Watts AERCO Benchmark BMK 1500DF User Manual Download Page 95

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Benchmark 750-3000 Operation, Service &

Maintenance Guide-Latin America

APPENDIX F – BENCHMARK 750/1000 PART LIST

Page

162

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0122_0C

10/25/2017

Ph.: 800-526-0288

GF-206-LA

Appendix F:

BENCHMARK 750/1000 PART LIST

Benchmark 750 and Benchmark 1000 Part List

Item # Qty Part #

Description

EXHAUST MANIFOLD

43086

MANIFOLD: EXHAUST

84045

SEAL: EXHAUST MANIFOLD

GAS TRAIN ASSEMBLY

22140-1

STD FM GAS TRAIN ASSY

22140-2

DBB GAS TRAIN ASSY

22140-3

PROPANE GAS TRAIN ASSY

81155

GASKET: 1 1/4" PIPE FLANGE

BURNER, AIR/FUEL VALVE, HEAT EXCHANGER

24276-TAB BURNER A/F ASSEMBLY

46026

BURNER

24367-1

BMK 1000 A/F Valve

Replacement Kit

24367-2

BMK 750 A/F Valve

Replacement Kit

24277

STAGED IGNITION ASSY

81143

GASKET: BURNER

28576

BMK 750 HEAT EXCHANGER

(Single Inlet)

28586

BMK 1000 HEAT EXCHANGER

(Single Inlet)

HOSES & INSULATION

97087-20

TUBE: FLEXIBLE GAS 20" (50.8 cm)

80080

INSULATION: SHELL

BLOWER

58061

BLOWER BMK 750/100

Replacement Kit

24356-1

FLAME DETECTOR

Replacement Kit

61026

LEAN OXYGEN SENSOR

58023

IGNITER-INJECTOR

Replacement Kit

59139

AIR FILTER: 6" X 4.5 (11.4 cm) LG

CONTROLS

123966

SWITCH: OVER TEMP-AUTO RESET

123552

SWITCH: OVER TEMP-MANUAL RESET

60011-4

BLOWER PROOF SWITCH ASSY:

61002-5

BLOCKED INLET SWITCH -4.5 W.C.

65085

IGNITION TRANSFORMER



61034

SPARK MONITOR (AC Transducer)

60026

CIRCUIT BREAKER 2 POLE 20A

64081

ECU

65011

TRANSFORMER 115V/24V 100VA

65109

12V POWER SUPPLY

65120

TERMINAL BLOCK: DIN MOUNTED: BLK

65121

TERMINAL BLOCK: DIN MOUNTED:

WHT

65122

TERMINAL GROUND BLOCK: DIN

MOUNTED

65118

FUSE TERMINAL: DIN MOUNTED

64088

LIMIT CONTROL TEMPERATURE

24327

ASSEMBLY: POWER SUPPLY COVER

69102-2

BENCHMARK PUMP RELAY



124512

FUSE: 4 AMP

123449

SENSOR: TEMPERATURE

58132

THERMOWELL

Replacement Kit

69186-4

C-MORE CONTROLLER

69172

I/O (PCB) ASSEMBLY

65156

FLAME ROD SIGNAL AMPLIFIER

61030

OUTLET TEMP SENSOR

61024

AIR INLET TEMPERATURE SENSOR

24468

208-230/380 TO 120 V

TRANSFORMER ASSY

(>120V input power only)

65162

24V POWER SUPPLY (FOR SEQUENCING

VALVE)

SHEET METAL/PANEL ASSEMBLY

37155

PANEL: LEFT (Black)

37156

PANEL: RIGHT (Black)

37154

TOP COVER ASSY (Black)

25087

FRONT FRAME ASSY. (Black)

25085-3

FRONT PANEL

59179

HANDLE, CONCEALED PULL

59133

LATCH: COMPRESSION

50010

LATCH: DRAW

50011

KEEPER: DRAW LATCH

39217

AIR INLET ADAPTER: 6" PVC (Black)

OTHER ACCESSORIES / PARTS

122843

LOW WATER CUTOFF

123863

VALVE: BALL 1/8" NPT

92094

BOILER DRAIN VALVE: 3/4 MNPT x GHT

59178

VENT: AIR 1/8 NPT



Not shown on drawing

AERCO International,

Inc. Blauvelt, NY

10913

Benchmark 750/1000 Part List

09/28/2017

BMK 750 28321-TAB rev F

BMK 1000 28253-TAB rev F

Sheet 1 of 6

Summary of Contents for AERCO Benchmark BMK 1500DF

Page 1: ...r Dual Fuel Fired Modulating Condensing Boilers Initial Release 01 02 2018 USER MANUAL 2 of 2 SEE ALSO Benchmark Installation and Startup Guide OMM 0131 GF 205 LA 750 1000 1500 2000 2500 and 3000 MBH...

Page 2: ...COMBUSTION CAL Menus 23 2 9 BST BOILER SEQUENCING TECHNOLOGY MENU 24 2 10 CALIBRATION MENU 27 SECTION 3 MODES OF OPERATION 29 3 1 INTRODUCTION 29 3 2 INDOOR OUTDOOR RESET MODE 29 3 2 1 Reset Ratio 29...

Page 3: ...SDUCER 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 DESC...

Page 4: ...000 Operation Service Maintenance Guide Latin America CONTENTS Page 4 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA This page inten...

Page 5: ...HR OUTPUT RANGE BTU HR MINIMUM MAXIMUM MINIMUM MAXIMUM BMK 750 50 000 14 6 kW 750 000 220 kW 47 750 14 kW 716 250 210 kW BMK 1000 50 000 14 6 kW 1 000 000 293 kW 48 300 14 15 kW 968 000 284 kW BMK 15...

Page 6: ...BMS II 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...

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 MA...

Page 8: ...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 Tempera...

Page 9: ...t 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 al...

Page 10: ...emergency 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...

Page 11: ...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 or 220 VA...

Page 12: ...ers utilize 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 i...

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 incl...

Page 14: ...was pressed 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 dis...

Page 15: ...essing 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 bas...

Page 16: ...oilier Sequencing Technology is enabled BST is described in detail in Section 6 of the Benchmark 750 3000 Installation and Startup Guide OMM 0131 GF 205 LA Figure 2 2 Menu Structure NOTE The following...

Page 17: ...4 C 240 F 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 Me...

Page 18: ...enter 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 i...

Page 19: ...itions no changes will be required TABLE 2 4 CONFIGURATION Menu MENU ITEM DISPLAY AVAILABLE CHOICES OR LIMIT DEFAULT Minimum Maximum 1 Internal Setpt 40 F 4 4 C 240 F 115 6 C 130 F 54 4 C 2 Unit Type...

Page 20: ...F 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...

Page 21: ...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 adjus...

Page 22: ...ent 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 MINIMUM MAXIMUM DEFAULT NATURAL GAS P...

Page 23: ...splays current value TABLE 2 8b COMBUSTION CAL Menu BMK 2500 3000 DUAL FUEL MENU ITEM DISPLAY MINIMUM MAXIMUM DEFAULT NATURAL GAS PROPANE BMK 2500 BMK 3000 BMK 2500 BMK 3000 1 CAL Voltage 14 0 25 10 0...

Page 24: ...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 Head...

Page 25: ...5 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 R...

Page 26: ...8 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 Thresh...

Page 27: ...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 Exh...

Page 28: ...34 Stop Level 0 Start Level 16 35 Start Level Stop Level 40 22 36 Skip Range Cntr 10 95 40 37 Skip Range Span 0 3 0 38 Skip Speed 0 5 2 0 0 5 39 O2 Gain 0 500 1 500 1 000 40 O2 Offset 24 0 2 0 1 0 41...

Page 29: ...Once 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 ou...

Page 30: ...to Section 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 Bui...

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 s...

Page 32: ...shield 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 set...

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 2...

Page 34: ...odbus 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...

Page 35: ...nt 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 b...

Page 36: ...oiler 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...

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...

Page 38: ...gnition 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 burn...

Page 39: ...Removed from Boiler Figure 4 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...

Page 40: ...from 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 d...

Page 41: ...er 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...

Page 42: ...re 4 3a BMK 750 1000 Igniter Injector Orientation Figure 4 3b BMK 1500 2000 Igniter Injector Orientation Figure 4 3c BMK 2500 3000 Igniter Injector Orientation IGNITER INJECTOR INJECTOR TUBE BURNER PL...

Page 43: ...If eroded 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 Reins...

Page 44: ...ECTION 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...

Page 45: ...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 10 Disconnect the wire leads connected to the...

Page 46: ...ket 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 p...

Page 47: ...er 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 sh...

Page 48: ...Details Figure 4 5c BMK 2500 3000 Burner Assembly Mounting Details 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 GAS TRAIN BLOWE...

Page 49: ...16 x 1 3 4 bolts washers and nuts from the blower plenum where it attaches to the blower See Figure 4 5a 4 5b BMK 1500 2000 or Figure 4 5c 4 5d BMK 2500 3000 10 You must either rig a support for the b...

Page 50: ...Location 15 Beginning with the burner assembly reinstall all the components in the reverse order that they were removed When reinstalling the blower plenum removed in step 11 tighten the 3 8 16 nuts...

Page 51: ...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...

Page 52: ...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 C More Controller to the OFF position Disconnect A...

Page 53: ...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...

Page 54: ...fore 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 fema...

Page 55: ...ng instructions must be followed Shutting Boiler Down For An Extended Period Instructions 1 Set ON OFF switch on the C More Controller to the OFF position to shut down the boiler s operating controls...

Page 56: ...tomatically 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 0131 GF 205 LA for de...

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 Troubleshooti...

Page 58: ...n Service Maintenance Guide Latin America SECTION 5 TROUBLESHOOTING GUIDE Page 58 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Thi...

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...

Page 60: ...wer 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 n...

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 s...

Page 62: ...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 Defe...

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...

Page 64: ...tch 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 repl...

Page 65: ...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 SSO...

Page 66: ...e that 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 no...

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...

Page 68: ...d 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 servic...

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 t...

Page 70: ...OTING GUIDE Page 70 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Figure 5 1 SSOV Actuator With Gas Pressure Adjustment SKP25 BRASS...

Page 71: ...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 F or C only if ou...

Page 72: ...0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA TABLE A 1 OPERATING Menu Item Descriptions MENU OPTIONS DESCRIPTION 19 Fault Log Displays information on the last 20 faults An additional parameter asso...

Page 73: ...llows 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 RS23...

Page 74: ...bination 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 Remot...

Page 75: ...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...

Page 76: ...D MODE 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...

Page 77: ...ortional 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 G...

Page 78: ...Guide OMM 0131 GF 205 LA 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 defa...

Page 79: ...ust 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 Modu...

Page 80: ...to the presently set Start Level 35 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 feat...

Page 81: ...ffset Range 20 to 20 either F or C 49 24 hr Max Cycles Maximum cycles in 24 hour period 50 24 hr Max Ovrtemp Maximum over temp in 24 hour period 51 0 10v Out Test Set the blower voltage at 0 10v for t...

Page 82: ...Service Maintenance Guide Latin America APPENDIX A BOILER MENU DESCRIPTIONS Page 82 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA T...

Page 83: ...the 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 elaps...

Page 84: ...nal was not seen during ignition or 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 fai...

Page 85: ...nsor is shorted OUTLET TEMPERATURE 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 SWTC...

Page 86: ...ice Maintenance Guide Latin America APPENDIX B STARTUP STATUS AND FAULT MESSAGES Page 86 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA...

Page 87: ...10 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...

Page 88: ...vice Maintenance Guide Latin America APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Page 88 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA...

Page 89: ...n Verify factory settings Annually Service Technician Check with combustion calibration test equipment see Section 4 4 of the Benchmark 750 3000 Installation and Startup Guide OMM 0131 GF 205 LA and t...

Page 90: ...ons 5 2 and 5 3 in the Benchmark 750 3000 Installation and Startup Guide OMM 0131 GF 205 LA Air Fuel Valve purge position switch Annually Service Technician See section 5 10 in the Benchmark 750 3000...

Page 91: ...150 160 170 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 Hea...

Page 92: ...197 209 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 2...

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 12...

Page 94: ...104 106 108 110 112 114 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...

Page 95: ...5 BLOCKED INLET SWITCH 4 5 W C 32 1 65085 IGNITION TRANSFORMER 33 1 61034 SPARK MONITOR AC Transducer 34 1 60026 CIRCUIT BREAKER 2 POLE 20A 35 1 64081 ECU 36 1 65011 TRANSFORMER 115V 24V 100VA 37 1 65...

Page 96: ...e 1 92015 15 Pressure Relief Valve 1 92015 16 Pressure Relief Valve 1 92015 20 Pressure Relief Valve 1 92015 484 Pressure Relief Valve 1 92015 361 Pressure Relief Valve 1 123659 Pressure Relief Valve...

Page 97: ...i Dr Blauvelt NY 10913 OMM 0122_0C 10 25 2017 Ph 800 526 0288 GF 206 LA FM Gas Train 22140 1 Propane Gas Train 22140 3 DBB Gas Train 22140 2 AERCO International Inc Blauvelt NY 10913 Benchmark 750 100...

Page 98: ...ritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 09 28 2017 BMK 750 28321 TAB rev F BMK 1000 28253...

Page 99: ...RK 750 1000 PART LIST Page 99 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 10 25 2017 Ph 800 526 0288 GF 206 LA AERCO International Inc Blauvelt NY 10913 Benchmark 750 1...

Page 100: ...f 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW REAR VIEW TOP VIEW AERCO International Inc B...

Page 101: ...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 V...

Page 102: ...5 VALVE BALL 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...

Page 103: ...HREADED 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 64048 ACTUATOR SSOV W REGULATOR 29 1 93474 REDUCING...

Page 104: ...ALVE ASSY 4 1 24111 BLOWER AMETEK 8 9 17 1 61002 5 BLOCKED INLET SWITCH 4 5 W C 5 1 59104 OBSERVATION PORT 18 1 59171 REFLECTOR SIGHT GLASS 6 1 24277 STAGED IGNITION ASSY 19 1 61026 LEAN OXYGEN SENSOR...

Page 105: ...UBBER AIR FUEL VALVE 35 1 64081 ECU O2 SENSOR 36 1 65011 TRANSFORMER 115V 24V 100VA 37 1 65109 12V POWER SUPPLY 38 3 69141 DIN RAIL MOUNT END STOP 39 2 65120 TERMINAL BLOCK DIN MOUNTED BLK 40 2 65121...

Page 106: ...IT CONBRACO 92023 7 123675 7 58087 7 125 PSI 862 kPa 123620 W125 123675 6 58088 W30 30 PSI 207 kPa KIT WATTS 92023 8 123675 5 58087 8 160 PSI 1103 kPa 123620 K160 123675 7 58088 W50 50 PSI 345 kPa KIT...

Page 107: ...RT LIST Page 107 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 10 25 2017 Ph 800 526 0288 GF 206 LA AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2...

Page 108: ...Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 10 02 2017 Benchmark 1500 29313 T...

Page 109: ...M 0122_0C 10 25 2017 Ph 800 526 0288 GF 206 LA Benchmark 1500 2000 Double Block Bleed Gas Train P N 22199 See full part lists below 4 Benchmark 1500 2000 Standard FM Gas Train P N 22188 See full part...

Page 110: ...6 0288 GF 206 LA LA Benchmark 1500DF 2000DF 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 4 PROPANE Gas Train P...

Page 111: ...526 0288 GF 206 LA PROPANE Gas Train P N 22200 NATURAL GAS Gas Train P N 22199 1 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 10 02 2017 Benchmark 1500 29313 T...

Page 112: ...AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA REAR VIEW TOP VIEW LEFT SIDE VIEW FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benc...

Page 113: ...age 113 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 10 25 2017 Ph 800 526 0288 GF 206 LA PARTIAL FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 150...

Page 114: ...1 123542 FLANGE 2 125 2 NPT 11 1 97087 20 FLEX 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 N...

Page 115: ...OV 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...

Page 116: ...42 FLANGE 2 125 2 NPT 20 1 93382 2 NPT CAP 7 1 64048 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...

Page 117: ...m 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 15 1 9 291 UNION 1 NPT 300 BI 3 2 12951 2 BUSHING...

Page 118: ...REGULATOR 25 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 8 2 12951 2 BUSHING CONTROL BOX 26 1 27086 1 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 1...

Page 119: ...1 64048 ACTUATOR SSOV W REGULATOR 17 2 92036 VALVE SSOV 1 NPT1 2 2 12951 2 BUSHING CONTROL BOX 20 1 27086 1 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 15...

Page 120: ...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 IGNI...

Page 121: ...BMK 3000 BLOWER PROOF SWITCH 60011 5 BMK 2500 BLOWER PROOF SWITCH 30 1 61002 5 BLOCKED INLET SWITCH 4 5 W C 31 1 69186 4 C MORE CONTROLLER 32 1 65085 IGNITION TRANSFORMER 34 1 93230 SNUBBER AIR FUEL...

Page 122: ...KIT WATTS 92016 10 123675 6 58048 W100 100 PSI 689 kPa KIT WATTS 92016 11 123675 6 58048 W125 125 PSI 862 kPa KIT WATTS 92016 12 123675 6 58048 W150 150 PSI 1034 kPa KIT WATTS 92016 13 123675 7 58048...

Page 123: ...RT LIST Page 123 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3...

Page 124: ...0 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 2500 3000 Burner Air Fuel Valve Assembly P N 26015 TAB 26014 TAB Full part lists below 8 AERCO International...

Page 125: ...Block Bleed Gas Train P N 22173 See full drawing below 4 Benchmark 3000 Standard FM Gas Train P N 22171 See full drawing below 4 Benchmark 2500 Double Block Bleed Gas Train P N 22211 See full drawing...

Page 126: ...opane P N 22178 Natural Gas P N 22177 1 Propane P N 22178 1 NATURAL GAS INLET PROPANE INLET NATURAL GAS INLET PROPANE INLET Benchmark 3000 Dual Fuel FM Gas Train P N 22174 See full diagram below 4 Ben...

Page 127: ...pane 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 Benchmark 2500 Dual Fuel FM Gas Train P N 22210 See full diagram below 4 Be...

Page 128: ...AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA REAR VIEW TOP VIEW LEFT SIDE VIEW FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benc...

Page 129: ...162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA PARTIAL FRONT VIEW FRONT PANEL REMOVED AERCO International Inc Blauvelt NY 10913 Benchmar...

Page 130: ...2 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 6404...

Page 131: ...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 64048 ACTUATOR SSOV W REGULATOR 35...

Page 132: ...25 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 64048 ACTUATOR S...

Page 133: ...015 DAMPING ORIFICE SSOV 9 1 64048 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 27...

Page 134: ...DAMPING ORIFICE SSOV 6 1 123542 FLANGE 2 125 2 NPT 20 1 123540 VALVE BALL 2 FULL PORT 7 1 64048 ACTUATOR SSOV W REGULATOR 21 1 9 294 UNION 2 NPT 300 8 4 12951 2 BUSHING CONTROL BOX 22 2 95030 FLANGE S...

Page 135: ...SOV DOUBLE BODY 2 NPT 13 4 12951 2 BUSHING CONTROL BOX 2 1 64048 ACTUATOR SSOV W REGULATOR 17 2 95030 FLANGE SSOV 2 NPT 3 1 27086 1 ACTUATOR SSOV W O P O C SWITCH 23 1 60032 SWITCH GAS PRESSURE 2 20 W...

Page 136: ...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 64048 ACTUATOR SSOV W REGULATOR 8 4 12951 2 BUSHING CONTROL BOX 25 1 9 294 UNION 2 NPT 300 9...

Page 137: ...SSOV 2 NPT 2 1 64048 ACTUATOR SSOV W REGULATOR 22 2 92143 1 4 BALL VALVE WATTS 3 1 27086 1 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...

Page 138: ...VE 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 64048 ACTUATOR SSOV W REGULATOR 29 1 93310 1 1 2 150 BLACK IRON UNION 14 1...

Page 139: ...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 12951 2 BUSHING CONTROL BOX 9 1 93382 2 NP...

Page 140: ...C SWITCH 9 1 64048 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 1 610...

Page 141: ...TUATOR 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...

Page 142: ...NPT STEEL 46039 BURNER BMK 3000 17 1 81057 GASKET BLOWER 5 1 See Table A F VALVE ASSY Replacement Kit 19 1 81157 BLOWER GASKET 6 1 59104 OBSERVATION PORT 25 1 61024 AIR INLET TEMPERATURE SENSOR 7 1 61...

Page 143: ...de Latin America APPENDIX I WIRING DIAGRAMS Page 143 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Appendix I WIRING DIAGRAMS Benchma...

Page 144: ...intenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 144 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 750 1000...

Page 145: ...aintenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 145 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 1500 2000...

Page 146: ...intenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 146 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 1500 2000...

Page 147: ...ntenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 147 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 1500 2000 DB...

Page 148: ...tenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 148 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 1500 2000 D...

Page 149: ...Maintenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 149 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 3000 208...

Page 150: ...tenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 150 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 3000 208 VA...

Page 151: ...ntenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 151 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 3000 460 VAC...

Page 152: ...tenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 152 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 3000 460 VA...

Page 153: ...ntenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 153 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 2500 208 VAC...

Page 154: ...tenance Guide Latin America APPENDIX I WIRING DIAGRAMS Page 154 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 2500 208 VA...

Page 155: ...nce Guide Latin America APPENDIX I WIRING DIAGRAMS Page 155 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 2500 3000 208 VAC...

Page 156: ...ce Guide Latin America APPENDIX I WIRING DIAGRAMS Page 156 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 2500 3000 208 VA...

Page 157: ...nce Guide Latin America APPENDIX I WIRING DIAGRAMS Page 157 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0122_0C 11 29 2017 Ph 800 526 0288 GF 206 LA Benchmark 2500 3000 460 VAC...

Page 158: ...ce Guide Latin America APPENDIX I WIRING DIAGRAMS Page 158 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Benchmark 2500 3000 460 VA...

Page 159: ...EWS Figure J 1 C More Controller 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 FRON...

Page 160: ...auvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA Figure J 2 C More Controller Rear View SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONN...

Page 161: ...58061 58038 58063 1 460V 58063 2 208 230V SSOV Actuator Regulator Combo Used on ALL FM gas trains Downstream SSOV on DBB gas trains 64048 64048 64048 SSOV Actuator Without Proof of Closure Switch Use...

Page 162: ...e Latin America Page 162 of 162 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0132_A 01 02 2018 Ph 800 526 0288 GF 206 LA LA AERCO International Inc 2018 Change log Date Description Cha...

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