 W C 6 4 12951 2 Bushing Control B...

Page 12: ...ressure 1 4 3 1 64048 Actuator SSOV w Regulator 32 1 97087 20 Flexible Gas Tube 20 11 1 93420 Union 1 2 NPT Female Black Mi 33 1 99015 Damping Orifice SSOV 12 2 9 22 Pipe Plug 1 4 NPT Steel 34 1 61002...

Page 13: ...sy BMK 750 3 1 81064 Gasket Blower 24298 2 A F Valve Assy BMK 750 1000 Propane 4 1 59104 Observation Port 16 1 61002 5 Blocked Inlet Switch 4 5 W C 5 1 24277 Staged Ignition Assy 17 1 59171 Reflector...

Page 14: ...rk with Edge I Controller Reference Manual SECTION 2 BENCHMARK 750 1000 PART LIST OMM 0146_A GF 219 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 14 of 76 This page intentionally...

Page 15: ...ipe Plug Exhaust Manifold HEAT EXCHANGER 5 1 58179 3 BMK 1500 Heat Exchanger 58179 4 BMK 2000 Heat Exchanger 6 2 123692 Plug 1 1 2 NTP 7 1 80089 Shell Insulation CONTROLS 8 2 123449 Temperature Sensor...

Page 16: ...er Assy 24378 1 BMK 2000 Burner Blower Assy 24378 2 BMK 2000 DF Burner Blower Assy 14 1 65085 Ignition Transformer 15 1 88003 O Ring 2 339 gas train to A F Valve 16 1 59138 Air Filter 6 17 1 97087 72...

Page 17: ...4 1 37157 BACK PANEL RIGHT 5 1 39218 6 Air Inlet Adapter BMK 1500 39215 8 Air Inlet Adapter BMK 2000 6 4 59133 Latch Compression 7 1 25087 Front Frame Assembly 8 2 30155 Side Panel 9 2 59179 Handel Co...

Page 18: ...Terminal Block Black 10 3 65122 Terminal Ground Block DIN Mounted 11 1 60037 2 Pole Circuit Breaker 20A 12 3 69141 DIN Rail End Stop 13 2 65121 Terminal Block White 14 1 69102 3 Relay 15 1 65156 Flame...

Page 19: ...8087 8 160 PSI 1103 kPa 123620 K160 123675 7 58088 W50 50 PSI 345 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...

Page 20: ...3542 Flange 2 125 2 NPT 11 1 97087 20 Flex Gas Hose 20 4 1 64048 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 NP...

Page 21: ...774 Vent Valve 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 Cap 2 NPT 36 1 61002 12 High Gas Pres...

Page 22: ...Flange 2 125 2 NPT 20 1 93382 2 NPT Cap 7 1 64048 Actuator SSOV w Regulator 21 1 92006 7 Ball Valve 1 1 2 NPT Brass 8 2 12951 2 Bushing Control Box 22 1 9 294 Union 2 NPT 300 9 3 92077 Ball Valve 1 4...

Page 23: ...Gas Train component of 22198 P N 22197 rev E Item Qty Part No Description Item Qty Part No Description 1 1 92036 Valve SSOV 1 NPT 11 1 99017 Snubber Pressure 1 4 2 1 64048 Actuator SSOV w Regulator 1...

Page 24: ...NPT 5 1 64048 Actuator SSOV w Regulator 23 1 27086 1 Actuator SSOV w o P O C Switch 6 2 12951 2 Bushing Control Box 24 2 95029 Flange SSOV 1 1 2 NPT 7 4 92077 1 4 NPT MXF Brass Ball Valve 30 1 124094...

Page 25: ...ator SSOV w Regulator 20 1 27086 1 Actuator SSOV w o P O C Switch 2 2 12951 2 Bushing Control Box 27 1 124094 Union 3 4 NPT 150 5 3 9 22 Pipe Plug 1 4 NPT Steel 28 1 93466 Cap 1 NPT M I 8 2 92077 Ball...

Page 26: ...1057 Gasket Blower 22 1 24356 1 Flame Rod 6 1 43095 Blower Plenum 23 1 59104 Observation Port 8 1 59138 Air Filter 6 24 1 81183 Burner Gasket Upper Release 9 5 9 21 Plug Hex Head 1 8 NPT 25 1 24277 St...

Page 27: ...aust Manifold HEAT EXCHANGER 5 1 58179 5 BMK 2500 Heat Exchanger single inlet 58179 6 BMK 3000 Heat Exchanger single inlet 6 1 123692 Plug 1 1 2 NTP 7 1 80081 Insulation Shell CONTROLS 8 2 123449 Temp...

Page 28: ...Propane Gas Train 22209 BMK 2500 DBB GAS TRAIN Dual Fuel includes 22209 1 Natural Gas Gas Train 22209 2 Propane Gas Train 22171 BMK 3000 FM GAS TRAIN 22173 BMK 3000 GAS TRAIN DBB 22174 BMK 3000 GAS T...

Page 29: ...ET COVER 4 1 37148 BACK PANEL RIGHT 5 1 37149 BACK PANEL LEFT 6 1 39215 8 AIR INLET ADAPTER 7 4 59133 LATCH COMPRESSION 8 1 25087 FRONT FRAME ASSEMBLY 9 2 30155 SIDE PANEL 10 2 59179 HANDEL CONCEALED...

Page 30: ...LY 8 2 65118 Fuse Terminal DIN Mounted 9 2 65120 Terminal Block Black 10 3 65122 Terminal Ground Block DIN Mounted 11 1 60036 3 Pole Circuit Breaker 12 3 69141 DIN Rail End Stop 13 2 65121 Terminal Bl...

Page 31: ...92016 12 123675 6 58048 W150 150 PSI 1034 kPa KIT WATTS 92016 13 123675 7 58048 K160 160 PSI 1103 kPa KIT KUNKLE 92016 14 123675 7 For Dual Fuel units add DF to the part number i e 58048 C30 DF Wiring...

Page 32: ...125 2 NPT 18 1 97087 12 Flex Gas Tubing 12 5 1 123540 Ball Valve 2 Full Port 26 1 60020 Gas Pressure Switch 2 20 W C 7 1 99015 Damping Orifice SSOV 27 2 9 22 Pipe Plug 1 4 NPT Steel 9 1 64048 Actuator...

Page 33: ...nubber Pressure 1 4 6 2 95030 Flange SSOV 2 NPT 28 3 9 22 Pipe Plug 1 4 NPT Steel 7 1 124142 SSOV Valve Double Body 2 NPT 31 1 97087 16 Flexible Gas Tubing 16 11 1 64048 Actuator SSOV w Regulator 35 3...

Page 34: ...92077 Ball Valve 1 4 NPT MXF Brass 7 1 92006 7 Ball Valve Brass 1 1 2 NPT 26 3 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 64048 Actuator SSOV...

Page 35: ...Body 1 1 2 NPT 9 1 64048 Actuator SSOV w Regulator 31 2 95029 Flange SSOV 1 1 2 NPT 13 1 93382 Cap 2 NPT 32 1 27086 1 Actuator SSOV w o P O C Switch 17 1 97087 12 Flex Gas Tubing 12 33 1 GP 122774 Ven...

Page 36: ...Double BODY 2 NPT 16 1 99015 Damping Orifice SSOV 6 1 123542 Flange 2 125 2 NPT 20 1 123540 Ball Valve 2 Full Port 7 1 64048 Actuator SSOV w Regulator 21 1 9 294 Union 2 NPT 300 8 4 12951 2 Bushing Co...

Page 37: ...n Item Qty Part Description 1 1 124142 Valve SSOV Double Body 2 NPT 12 1 99015 Damping Orifice SSOV 2 1 64048 Actuator SSOV w Regulator 13 4 12951 2 Bushing Control Box 3 1 27086 1 Actuator SSOV W O P...

Page 38: ...1 99015 Damping Orifice SSOV 4 1 123540 Ball Valve 2 full port 19 1 123769 Valve Solenoid N O 1 NPT 7 1 123542 Flange 2 125 2 NPT 23 1 64048 Actuator SSOV w Regulator 8 4 12951 2 Bushing Control Box 2...

Page 39: ...ve SSOV Double Body 2 NPT 13 4 12951 2 Bushing Control Box 2 1 64048 Actuator SSOV w Regulator 16 2 95030 Flange SSOV 2 NPT 3 1 27086 1 Actuator SSOV w o P O C Switch 22 3 92143 Ball Valve 1 4 WATTS 6...

Page 40: ...4 NPT Steel 7 1 92006 7 Ball Valve 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 64048 Actuator SSOV w Regulator 29 1 93310 Uni...

Page 41: ...16 component of Dual Fuel gas train 22210 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 64048 Actuator SSOV w Regulator 19 2 1...

Page 42: ...SOV 1 1 2 NPT 9 1 64048 Actuator SSOV w Regulator 29 1 27086 1 Actuator SSOV w o P O C Switch 13 1 93382 Cap 2 NPT 30 1 GP 122774 Vent Valve 3 4 NPT 17 1 97087 12 Flexible Gas Tubing 12 35 1 124094 Un...

Page 43: ...Part Description Item Qty Part Description 7 1 64048 Actuator SSOV w Regulator 20 1 9 294 Union 2 NPT 300 10 1 93382 Cap 2 NPT 22 1 124137 Valve SSOV Double Body 1 1 2 NPT 15 1 61002 11 Low Gas Press...

Page 44: ...NPT Steel 46038 Burner BMK 3000 17 1 81057 Blower Gasket A F Valve to A F Valve Plenum 5 1 See Table A F Valve Assy 19 1 81157 Blower Gasket Blower to Blower Plenum 6 1 59104 Observation Port 26 1 880...

Page 45: ...K 4000 DBB Gas Train 22373 4 BMK 4000 FM Gas Train with VPS 22358 1 BMK 5000N FM Gas Train 22358 3 BMK 5000N DBB Gas Train 22358 4 BMK 5000N FM Gas Train with VPS Item Qty Part Description HEAT EXCHAN...

Page 46: ...64081 ECU for O2 Sensor behind cover 21 1 65085 Ignition Transformer BURNER BLOWER ASSY See full diagram 26017 TAB below 22 1 58195 1 Blower 480 V BMK 4000 5000N 23 1 97087 72 Flex Gas Tube 72 1 83 m...

Page 47: ...Center 5 1 39238 10 Air Inlet Adapter 6 1 30179 Back Panel Lower 7 2 38047 14 Air Inlet Cover Plate 8 4 59133 Latch Compression 9 1 25088 Front Panel Control Assy BMK4000 24682 Front Panel Control Ass...

Page 48: ...Terminal Block White 10 3 65122 Terminal Ground Block DIN Mounted 11 1 60039 3 Pole Circuit Breaker 12 3 69141 DIN Rail End Stop 13 1 65194 Terminal Block Red 14 1 123552 Over Temp Switch Manual Reset...

Page 49: ...not shown 27086 1 ACTUATOR SSOV w o P O C SWITCH 64048 SSOV with Pressure Regulator Replacement Kit and or Catalog number Benchmark Platinum 4000 Spare Parts Kit P N 58187 Kit Number Description Press...

Page 50: ...e SSOV Double Body 3 NPT 11 1 97087 12 Flex Hose 12 4 2 92143 1 4 Ball Valve WATTS 15 1 93634 Cap 3 NPT 5 3 9 22 Pipe Plug 1 4 NPT 16 1 60020 Gas Pressure Switch 6 1 64048 Actuator SSOV w Regulator 17...

Page 51: ...1 4 Ball Valve WATTS 16 1 60020 Gas Pressure Switch 5 3 9 22 Pipe Plug 1 4 NPT 17 1 41041 1 Gas Manifold Assy 6 1 64048 Actuator SSOV w Regulator 19 1 93471 Cap 1 1 2 NPT 7 1 99015 Damping Orifice SS...

Page 52: ...ll Valve WATTS 16 1 60020 Gas Pressure Switch 5 2 9 22 Pipe Plug 1 4 NPT 17 1 41041 1 Gas Manifold Assy 6 1 64048 Actuator SSOV w Regulator 19 1 93471 Cap 1 1 2 NPT 7 1 99015 Damping Orifice SSOV 21 1...

Page 53: ...below a fixed value indicating the failure of the Actuator or leakage in the gas line it triggers the shutdown of the unit When this occurs a SSOV SWITCH OPEN message appears in the Edge Controller d...

Page 54: ...PORT 3 NPT 12 1 97087 26 Flex Hose 26 3 1 92146 VALVE SSOV DOUBLE BODY 3 NPT 18 1 93634 3 NPT CAP 5 2 92143 1 4 BALL VALVE WATTS 19 1 60020 SWITCH GAS PRESSURE 6 3 9 22 PIPE PLUG 1 4 NPT STEEL 20 1 4...

Page 55: ...SSOV DOUBLE BODY 3 NPT 18 1 93634 3 NPT CAP 5 2 92143 1 4 BALL VALVE WATTS 19 1 60020 SWITCH GAS PRESSURE 6 3 9 22 PIPE PLUG 1 4 NPT STEEL 20 1 41041 1 GAS MANIFOLD ASSY 7 1 64048 ACTUATOR SSOV W REG...

Page 56: ...146 VALVE SSOV DOUBLE BODY 3 NPT 18 1 93634 3 NPT CAP 5 2 92143 1 4 BALL VALVE WATTS 19 1 60020 SWITCH GAS PRESSURE 6 2 9 22 PIPE PLUG 1 4 NPT STEEL 20 1 41041 1 GAS MANIFOLD ASSY 7 1 64048 ACTUATOR S...

Page 57: ...5 1 59104 Observation Port 23 1 88024 O Ring BMK 4000 5000N Blower 6 1 61026 O2 Sensor 24 1 81216 Gasket Blower Adapter Plate 7 1 24356 1 Flame Rod and gasket 32 1 60011 2 Blower Proof Switch Assy 10...

Page 58: ...46060 Burner 20 3 9 21 Plug Hex Hd 1 8 NPT 3 1 59104 Observation Port 21 1 93367 Snubber Fan Proving Switch 4 1 61026 O2 Sensor 24 1 60041 2 Blocked Inlet Switch Assy 5 1 24356 1 Flame Rod and gasket...

Page 59: ...Lower 4 2 9 22 Pipe Plug Exhaust Manifold 8 1 83028 Front Refractory GAS TRAIN ASSEMBLIES See full diagram below 9 1 83027 Rear Refractory 5 1 22330 1 FM Gas Train 10 1 39170 Refractory Shield Assy 2...

Page 60: ...p Sensor 21 1 123449 Temperature Sensor 22 1 61002 5 Blocked Inlet Switch 4 5 W C 23 1 60011 4 Blower Proof Switch Assy 24 1 65220 Cable H V Ignition 25 2 61031 Flame Detector 26 1 65085 Transformer G...

Page 61: ...62 Top Panel Front 5 3 30155 Side Panel 6 2 35049 Side Pillar 7 2 59179 Handel Concealed Pull 8 1 25085 3 Front Panel Assembly 9 1 25088 Front Frame Assembly 10 8 59133 Latch Compression 11 1 30178 Si...

Page 62: ...w Water Capacity Cutoff 6 1 69151 I O Board 2 1 61056 Thermocouple Temperature Sensor 7 1 64081 ECU for O2 Sensor 3 1 61030 Direct Immersed Temperature Sensor 8 1 25089 Power Panel see next page 4 1 1...

Page 63: ...rminal Ground Block DIN Mounted 11 1 60042 3 Pole Circuit Breaker 12 3 69141 DIN Rail End Stop 13 2 65121 Terminal Block White 14 1 123552 Over Temp Switch Manual Reset Front View Front panel and fram...

Page 64: ...lower 63148 1 HARNESS SSOV 65220 Ignition Cable Relay Bracket Item Qty Part Description 1 1 65122 Terminal Ground Block DIN Mounted 2 1 65121 Terminal Block White 3 1 65120 Terminal Block Black 4 1 65...

Page 65: ...5 6 58053 4 75 PSI 517 kPa 92102 4 123675 6 WATTS 174A Series 58053 5 60 PSI 414 kPa 92102 5 123675 6 58053 6 75 PSI 517 kPa 92102 6 123675 6 58053 7 80 PSI 1034 kPa 92102 7 123675 6 58053 8 100 PSI 6...

Page 66: ...4 1 123540 Ball Valve Full Port 2 NPT 16 4 9 22 Pipe Plug 1 4 NPT Steel 5 1 64048 Actuator SSOV w Regulator 18 2 95030 Flange SSOV 2 NPT 7 1 99015 Damping Orifice SSOV 19 1 60020 Gas Pressure Switch...

Page 67: ...Port 2 NPT 16 4 9 22 Pipe Plug 1 4 NPT Steel 5 1 64048 Actuator SSOV w Regulator 18 2 95030 Flange SSOV 2 NPT 7 1 99015 Damping Orifice SSOV 19 1 60020 Gas Pressure Switch 2 20 W C 8 4 12951 2 Bushin...

Page 68: ...rain P N 22330 2 operates in conjunction with a Valve Proving System P N 24655 This system monitors the gas pressure on both sides of the Actuator If the pressure difference falls below a fixed value...

Page 69: ...w 2 6 Spring 3 1 92006 9 Ball Valve Full Port 3 NPT 18 2 58089 Solenoid Valve 1 4 NPT 4 1 92146 Valve SSOV Double Body 3 NPT 19 1 64048 Actuator SSOV w Regulator 5 1 95035 Flange SCH 40 3 NPT 125 B I...

Page 70: ...92006 9 Ball Valve Full Port 3 NPT 18 2 58089 Solenoid Valve 1 4 NPT 4 1 92146 Valve SSOV Double Body 3 NPT 19 1 64048 Actuator SSOV w Regulator 5 1 95035 Flange SCH 40 3 NPT 125 B I 21 1 99015 Dampi...

Page 71: ...OMM 0146_A GF 219 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 71 of 76 Benchmark 5000 6000 Dual Fuel Gas Train P N 22328 rev B 9 11 2018 Item Qty Part Description 1 1 22330 3 N...

Page 72: ...SSOV Double Body 2 NPT 4 1 123540 Ball Valve 2 Full Port 16 4 9 22 Pipe Plug 1 4 NPT Steel 5 1 64048 Actuator SSOV w Regulator 18 2 95030 Flange SSOV 2 NPT 7 1 99015 Damping Orifice SSOV 19 1 60020 Ga...

Page 73: ...r SSOV w Regulator 13 1 60020 Gas Pressure Switch 2 20 W C 3 1 99015 Damping Orifice SSOV 14 1 60032 1 Gas Pressure Switch 1 20 W C 5 4 12951 2 Bushing Control Box 17 1 99017 Snubber Pressure 1 4 7 1...

Page 74: ...Assy 3 2 81159 Gasket Burner 15 1 61002 5 BMK 6000 Blocked Inlet Switch 4 5 W C 4 1 See Table Blower 61002 23 BMK 5000 Blocked Inlet Switch 3 9 W C 5 2 59192 Observation Port 16 1 65150 Flame Rod Assy...

Page 75: ...e Ohms F C PT 1000 Balco 40 40 0 843 779 30 34 4 865 797 5 20 28 9 887 816 3 10 23 3 908 835 4 0 17 8 930 854 8 10 12 2 952 874 6 20 6 7 974 894 7 30 1 1 996 915 1 40 4 4 1000 935 9 50 10 0 1017 956 9...

Page 76: ...ller Reference Manual CHANGE LOG OMM 0146_A GF 219 5 25 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 76 of 76 Change Log Date Description Changed By 5 25 2020 Rev A Initial release A...

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