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Benchmark 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 65  of 164 

 

TABLE 5-1:   Boiler Troubleshooting Procedures 

Fault 
Indication 

Probable Causes 

Corrective Action 

HIGH WATER 
TEMP 
SWITCH OPEN 

1. 

Faulty Water temperature switch. 
 

2. 

Incorrect PID settings. 
 
 

3. 

Faulty shell temperature sensor. 
 

4. 

Unit in MANUAL mode. 

5. 

Unit setpoint is greater than Over Temperature 
switch setpoint. 

6. 

System flow rate changes are occurring faster 
than units can respond.   

1. 

Test the temperature switch to insure it trips at its actual water 
temperature setting. 

2. 

Check PID settings (see Section 2-7: 

Tuning Menu, 

 items 1 -3, for 

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 sensor at a known water temperature. 

4. 

If unit is in MANUAL mode, switch to AUTO mode. 

5. 

Check setpoint of unit and setpoint of Temperature switch; Ensure 
that the temperature switch is set higher than the unit’s setpoint. 

6. 

If the system is a variable flow system, monitor system flow changes 
to ensure that the rate of flow change is not faster than what the 
units can respond to. 

HIGH WATER 
TEMPERATURE 

1. 

See HIGH WATER TEMPERATURE SWITCH 
OPEN. 

2. 

Temp HI Limit setting is too low. 

1. 

See HIGH WATER TEMPERATURE SWITCH OPEN. 
 

2. 

Check Temp HI Limit setting. 

IGN BOARD 
COMM FAULT 

1. 

Communication fault has occurred between the 
PMC board and Ignition/Stepper (IGST) board. 

1. 

Press 

CLEAR

 button and restart unit.  If fault persists, contact 

qualified Service Personnel. 

Содержание AERCO Benchmark OMM-0121

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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