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Watts AERCO Benchmark OMM-0121 Operation And Maintenance Manual Download Page 42

Benchmark 750-3000 Boiler Operation & Maintenance Manual

 

SECTION 4 – MAINTENANCE 

 

OMM-0122_D

  •

  GF-206  

•

  5/9/2019            

Technical Support

  

•

  (800) 526-0288  

•

  Mon-Fri, 8 am - 5 pm EST            Page 42  of 164 

 

The igniter-injector may be hot, therefore, care should be exercised to avoid burns. It is easier to 
remove the igniter-injector from the unit after  the unit has cooled to room temperature. To 
inspect/replace the Igniter: 

Igniter-Injector Maintenance Procedure Instructions 

1.  Set the ON/OFF switch on the C-More Controller  to the 

OFF

  position.  Disconnect AC 

power from the unit 

2.  Remove the top shroud from the unit by grasping the top handle and lifting straight up. This 

will disengage the shroud from the four (4) pins in the side panels. 

3.  Disconnect the cable from the igniter-injector (see Figure 4-1a – Figure 4-1c, above). 

4.  Referring to Figure 4-2a – Figure 4-2c, below, use a 7/16” open-end wrench to disconnect 

the compression nut securing the gas injector tube of the igniter-injector to the elbow of the 
staged ignition assembly. Disconnect the staged ignition assembly from the igniter-injector. 

 

Figure 4-2a: BMK 750/1000 Igniter-Injector & Flame Detector Mounting Details 

 

 

  

Figure 4-2b:  BMK 1500/2000 Igniter-Injector & Flame Detector Mounting Details 

LEAN O

2

 SENSOR  

& WASHER 

STAGED  
IGNITION 
SOLENOID 

IGNITER-INJECTOR 

INDEXING  
(CLOCKING) 
WASHERS 
(0-3 as required) 

FLAME  

DETECTOR 

& GASKET 

BURNER 

PLATE 

STAGED 

IGNITION 

SOLENOID 

 

FLAME 
DETECTOR & 
GASKET 
 

FLAME 
OBSERVATION  
PORT 
 

INJECTOR-IGNITER  

ASSY WITH INDEXING 

(CLOCKING) WASHERS  

(0-3 as needed) 

 

LEAN O2 SENSOR 

& WASHER 

 

BURNER PLATE 

FLANGE 

 

BLOWER 
PLENUM 
 

COMPRESSION 
FITTING &  ELBOW 

 

Summary of Contents for AERCO Benchmark OMM-0121

Page 1: ...s subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and...

Page 2: ...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...

Page 3: ...SECTION 5 TROUBLESHOOTING GUIDE 59 5 1 INTRODUCTION 59 5 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 71 APPENDIX A BOILER MENU ITEM DESCRIPTIONS 73 TABLE A 1 OPERATING MENU ITEM DESCRIPTIONS...

Page 4: ...Benchmark 750 3000 Boiler Operation Maintenance Manual CONTENTS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 4 of 164 This page intentionally blank...

Page 5: ...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...

Page 6: ...anagement 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 wate...

Page 7: ...et 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 10...

Page 8: ...ata 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...

Page 9: ...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 le...

Page 10: ...boilers in a location other than a boiler room provide a manually operated remote shutdown switch or circuit breaker marked for easy identification at a location readily accessible in the event of bo...

Page 11: ...d 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 ala...

Page 12: ...ign 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...

Page 13: ...tory 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...

Page 14: ...e Controller shown in Figure 2 1 This panel contains all of the controls indicators and displays necessary to operate adjust and troubleshoot the boiler These operating controls indicators and display...

Page 15: ...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 Message...

Page 16: ...enu 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...

Page 17: ...sing 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 attemp...

Page 18: ...bled BST is described in detail in Section 6 of the Benchmark 750 3000 Installation and Startup Guide OMM 0121 GF 205 Figure 2 2 Menu Structure NOTE The following sections provide brief descriptions o...

Page 19: ...utlet 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...

Page 20: ...and units of temperature measurements A view only software version display is also provided to indicate the current C More Controller software version A full description of each item appears in Append...

Page 21: ...ll 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 BMK Blr Std BMK Blr...

Page 22: ...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...

Page 23: ...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 s...

Page 24: ...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 PROPANE BMK 1500 BMK 2...

Page 25: ...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 00 2 40 CAL Voltage 1...

Page 26: ...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 disp...

Page 27: ...Disable Enable Disable 29 Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130 F 54 4 C 30 Setback Start 12 00am 11 59pm 12 00am 31 Setback End 12 00am 11 59pm 12 00am 32 Rate Threshold 1 F 0 5...

Page 28: ...BST COMM MENU Disabled Enabled Disabled 59 Comm Address 0 127 0 60 BST Min Addr 1 128 1 61 BST Max Addr 1 128 8 62 SSD Address 0 250 247 63 SSD Poll Control 0 1000 0 64 Err Threshold 1 9 5 65 SSD Temp...

Page 29: ...ly 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...

Page 30: ...nabled 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 4...

Page 31: ...upply 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 temperatu...

Page 32: ...Controller Menus above for detailed instructions on navigating the menus 7 Press the CHANGE key The display will begin to flash 8 Use the and arrow keys to select the desired Building Reference Tempe...

Page 33: ...t 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...

Page 34: ...ted 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 extern...

Page 35: ...rect 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...

Page 36: ...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 Bo...

Page 37: ...ight 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...

Page 38: ...nal 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...

Page 39: ...ilter 2500 3000 58025 10 24 Month Water Fireside 58025 01 plus Burner LWCO Air Filter replacement 58025 18 Same as 58025 10 except clean Air Filter WARNING Prior to servicing ensure that the following...

Page 40: ...d to light the burner the igniter injector also contains a gas injector tube which connects to the staged ignition assembly Figure 4 1a through Figure 4 1c shows the complete burner assembly removed f...

Page 41: ...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 PORT AIR FUEL VALVE...

Page 42: ...in the side panels 3 Disconnect the cable from the igniter injector see Figure 4 1a Figure 4 1c above 4 Referring to Figure 4 2a Figure 4 2c below use a 7 16 open end wrench to disconnect the compres...

Page 43: ...gh 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...

Page 44: ...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 PLATE BLOWER O2 SENSOR...

Page 45: ...or should be replaced Otherwise clean the detector with a fine emery cloth 7 Reinstall the flame detector and flame detector gasket 8 Reconnect the flame detector lead wire 9 Reinstall the shroud on t...

Page 46: ...ssembly 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...

Page 47: ...n the C More Controller 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...

Page 48: ...screws securing the blower to the burner plate Figure 4 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...

Page 49: ...sembly Mounting Details Figure 4 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...

Page 50: ...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 FUE...

Page 51: ...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 Figure 4 5a 4 5b BMK 1500 20...

Page 52: ...ird 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...

Page 53: ...Drain Trap Maintenance Instructions 1 Disconnect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap see Figure 4 7 2 Loosen th...

Page 54: ...nspect replace the air filter proceed as follows Air Filter Cleaning and Replacement Instructions 1 Set the ON OFF switch on the C More Controller to the OFF position Disconnect AC power from the unit...

Page 55: ...river 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 FRU Kit P N 69126 should be tested for...

Page 56: ...rocedure 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 r...

Page 57: ...more the following 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 op...

Page 58: ...AC CURRENT TRANSDUCER The spark monitor P N 61034 evaluates the strength of the current between the ignition transformer and igniter injector Wire 140 connected to the ignition transformer see Figure...

Page 59: ...and correct the fault Fault Correction Instructions 1 Observe the fault messages displayed in the C More Controller display 2 Refer to the Fault Indication column in Troubleshooting Table 5 1 which f...

Page 60: ...ark 750 3000 Boiler Operation Maintenance Manual SECTION 5 TROUBLESHOOTING GUIDE OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 60 of 164 This page intentionally...

Page 61: ...blockage clean or replace as necessary 4 Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary 5 Check the continuity of the Blower Proof switch with the comb...

Page 62: ...twork 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 faul...

Page 63: ...nt 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 e...

Page 64: ...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...

Page 65: ...ings have been changed record the current readings then reset them to the default values 3 Using the resistance charts in Appendix C measure the resistance of Shell sensor and BTU sensor at a known wa...

Page 66: ...y 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 Boar...

Page 67: ...nsformer 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...

Page 68: ...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 P...

Page 69: ...e 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 continuity of wiring between source and unit 2 Check signal a...

Page 70: ...ve 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...

Page 71: ...hrough Figure 4 1c and inspect Gas Injector to ensure it is not clogged or damaged 2 Close the Manual Shutoff Valve Attempt to start the unit and listen for a clicking sound that the Staged Ignition S...

Page 72: ...UBLESHOOTING GUIDE OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 72 of 164 Figure 5 1 SSOV Actuator With Gas Pressure Adjustment SKP25 BRASS HEX HEAD Remove to a...

Page 73: ...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 outdoor temperature sensor is installed and enabled...

Page 74: ...22_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 74 of 164 An additional parameter associated with the Operating menu Manual Valve Pos Min 0 Max 100 does not appear in th...

Page 75: ...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...

Page 76: ...eset 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 Dri...

Page 77: ...led 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 2...

Page 78: ...ated 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...

Page 79: ...g 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 fr...

Page 80: ...05 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 pr...

Page 81: ...r Disabled 11 Exhaust Safety Enabled or Disabled 12 Flue Material Select flue material PVC Polypropylene or stainless 13 Exhst Fault Temp Fault threshold temperature 14 Exhst Module Temp Decreases Val...

Page 82: ...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 Leve...

Page 83: ...either F or C 50 Outlet Wtr Offset Range 20 to 20 either F or C 51 24 hr Max Cycles Maximum cycles in 24 hour period 52 24 hr Max Ovrtemp Maximum over temp in 24 hour period 53 0 10v Out Test Set the...

Page 84: ...k 750 3000 Boiler Operation Maintenance Manual APPENDIX A BOILER MENU DESCRIPTIONS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 84 of 164 This page intentionall...

Page 85: ...d 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...

Page 86: ...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 Th...

Page 87: ...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 th...

Page 88: ...0 3000 Boiler Operation Maintenance Manual APPENDIX B STARTUP STATUS AND FAULT MESSAGES OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 88 of 164 This page intenti...

Page 89: ...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...

Page 90: ...50 3000 Boiler Operation Maintenance Manual APPENDIX C SENSOR RESISTANCE VOLTAGE CHART OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 90 of 164 This page intentio...

Page 91: ...y settings Annually Service Technician Check with combustion calibration test equipment see Section 4 4 of the Benchmark 750 3000 Installation and Startup Guide OMM 0121 GF 205 and the O2 sensor in Se...

Page 92: ...the Benchmark 750 3000 Installation and Startup Guide OMM 0121 GF 205 Air Fuel Valve purge position switch Annually Service Technician See section 5 10 in the Benchmark 750 3000 Installation and Star...

Page 93: ...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...

Page 94: ...17 130 143 156 169 182 195 208 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...

Page 95: ...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 21...

Page 96: ...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...

Page 97: ...OWER PROOF SWITCH ASSY 31 1 61002 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...

Page 98: ...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 1 9 234 Close Nipple...

Page 99: ...t 800 526 0288 Mon Fri 8 am 5 pm EST Page 99 of 164 FM Gas Train 22140 1 Propane Gas Train 22140 3 DBB Gas Train 22140 2 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 09 28 20...

Page 100: ...06 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 100 of 164 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 09 28 2017 BMK 750 28321 TAB rev F BMK 1000 2825...

Page 101: ...ENCHMARK 750 1000 PART LIST OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 101 of 164 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 09 28...

Page 102: ...0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 102 of 164 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW REAR VIEW TOP VIEW AERCO International Inc Blauvelt NY 10913 Benc...

Page 103: ...ANGE 16 1 92006 5 VALVE BALL 1 NPT 3 1 92036 VALVE SSOV 1 NPT 23 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 4 1 64048 ACTUATOR SSOV W REGULATOR 25 3 92077 1 4 NPT MXF BRASS BALL VALVE 6 2 12951 2 BUS...

Page 104: ...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 BOX 21 1 GP 122774 VAL...

Page 105: ...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 COUPLING 1 X 1 2 11...

Page 106: ...SSY BMK 750 Replacement Kit 4 1 58061 BLOWER AMETEK 8 9 Replacement Kit 24298 2 A F VALVE ASSY BMK 750 1000 PROPANE 5 1 59104 OBSERVATION PORT 17 1 61002 5 BLOCKED INLET SWITCH 4 5 W C 6 1 24277 STAGE...

Page 107: ...1 93230 SNUBBER 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 4...

Page 108: ...23675 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 WATTS 92023 9 123675...

Page 109: ...000 PART LIST OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 109 of 164 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 10 0...

Page 110: ...Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 110 of 164 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part List 10 02 2017 Benchmark 1500 29313 TAB rev G Benchmark 20...

Page 111: ...m 5 pm EST Page 111 of 164 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 lists below 4 AERCO...

Page 112: ...enchmark 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 N 22197 NATURAL GAS G...

Page 113: ...ROPANE 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 TAB rev G Benchmark 2...

Page 114: ..._D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 114 of 164 LEFT SIDE VIEW FRONT VIEW REAR VIEW TOP VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 200...

Page 115: ...LIST OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 115 of 164 PARTIAL FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 1500DF 2000 2000DF Part...

Page 116: ...5 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 NPT 6 3 92077 1 4 NPT...

Page 117: ...P 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...

Page 118: ...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 BRASS BALL VALVE 24 1...

Page 119: ...ption 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 CONTROL BOX 19 1 934...

Page 120: ...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 10 3 9 22 PIPE PLUG 1 4...

Page 121: ...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 150 8 2 92077 1 4 NPT M...

Page 122: ...81057 GASKET BLOWER 23 1 24356 1 FLAME ROD Replacement Kit 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 N...

Page 123: ...TCH 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 VALVE 35 1 64081 ECU O2 SE...

Page 124: ...3675 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 K160 160 PSI 1103 kPa...

Page 125: ...000 PART LIST OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 125 of 164 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3000DF Part List 10 0...

Page 126: ...l Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 126 of 164 Benchmark 2500 3000 Burner Air Fuel Valve Assembly P N 26015 TAB 26014 TAB Full part lists below 8 AERCO International Inc Blauvelt NY 1091...

Page 127: ...in 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 below 4 Benchmark 2...

Page 128: ...al 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 Benchmark 3000 Dual Fuel...

Page 129: ...URAL 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 Benchmark 2500 Dual Fu...

Page 130: ..._D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 130 of 164 REAR VIEW TOP VIEW LEFT SIDE VIEW FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 300...

Page 131: ...122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 131 of 164 PARTIAL FRONT VIEW FRONT PANEL REMOVED AERCO International Inc Blauvelt NY 10913 Benchmark 2500 2500DF 3000 3...

Page 132: ...6 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 64048 ACTUATOR SSOV W REGU...

Page 133: ...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 2 92143 1 4 BALL VALV...

Page 134: ...F 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 SSOV W REGULATOR 29 1...

Page 135: ...OV 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 27086 1 ACTUATOR SSOV W...

Page 136: ...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 SSOV 2 NPT 9 1 99017 SN...

Page 137: ...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 1 SWITCH GAS PRESSURE 1 20 W C 6 2 9 22 PIPE PL...

Page 138: ...L 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 1 99017 SNUBBER PRESS...

Page 139: ...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 1 SWITCH GAS PRESSURE 1 20 W C 6 2 9 22 PIPE PLUG 1 4 NPT STEEL 25 1 60020 SWITCH GAS P...

Page 140: ...PT 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 93382 2 NPT CAP 30 2...

Page 141: ...ption 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 NPT CAP 21 1 99015 DAM...

Page 142: ...TUATOR SSOV W REGULATOR 30 1 GP 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 PRESS...

Page 143: ...R 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 BRAS...

Page 144: ...057 GASKET BLOWER 5 1 See Table A F VALVE ASSY Replacement Kit 19 1 81157 BLOWER GASKET 6 1 59104 OBSERVATION PORT 25 1 123449 AIR INLET TEMPERATURE SENSOR 7 1 61026 LEAN OXYGEN SENSOR 27 1 88015 O RI...

Page 145: ...ion Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 145 of 164 Appendix I WIRING DIAGRAMS Benchmark 750 1000 Drawing...

Page 146: ...Boiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 146 of 164 Benchmark 750 1000 Drawing Number 68038...

Page 147: ...Boiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 147 of 164 Benchmark 1500 2000 Drawing Number 68050...

Page 148: ...Boiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 148 of 164 Benchmark 1500 2000 Drawing Number 68050...

Page 149: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 149 of 164 Benchmark 1500 2000 DBB Drawing Number 680...

Page 150: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 150 of 164 Benchmark 1500 2000 DBB Drawing Number 680...

Page 151: ...0 Boiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 151 of 164 Benchmark 3000 208 VAC Diagram 68040 re...

Page 152: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 152 of 164 Benchmark 3000 208 VAC Drawing Number 6804...

Page 153: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 153 of 164 Benchmark 3000 460 VAC Drawing Number 6804...

Page 154: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 154 of 164 Benchmark 3000 460 VAC Drawing Number 6804...

Page 155: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 155 of 164 Benchmark 2500 208 VAC Drawing Number 6806...

Page 156: ...oiler Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 156 of 164 Benchmark 2500 208 VAC Drawing Number 6806...

Page 157: ...Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 157 of 164 Benchmark 2500 3000 208 VAC DBB Drawing Number...

Page 158: ...Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 158 of 164 Benchmark 2500 3000 208 VAC DBB Drawing Number...

Page 159: ...Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 159 of 164 Benchmark 2500 3000 460 VAC DBB Drawing Number...

Page 160: ...Operation Maintenance Manual APPENDIX I WIRING DIAGRAMS OMM 0122_D GF 206 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 160 of 164 Benchmark 2500 3000 460 VAC DBB Drawing Number...

Page 161: ...e 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 FRONT FACE PLATE BENCHMA...

Page 162: ...26 0288 Mon Fri 8 am 5 pm EST Page 162 of 164 Figure J 2 C More Controller Rear View SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT...

Page 163: ...1 460V 58063 2 208V 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 Used on Upstream SSOV on...

Page 164: ...e 17 076 DIR 17 080 Verified and corrected part numbers in Appendix F through G Chris Blair 5 9 2019 Rev D DIR 18 05 Replaced schematic drawings in Appendix I DIR 18 27 Corrected burner part numbers B...

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