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Benchmark 3.0LN 24-Month Maintenance Kit 58015-04

Technical Instruction Document

TID-0135_0C

/12/2017

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, New York 10913

•

Phone: 800-526-0288

Page 19 of 20

FINAL REASSEMBLY AND TESTING

Upon completion of all waterside and fireside inspections, reassemble the unit and perform the
tests specified in sections 7.1 and 7.2.

7.1

Reassembly and Set-Up Following Completion of Inspections

Following completion of the all required inspections and replacements, perform the following
reassembly and setup procedures:

1. Ensure that the heat exchanger has been filled and the water supply and return valves

have been opened.

2. Turn ON the external circuit breaker to the unit.

3. At the front panel of the unit, set the

ON/OFF

switch on the C-More Control Panel to the

position.

4. Press the

LOW WATER LEVEL RESET

button to reset the low water cutoff.

5. Press the

CLEAR

switch to reset the fault relay. This will turn off the

FAULT

LED and

clear any displayed error message.

6. Replace the unit side panels and top panels.

7.2

Final Testing Following Inspections

Upon completion of the inspections and replacements specified in this document, perform the
Combustion Calibration Tests specified in Chapter 4 of the O & M Manual GF-116, or GF-117
(Dual-Fuel).

Perform a water bubble test during purge to ensure the burner gaskets, replaced in section
6.1.2, are providing a good seal.

Following successful completion of the Combustion Calibration Tests, return the Benchmark
3.0LN Boiler to service use.

Содержание AERCO 58015-04

Страница 1: ...liable for errors appearing in this manual nor for incidental or consequential damages occurring in connection with the furnishing performance or use of these materials TECHNICAL INSTRUCTIONS Benchmark 3 0LN 24 Month Maintenance Kit 58015 04 This kit applies to units with an Ignitor and a separate gas injector For units with an Ignitor Injector P N 58023 see Kit 58025 04 and TID 0065 ITEM 7 Conden...

Страница 2: ...IONS COMPONENT REPLACEMENTS 7 6 1 Fireside Inspection of Benchmark 3 0 Heat Exchangers 7 6 1 1 Burner Inspection 7 6 1 2 Burner Reassembly 9 6 1 3 Igniter Replacement 10 6 1 4 Flame Detector Replacement 11 6 1 5 Exhaust Manifold Inspection 11 6 1 6 External Condensate Trap Maintenance 14 6 2 Replacing the LWCO Probe Capacitor Assembly 16 6 3 Low Water Cutoff LWCO Capacitor Integrity Test 16 6 3 1 ...

Страница 3: ...n Kit Part Number 58015 04 ITEM QTY PART NO DESCRIPTION 1 1 GP 122435 S IGNITER 2 1 66034 FLAME DETECTOR 3 1 81048 FLAME DETECTOR GASKET 4 1 81047 GAS INJECTOR GASKET 5 1 49102 EXHAUST MANIFOLD SEAL 6 2 81030 BURNER GASKETS 7 1 84017 CONDENSATE TRAP O RING 8 1 81092 CONDENSATE TRAP ORIFICE GASKET 25 I D 9 1 81098 EXHAUST MANIFOLD ORIFICE GASKET 10 1 81019 BURNER HOUSING GASKET 11 1 69126 LWCO CAPA...

Страница 4: ...ded in this document WARNING High voltages are used to power these boilers and so it is required that all power applied to these boilers is removed first before performing any of the procedures described in this document Serious personal injury or death may occur if this warning is not observed 1 At the front panel of the unit set the ON OFF switch on the C More Control Panel to the OFF position 2...

Страница 5: ...the drain valve and drain the boiler water from both heat exchangers 4 Open the P T relief valve or loosen remove the shell sensor to allow air to enter the heat exchangers during draining 5 After the heat exchangers have been drained remove the 2 1 2 inch access port plugs on the right side of the primary and secondary heat exchangers as shown in Figure 2 6 If waterside inspection is required by ...

Страница 6: ... Blauvelt New York 10913 Phone 800 526 0288 Page 6 of 20 PRIMARY HEAT EXCHANGER SECONDARY HEAT EXCHANGER ACCESS PORT ACCESS PORT DRAIN VALVE EXHAUST MANIFOLD Figure 2 Benchmark 3 0LN Right Side View DRAIN VALVE EXHAUST MANIFOLD WATER INLET CONNECTION HOT WATER OUTLET CONNECTION GAS INLET CONNECTING MANIFOLD Figure 3 Benchmark 3 0LN Rear View ...

Страница 7: ... The burner assembly is located at the top of the primary heat exchanger as shown in Figure 4 1 Ensure that all preliminary set up and disassembly procedures in section 4 have been completed WARNING THE BURNER ASSEMBLY MAY BE EXTREMELY HOT TO AVOID BURNS ALLOW IT TO COOL SUFFICIENTLY BEFORE ATTEMPTING TO REMOVE IT FOR INSPECTION 2 Disconnect the lead wire from the flame detector shown in Figure 5 ...

Страница 8: ... burner and two 2 burner gaskets by pulling straight up Figure 6 shows an exploded view of the Benchmark 3 0LN burner assembly AIR FUEL VALVE BURNER HOUSING BURNER HEAT EXCHANGER EXHAUST MANIFOLD AIR INLET Figure 4 Benchmark 3 0LN Top View 3 8 16 NUTS 8 BURNER HOUSING BURNER STAGED IGNITION ASSEMBLY GROUNDING SCREW 1 4 20 SCREWS 6 10 32 SCREWS 2 SPARK IGNITER FLAME DETECTOR Figure 5 Benchmark 3 0L...

Страница 9: ... burner gaskets with two new burner gaskets P N 81030 one above and one below the burner flange IMPORTANT When installing new burner gaskets it is imperative that the gaskets be properly aligned to assure that the cutouts for the observation port igniter injector and flame detector line up with those in the heat exchanger top plate burner flange and burner housing Failure to properly align these i...

Страница 10: ... torque the eight nuts in a star or alternating pattern to 35 5 ft lbs to to ensure a uniform seal 9 Fully tighten the the six 6 1 4 20 screws hand tighten in step 5 to fully connect the burner housing to the blower DO NOT ATTEMPT to pull the burner housing down to meet the blower If there is a gap adjust the blower mounting plate till the blower contacts the housing 10 Check to ensure that the gr...

Страница 11: ... top of the secondary heat exchanger at the rear of the unit as shown below in Figure 8 Perform the following steps to remove and inspect the manifold 1 Remove the four 4 bolts securing the flue starter section collar to the top of the exhaust manifold 2 Disconnect the flue starter section from the exhaust manifold 3 Disconnect the condensate trap drain hose from the 1 1 2 O D pipe on the bottom o...

Страница 12: ...nately tighten the bolts and nuts to obtain a uniform seal 10 From the opening at the top of the manifold install the new orifice gasket 0 75 I D P N 81098 provided in the kit Ensure that the gasket is lying flat in the bottom of the condensate trap 11 Next insert the condensate float with guide attached into the trap 12 Reconnect the 1 1 2 I D drain hose to the condensate trap drain opening 13 Re...

Страница 13: ...26 0288 Page 13 of 20 B B A A SECONDARY HEAT EXCHANGER EXHAUST MANIFOLD PRIMARY HEAT EXCHANGER MANIFOLD MOUNTING BOLTS 3 VIEW A A VIEW B B STARTER SECTION BOLTS 4 ORIFICE GASKET FLOAT Figure 8 Benchmark 3 0LN Exhaust Manifold Location TOP VIEW BOTTOM VIEW PEM STUDS 3 INSERT SEAL IN RECESS OF FLANGE Figure 9 Benchmark 3 0LN Exhaust Manifold EXHAUST MANIFOLD ORIFICE GASKET 81098 ...

Страница 14: ...des of the condensate trap as shown in Figure 10 3 Refer to Figure 10 and loosen the four 4 thumb screws securing the cover on the condensate trap and then remove the cover 4 Remove and discard the cover O ring gasket currently installed in trap It will be replaced with the new O ring included in the kit during reassembly 5 Remove the float with float guide attached from the condensate trap 6 On o...

Страница 15: ...12 2017 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Page 15 of 20 Figure 10 Condensate Trap P N 24060 CONDENSATE TRAP CONNECTING MANIFOLD DRAIN PIPE 3 4 NPT NIPPLES TO FLOOR DRAIN CLAMP 1 I D HOSE ADAPTER Figure 11 Connecting Manifold Condensate Drain Location ...

Страница 16: ...e threads of the brass coupling Do NOT use Teflon tape and install into the probe well vacated by the old LWCO probe 4 The new LWCO assembly comes with a spare female connector already inserted into the male connector and this should be crimped onto the stripped end of the shell harness wire 6 3 Low Water Cutoff LWCO Capacitor Integrity Test The LWCO capacitor should be tested for electrical short...

Страница 17: ...Turn OFF AC power to the unit WARNING High voltages are used to power these units and so it is required that power applied to these units is removed first before performing the procedure described in this instruction Serious personal injury or death may occur if this warning is not observed 2 Remove the Shell Harness Cable male connector from the P 5 female connector on the rear panel of the C Mor...

Страница 18: ... C More controller as shown on right in Figure 15 Figure 15 Connecting Ohmmeter between LWCO Probe Shell Harness Cable 5 Confirm that the ohmmeter does NOT read a short NOTE If the ohmmeter reads a short the capacitor assembly needs to be replaced See section 4 9 for replacement instructions or contact AERCO technical support for more information 6 Remove both ohmmeter probes and reconnect the She...

Страница 19: ...2 Turn ON the external circuit breaker to the unit 3 At the front panel of the unit set the ON OFF switch on the C More Control Panel to the ON position 4 Press the LOW WATER LEVEL RESET button to reset the low water cutoff 5 Press the CLEAR switch to reset the fault relay This will turn off the FAULT LED and clear any displayed error message 6 Replace the unit side panels and top panels 7 2 Final...

Страница 20: ...20 AERCO International Inc 2017 Change Log Date Description Changed By 06 03 2016 Rev B DIR 335 Clarified reassembly order in section 6 1 2 added water bubble test to section 7 2 Chris Blair 10 12 2017 Rev C DIR 335 Changed Blower Plenum to Burner Housing and Burner Housing Gasket P N 81019 modified section 6 1 2 Chris Blair AERCO Technical Support Mon Fri 8am 5pm EST 1 800 526 0288 www aerco com ...

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