Benchmark BMK 1500 User Manual
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Benchmark BMK 1500 User Manual

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Benchmark 1500 - 2000 Boilers
Installation, Operation & Maintenance Manual (IOMM)
USER MANUAL
Natural Gas Modulating
Installation, Operation and Maintenance
& Condensing Hot Water
Boiler Models:
BENCHMARK
• BMK 1500
1500 / 2000
• BMK 2000
Gas-Fired Boilers
Applicable to Serial Numbers:
G-13-1690 and Above
Latest Update: 11/21/2013
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
OMM-0097_0C
Page 1 of 184
Ph.: 800-526-0288
GF-142

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  • Page 1 Benchmark 1500 - 2000 Boilers Installation, Operation & Maintenance Manual (IOMM) USER MANUAL Natural Gas Modulating Installation, Operation and Maintenance & Condensing Hot Water Boiler Models: BENCHMARK • BMK 1500 1500 / 2000 • BMK 2000 Gas-Fired Boilers Applicable to Serial Numbers:...
  • Page 2 Benchmark 1500 - 2000 Boilers Installation, Operation & Maintenance Manual (IOMM) Technical Support (Mon-Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com Disclaimer The information contained in this manual is 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 fitness for a particular application.

  • Page 3: Table Of Contents

    Benchmark 1500 - 2000 Boilers Installation, Operation & Maintenance Manual (IOMM) TABLE OF CONTENTS FOREWORD 7 CHAPTER 1. SAFETY PRECAUTIONS ..................11 1.1 WARNINGS & CAUTIONS ........................11 1.2 EMERGENCY SHUTDOWN ......................... 12 1.3 PROLONGED SHUTDOWN ......................... 12 CHAPTER 2. INSTALLATION ......................15 2.1 INTRODUCTION ...........................
  • Page 4 4.2.2 Installing Gas Supply Manometer ........................50 4.2.3 Accessing the Analyzer Probe Port ......................... 51 4.3 NATURAL GAS COMBUSTION CALIBRATION .................. 52 BMK 1500 Natural Gas Combustion Calibration ............ 52 4.3.1 BMK 2000 Natural Gas Combustion Calibration ............. 56 4.3.2 4.4 REASSEMBLY ............................
  • Page 5 Benchmark 1500 - 2000 Boilers Installation, Operation & Maintenance Manual (IOMM) 6.10 PURGE SWITCH OPEN DURING PURGE ..................79 6.11 IGNITION SWITCH OPEN DURING IGNITION ................. 80 6.12 SAFETY PRESSURE RELIEF VALVE TEST ..................81 CHAPTER 7. MAINTENANCE ......................83 7.1 MAINTENANCE SCHEDULE .......................
  • Page 6 Benchmark 1500 - 2000 Boilers Installation, Operation & Maintenance Manual (IOMM) (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 7: Foreword

    20:1. These BMK models provide extremely high efficiency operation and are ideally suited for modern low temperature, as well as, conventional heating systems. The Benchmark Model BMK 1500 and BMK 2000 boilers operate within the following input and output ranges: Input Range (BTU/hr.) Output Range (BTU/hr.)
  • Page 8 1 pound of water 1° F. Combustion Control Panel C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Carbon Monoxide COMM (Comm) Communication Cal.
  • Page 9 IGST Board Ignition/Stepper Board contained in C-More Control Box INTLK (INTL’K) Interlock Input/Output Input/Output (I/O) Box currently used on Benchmark, Innovation and I/O Box KC1000 Series products Internet Protocol Industrial Risk Insurers. A now discontinued code used to define gas trains containing two SSOVs and a solenoid operated vent valve.
  • Page 10 Benchmark 1500 - 2000 Boilers FORWARD Phrases, Abbreviations and Acronyms – Continued Phrase, Abbreviation or Meaning Acronym SSOV Safety Shut Off Valve TEMP (Temp) Temperature A resistor placed at each end of a daisy-chain or multi-drop network in Terminating Resistor...

  • Page 11: Chapter 1. Safety Precautions

    Benchmark 1500 - 2000 Boilers CHAPTER 1 – SAFETY PRECAUTIONS CHAPTER 1. SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.

  • Page 12: Emergency Shutdown

    Benchmark 1500 - 2000 Boilers CHAPTER 1 – SAFETY PRECAUTIONS WARNING A THREE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL SUPPLY LINE OF THE UNIT. THE SWITCH MUST BE INSTALLED IN AN EASILY ACCESSIBLE POSITION QUICKLY SAFELY DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO UNIT SHEET METAL ENCLOSURES.
  • Page 13 Benchmark 1500 - 2000 Boilers CHAPTER 1 – SAFETY PRECAUTIONS IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements: • Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
  • Page 14 Benchmark 1500 - 2000 Boilers CHAPTER 1 – SAFETY PRECAUTIONS (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 2.

  • Page 15: Chapter 2. Installation

    AERCO Benchmark Boiler Model BMK 1500 and BMK 2000. 2.2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for these BMK models is approximately 1800 pounds. The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage.

  • Page 16: Site Preparation

    • Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps • Access to Natural Gas line at a minimum pressure of 8 inches W.C. at gas flow for 1,500,000 BTU/hr energy input for the BMK 1500 OR 2,000,000 BTU/hr energy input for the BMK 2000.

  • Page 17: Setting The Unit

    If anchoring the unit, refer to Figure 2-1b for anchor locations. Figure 2-1b: Benchmark 1500/2000 Anchor Bolt Locations A total of 3 lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-2.
  • Page 18 Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION LIFTING LUGS (3 POSITIONS) 2” GAS INLET Figure 2-2: Boiler Lifting Provisions In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration.

  • Page 19: Supply And Return Piping

    CHAPTER 2 – INSTALLATION 2.5 SUPPLY AND RETURN PIPING The Benchmark Boiler utilizes 4” 150# flanges for the water system supply and return piping connections. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-3.

  • Page 20: Condensate Drain & Piping

    Figure 2-4: P&T Relief Valve Location 2.7 CONDENSATE DRAIN & PIPING The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore, the installation must have provisions for suitable condensate drainage or collection. The condensate drain port located on the exhaust manifold (Figure 2-5) must be connected to the condensate trap (P/N 24060) which is packed separately within the unit’s shipping container.

  • Page 21: Condensate Trap Installation

    Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION While observing the above guidelines, install the condensate trap as follows: Condensate Trap Installation 1. Connect the condensate trap inlet to the exhaust manifold drain connection by inserting the drain port directly into the trap adaptor inlet, and then tightening the inlet thumbscrew, as shown in Figure 2-6.

  • Page 22: Gas Supply Piping

    Benchmark 1500 MBH and 2000 MBH units contain a 2 inch NPT gas inlet connection on the top of the unit, as shown in Figure 2-2 and 2-3.

  • Page 23: External Gas Supply Regulator

    Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION 2.8.3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions (see sections 2.8.3.1 and 2.8.3.2, below). Regulators must conform to the following specifications: •...

  • Page 24: Ac Electrical Power Wiring

    CHAPTER 2 – INSTALLATION 2.9 AC ELECTRICAL POWER WIRING The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to connecting any AC power wiring to the unit. External AC power connections are made to the unit inside the Power Box on the front of the unit. Remove the front panel to access the Power Box, which is mounted in the upper right corner of the unit as shown in Figure 2-8.

  • Page 25: Electrical Power Requirements

    2.9.1 Electrical Power Requirements The Benchmark 1500 and Benchmark 2000 models are available in one voltage configuration: • 120 VAC, Single-Phase, 60 Hz @ 20 Amps The Power Box contains terminal blocks as shown in Figure 2-9. In addition, a label showing the required AC power connections is provided on the front cover of the Power Box as shown in Figure 2-10.

  • Page 26: Field Control Wiring

    However, the C-More Control system used with all Benchmark units does allow for some additional control and monitoring features. Wiring connections for these features are made on the Input/Output (I/O) board located behind the removable front panel assembly of the unit.

  • Page 27: Outdoor Air In (Out) & Air Sensor Common (Com)

    Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION Figure 2-12: I/O Box Terminal Strips 2.10.1 Outdoor Air In (OUT) & Air Sensor Common (COM) The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO P/N GM-123525) as required primarily for the Indoor/Outdoor reset mode of operation. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature.

  • Page 28: Combustion Air Terminal

    Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION 2.10.2 COMBUSTION AIR Terminal The COMBUSTIAN AIR terminal is used to monitor the combustion air temperature sensor. This input is always enabled and is a “to view only” input that can be seen in the operating menu.

  • Page 29: Comm (+, Gnd, & -)

    Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION • When 0-10VDC is selected, the voltage output is used by the controller to modulate the combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.10.11). • If “On Board” boiler or Water Heater Management is enabled, the Analog Output terminals are used to drive the isolation valve, open and closed.

  • Page 30: Fault Relay (Nc, Com, & No)

    2.12 COMBUSTION AIR The AERCO Benchmark Boiler Venting and Combustion Air Guide, GF-2050 MUST be consulted before any flue or inlet air venting is designed or installed. Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be consulted before a permanent design is determined.

  • Page 31: Combustion From Outside The Building

    4000 BTUs input of the equipment or 375 square inches of free area for the BMK 1500 or 500 square inches of free area for the BMK 2000. The free area must take into account restrictions such as louvers and bird screens.
  • Page 32 Benchmark 1500 - 2000 Boilers CHAPTER 2 – INSTALLATION (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 32 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 33: Chapter 3. Operation

    CHAPTER 3. OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark Boiler using the Control Panel mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • Page 34 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Figure 3-1: Control Panel Front View *NOTE If there is a requirement to use the RS232 port (Item 4) on the C- More controller front panel, contact AERCO to purchase the RS232 Adaptor Cable (P/N 124675), which is designed for this purpose.
  • Page 35 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays CONTROL, ITEM INDICATOR OR FUNCTION DISPLAY LED Status Indicators Four Status LEDs indicate the current operating status as follows: COMM Lights when RS-232 communication is occurring...
  • Page 36 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays – Continued CONTROL, ITEM INDICATOR OR FUNCTION DISPLAY MENU Keypad Six (6) keys which provide the following functions for the Control Panel Menus: Steps through the main menu categories shown in Figure MENU 3-2.

  • Page 37: Control Panel Menus

    Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION 3.3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of five major menu categories which are applicable to this manual.
  • Page 38 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION OPERATING LEVEL 1 PWD SETUP CONFIGURATION TUNING LEVEL 2 PWD COMBUSTION CAL CALIBRATION (NOT USED IN THIS O & M) SEE GF-112 FOR MENU ITEM DESCRIPTIONS DIAGNOSTICS (NOT USED IN THIS O & M)

  • Page 39: Operating Menu

    Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION 3.4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3-2. This menu is “Read-Only” and does not allow personnel to change or adjust any displayed items.

  • Page 40: Configuration Menu

    Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Table 3-3: Setup Menu Available Choices or Limits Menu Item Display Default Minimum Maximum Passsword 9999 Language English English Time 12:00 am 11:59 pm Date 01/01/00 12/31/99 Unit of Temp Fahrenheit or Celsius...
  • Page 41 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Table 3-4: Configuration Menu Available Choices or Limits Menu Item Display Default Minimum Maximum Internal Setpt Lo Temp Limit Hi Temp Limit 130°F KC Boiler, KC Boiler LN, BMK Boiler Std, BMK Boiler LN,...

  • Page 42: Tuning Menu

    Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION Table 3-4: Configuration Menu - Continued Available Choices or Limits Menu Item Display Default Minimum Maximum Max Valve Position 100% 100% Pump Delay Timer 0 min. 30 min. 0 min. Aux Start On Dly 0 sec.

  • Page 43: Combustion Cal Menu

    Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION 3.8 COMBUSTION CAL MENU The Combustion Cal (Calibration) Menu is protected by the level 2 password (6817) which must be entered to view or change the menu items shown in Table 3-6. These menu items are used to vary the speed of the unit’s blower motor based on air temperature and air density at...
  • Page 44 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION When there is a demand for heat, the following events will occur: NOTE If any of the Pre-Purge safety device switches are open, the appropriate fault message will be displayed. Also, the appropriate messages will be displayed throughout the start sequence, if the required conditions are not observed.
  • Page 45 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION c. The VALVE POSITION bargraph will show 100%. TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN Figure 3-4: Air/Fuel Valve In Purge Position Next, the blower proof switch on the Air/Fuel Valve (Figure 3-5) closes. The display will show Purging and indicate the elapsed time of the purge cycle in seconds.
  • Page 46 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION (b) The “Spark Cycle Time” item in the Factory menu can be set to either 0 Sec, 2 Sec or 7 Sec to define the duration of the Spark Element Cleaning Cycle. This cycle turns on the spark transformer to produce a spark (with no gas flowing) to clean the spark element of moisture or carbon buildup.

  • Page 47: Start/Stop Levels

    Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION 3.10 START/STOP LEVELS The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows:...
  • Page 48 Benchmark 1500 - 2000 Boilers CHAPTER 3 – OPERATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 49: Chapter 4. Initial Start-Up

    Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP CHAPTER 4. INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark boiler consists of the following: • Complete installation (Chapter 2) • Set proper controls and limits (Chapter 3) •...

  • Page 50: Required Tools & Instrumentation

    1/4” NPT PLUG LEAK DETECTION BALL VALVE (Install manometer here for Combustion Calibration) Figure 4-1: BMK 1500/2000: 1/4 Inch Gas Plug Location for Combustion Calibration AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 184 OMM-0097_0C Ph.: 800-526-0288...

  • Page 51: Accessing The Analyzer Probe Port

    Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP Install the 16” W.C. manometer(s) as described in the following steps: Installing Gas Supply Manometer 1. Turn off the main gas supply upstream of the unit. 2. Remove the top panel and front panel from the boiler to access the gas train components.

  • Page 52: Natural Gas Combustion Calibration

    CHAPTER 4 – INITIAL START-UP 4.3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated at the factory prior to shipping. This gas pressure must be within the following ranges for each model of boiler at full fire: BMK Boiler Model...
  • Page 53 Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP BMK 1500 Natural Gas Combustion Calibration (Cont.) 13. Compare the oxygen readings on the combustion analyzer to the on-board O sensor value displayed in the Operating Menu of the C-More Control Panel. If the values differ by more than ±0.5%, have your combustion analyzer calibration checked as soon as...
  • Page 54 Recalibration MUST be performed again from 60% down to 16% after making a change to the idle screw (TAC valve). 30. This completes the BMK 1500 Natural Gas combustion calibration procedures. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 55 Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). Figure 4-3: Gas Pressure Adjustment Screw Location TAC VALVE IDLE SCREW Figure 4-4: TAC Valve Adjust (Idle Screw) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 56: Bmk 2000 Natural Gas Combustion Calibration

    Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP BMK 2000 Natural Gas Combustion Calibration 4.3.2 1. Open the water supply and return valves to the unit and ensure that the system pumps are running. 2. Open the natural gas supply valve to the unit.
  • Page 57 Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP BMK 2000 Natural Gas Combustion Calibration (Cont.) 15. If the oxygen level is not within the required tolerance, the gas pressure on the downstream side of the SSOV must be adjusted using the gas pressure adjustment screw on the SSOV (Figure 4-3).

  • Page 58: Reassembly

    Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP BMK 2000 Natural Gas Combustion Calibration (Cont.) 27. Once the oxygen level is within the specified range at 80%, press the ENTER key to store the selected blower output voltage for the 80% valve position. Record all readings on the Combustion Calibration Sheets provided.

  • Page 59: Over-Temperature Limit Switches

    Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP 4.5 OVER-TEMPERATURE LIMIT SWITCHES The unit contains three (3) types of over-temperature limit switches. These switches consist of a manual reset switch, a rotary dial adjustable switch and a digital alarm switch. These switches are mounted on a plate as shown in Figure 4-5.
  • Page 60 Benchmark 1500 - 2000 Boilers CHAPTER 4 – INITIAL START-UP Table 4-1: Digital Alarm Switch Controls and Display CONTROL OR MEANING FUNCTION DISPLAY Displays current water temperature or LED Display TEMP status setpoint. RESET Button Resets the unit after an alarm condition.

  • Page 61: Chapter 5. Mode Of Operation

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION CHAPTER 5. MODE OF OPERATION 5.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The following sections in this Chapter provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation.

  • Page 62: Constant Setpoint Mode

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION Indoor/Outdoor Startup 1. Refer to the Indoor/Outdoor reset ratio charts in Appendix F. 2. Choose the chart corresponding to the desired Building Reference Temperature. 3. Go down the left column of the chart to the coldest design outdoor air temperature expected in your area.

  • Page 63: Remote Setpoint Modes

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION 5.4 REMOTE SETPOINT MODES The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal within the following ranges: •...

  • Page 64: Remote Setpoint Startup

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION 5.4.2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when the external signal is present.

  • Page 65: Direct Drive Field Wiring

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION 5.5.1 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 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box.

  • Page 66: Acs Setup And Startup

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION 5.6.2 ACS Setup and Startup This mode of operation is factory preset and the ACS controls the firing rate (air/fuel valve % open position). There are no setup instructions for each individual unit.

  • Page 67: Combination Control System Field Wiring

    Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boilers are not able to satisfy the domestic hot water demand. When the combo units are satisfying the domestic load, they are in the constant setpoint mode of operation.
  • Page 68 Benchmark 1500 - 2000 Boilers CHAPTER 5 – MODE OF OPERATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 69: Chapter 6. Safety Device Testing

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING CHAPTER 6. SAFETY DEVICE TESTING 6.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion- related safety devices before, during and after the start sequence.

  • Page 70: Low Gas Pressure Fault Test

    7. The unit should shut down and display a GAS PRESSURE fault message at approximately: 4.4” W.C. for both BMK 1500 and BMK 2000. 8. Fully open the external manual gas shut-off valve and press the CLEAR button on the Control Box.

  • Page 71: High Gas Pressure Test

    9. Reduce the gas pressure back to the value recorded in step 5. This pressure should be within the range of 3.6” ± 0.2” W.C. for BMK 1500 and 3.9” ± 0.2” W.C. for BMK 2000. 10. Press the CLEAR button on the Control Box to clear the fault.

  • Page 72: Low Water Level Fault Test

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: Low Water Level Fault 1. Set the ON/OFF switch to the OFF position 2.

  • Page 73: Water Temperature Fault Test

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the automatic over-temperature switch. This switch is accessible from the front of the unit as shown in Figure 6-2.

  • Page 74: Interlock Tests

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2-13) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.

  • Page 75: Flame Fault Tests

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.7 FLAME FAULT TESTS Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: Flame Fault Tests 1.
  • Page 76 SWITCH AIR/FUEL VALVE MANUAL SHUT-OFF VALVE SSOV BLOCKED INLET SWITCH FILTER TRAIN Figure 6-3: Bare Boiler – Partial View (BMK 1500/2000) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 77: Air Flow Fault Tests

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-3. Air Flow Fault Tests 1. Disable the blower output drive voltage as follows: (a) Press the MENU key until CONFIGURATION MENU is displayed.

  • Page 78: Ssov Proof Of Closure Switch

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING AIR INLET PRIMARY WATER INLET EXHAST MANIFOLD ANALYZER PORT DRAIN VALVE CONDENSATE DRAIN Figure 6-4: Boiler Rear View Showing Air Inlet Location 6.9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6-1 contains the proof of closure switch. The proof of closure switch...

  • Page 79: Purge Switch Open During Purge

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING SSOV ACTUATOR ACTUATOR COVER COVER SCREW Figure 6-5: SSOV Actuator Cover Location 6.10 PURGE SWITCH OPEN DURING PURGE The Purge Switch (and Ignition Switch) is located on the Air/Fuel Valve. To check the switch,...

  • Page 80: Ignition Switch Open During Ignition

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING 6.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Ignition Switch Open During Ignition 1.

  • Page 81: Safety Pressure Relief Valve Test

    Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING TO BLOWER Ignition Position Switch VALVE POSITION DIAL AIR/FUEL VALVE SWITCH WIRING BREAKOUT Purge Position Switch AIR IN Figure 6-7: Air/Fuel Valve Purge and Ignition Switch Locations 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.
  • Page 82 Benchmark 1500 - 2000 Boilers CHAPTER 6 – SAFETY DEVICE TESTING (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 83: Chapter 7. Maintenance

    Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE CHAPTER 7. MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 7-1.

  • Page 84: Igniter-Injector

    PORT BURNER Figure 7-1: Benchmark 1500/2000 Burner Assembly (Removed from Boiler) 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...
  • Page 85 Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE Igniter-Injector Maintenance Procedures – Continued Refer to the partial exploded view in Figure 7-2. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly.

  • Page 86: Flame Detector

    Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE IGNITER-INJECTOR MAINTENANCE PROCEDURES – Continued NOTE If a replacement igniter-injector (part no. 66026) is being installed, a compression nut containing a built-in ferrule will be included with the replacement part. If needed, 3 indexing washers are also included These washers may be needed to properly position the gas injector tube of the igniter-injector within the 120°...

  • Page 87: O 2 Sensor

    Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE Flame Detector Maintenance – Continued Disconnect the flame detector lead wire. Remove the two (2) screws securing the flame detector to the plate (Figure 7-2). The flame detector is secured to the burner plate with one #10-32 screw and one #8-32 screw.

  • Page 88: Burner Assembly Inspection

    Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE 7.6 BURNER ASSEMBLY INSPECTION The burner assembly 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.
  • Page 89 Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedures (Cont.) Remove the eight (8) 3/8-16 nuts, using a 9/16” wrench, attaching the blower plenum to the burner beneath (see Figure 7-4a & 7-4b). Remove the blower plenum from between the blower and the burner and set aside for later reassembly.
  • Page 90 Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedure (Cont.) BLOWER PLENUM 5/16” x 1-3/4” BOLTS, 5/16” IGNITER- WASHERS & INJECTOR NYLOCK NUTS ASSEMBLY (4 each) BLOWER A/F VALVE PLENUM 3/8”-16 HEX NUTS BURNER...
  • Page 91 Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE Burner Assembly Inspection and Maintenance Procedure – Continued BLOWER PLENUM 5/16” x 1-3/4” BOLTS, 5/16” WASHERS & NYLOCK NUTS (4 each) BLOWER 3/8”-16 HEX NUTS (8 each) VALVE PLENUM GAS INLET...

  • Page 92: Condensate Drain Trap

    CHAPTER 7 – MAINTENANCE 7.7 CONDENSATE DRAIN TRAP Benchmark boilers contains a condensate trap as shown in Chapter 2, Figure 2-5. The trap is located external to the unit and attached to the drain pipe from the exhaust manifold. This trap should be inspected and cleaned in accordance with the maintenance schedule shown in Table 7-1 to ensure proper operation.

  • Page 93: Air Filter Cleaning & Replacement

    7.8 AIR FILTER CLEANING & REPLACEMENT The Benchmark boiler is equipped with an air filter (part no. 88014) which should be cleaned and re-oiled every 12 months and replaced every 24 months. The air filter is located at the inlet of the air fuel valve at the top of the boiler as shown in Figure 7-7.

  • Page 94: Shutting The Boiler Down For An Extended Period Of Time

    Benchmark 1500 - 2000 Boilers CHAPTER 7 – MAINTENANCE 7.9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be taken out of service for an extended period of time (one year or more), the following instructions must be followed.

  • Page 95: Chapter 8. Troubleshooting Guide

    This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 1500 MBH and 2000 MBH boilers. The troubleshooting procedures contained herein are presented in tabular form on the following pages. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action.
  • Page 96 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 97 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT Blower stopped running due to thermal Check combustion blower for signs of excessive heat or high DURING IGNITION or current overload.
  • Page 98 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT Blower not running or running too Start the unit. If the blower does not run check the blower solid DURING PURGE slow.
  • Page 99 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED Delayed Interlock Jumper not Check to insure jumper is properly installed across the delayed INTERLOCK OPEN properly installed or missing.
  • Page 100 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) Carbon or other debris on Remove View-Port and inspect Burner with Boroscope. If Burner. it is fouled or black with soot, remove the Burner and inspect for any carbon build-up or debris.
  • Page 101 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Incorrect supply gas pressure. Check to ensure gas pressure at inlet of SSOV does not HIGH GAS exceed 14” W.C.
  • Page 102 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED Air/Fuel Valve not rotating. Start the unit. The Air/Fuel Valve should rotate to the purge DURING PURGE (open) position.
  • Page 103 Defective Low Pressure Gas Measure gas pressure at the low gas pressure switch. If it is greater Switch. than 4.7” W.C. (for both BMK 1500 and BMK 2000), measure continuity across the switch and replace if necessary. LOW WATER Insufficient water level in system.
  • Page 104 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) Defective or shorted switch. If the Air/Fuel Valve does rotate to the ignition position, check the purge switch for continuity between the N.O. and COM terminals.
  • Page 105 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Internal recirculation pump failed. 1. Replace recirculation pump. RECIRC PUMP FAILURE Remote setpoint signal not present: Check I/O Box to ensure signal is hooked up.
  • Page 106 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1: BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV Actuator not allowing for full Observe operation of the Safety Shut-Off Valve (SSOV) SWITCH OPEN closure of gas valve.

  • Page 107: Additional Faults Without Specific Fault Messages

    Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 8-2: BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED...
  • Page 108 Benchmark 1500 - 2000 Boilers CHAPTER 8 – TROUBLESHOOTING GUIDE STAGED IGNITION SOLENOID BLOWER PLENUM INJECTOR- IGNITOR ASSY WITH INDEXING FLAME (CLOCKING) OBSER- WASHERS VATION (0-3 as PORT needed) O2 SENSOR & WASHER FLAME BURNER PLATE DETECTOR & FLANGE GASKET Figure 8-1: Igniter-Injector &...

  • Page 109: Chapter 9. Rs-232 Communication

    Benchmark 1500 - 2000 Boilers CHAPTER 9 – RS232 COMMUNICATION CHAPTER 9. RS-232 COMMUNICATION 9.1 INTRODUCTION The RS-232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line, Fault and Sensor log displays.

  • Page 110: Running A Command On A Remote Machine Using Putty

    Benchmark 1500 - 2000 Boilers CHAPTER 9 – RS232 COMMUNICATION Now, to connect to the remote server, simply click the Open button at the bottom of the dialog box. A new terminal window will pop up and ask you to log in.

  • Page 111: Communication Setup

    Benchmark 1500 - 2000 Boilers CHAPTER 9 – RS232 COMMUNICATION 9.2 RS-232 COMMUNICATION SETUP Regardless of the terminal emulation utilized, the following guidelines must be adhered to when setting up the RS-232 communication link: • Baud Rate – The baud rates which can be used with the C-More Control Panel are:...

  • Page 112: Data Logging

    Benchmark 1500 - 2000 Boilers CHAPTER 9 – RS232 COMMUNICATION Menu Processing Utilizing Rs-232 Communication Shortcut keys are also available to go directly to a specific menu. These shortcut keys are: m0 = Default (Operating) Menu m1 = Setup Menu...

  • Page 113: Operation Time Log

    Benchmark 1500 - 2000 Boilers CHAPTER 9 – RS232 COMMUNICATION NOTE The Operation Time (T) Log can store thousands of records. Therefore, to view the most recently logged record, enter “T” followed by 0 (zero) and press Enter (i.e. T0 <Enter>). To view earlier records in reverse chronological order, enter T and press Enter.

  • Page 114: Sensor Log

    Benchmark 1500 - 2000 Boilers CHAPTER 9 – RS232 COMMUNICATION 9.4.3 Sensor Log The sensor values can be logged at a different rate if needed by setting the Sensor Log Interval in the Diagnostics Menu. The log interval can vary from once every minute to once every day.

  • Page 115: Appendix A: Boiler Menu Item Descriptions

    Benchmark 1500 - 2000 Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode.
  • Page 116 Benchmark 1500 - 2000 Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Allows password to be entered. Once the valid password (159) is entered, options in...
  • Page 117 Benchmark 1500 - 2000 Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set. Default is 130°F. Allows selection of KC Boiler, KC Boiler LN, BMK...
  • Page 118 Allows the Failsafe mode to be set to either Failsafe Mode Constant Setpoint or Shutdown. Default is Shutdown. Must be set to Valve Pos 0-10V for Benchmark 1500 Analog Output & 2000 Specifies how long (2 to 600 sec.) to remain in the...
  • Page 119 Benchmark 1500 - 2000 Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Deadband High and Deadband Low settings create an “Outlet Temperature” Zone. In which no Valve Position corrections will be attempted.
  • Page 120 Benchmark 1500 - 2000 Boilers APPENDIX A – BOILER MENU DESCRIPTIONS Appendix A: Boiler Menu Item Descriptions – Continued MENU LEVEL & OPTION DESCRIPTION COMBUSTION CAL MENU NOTE: The Level 2 Password (6817) must be entered to view the options in the Combustion Cal Menu.

  • Page 121: Appendix B: Startup, Status & Display Messages

    Benchmark 1500 - 2000 Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Appendix B: STARTUP, STATUS & DISPLAY MESSAGES Table B-1: Startup And Status Messages MESSAGE DESCRIPTION DEMAND DELAY Displayed if Demand Delay is active. XX sec DISABLED Displayed if ON/OFF switch is set to OFF. The display also...
  • Page 122 Benchmark 1500 - 2000 Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT The Blower Proof Switch opened during purge, DURING PURGE or air inlet is blocked. AIRFLOW FAULT The Blower Proof Switch opened during ignition.
  • Page 123 Benchmark 1500 - 2000 Boilers APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages – Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP The temperature measured by the Outdoor Air Sensor is out of range. SENSOR FAULT The temperature measured by the Outlet Sensor is out of range: •...
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  • Page 125: Appendix C: Sensor Resistance/Voltage Chart

    Benchmark 1500 - 2000 Boilers APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART Appendix C: SENSOR RESISTANCE/VOLTAGE CHART Temperature Sensor Resistance Voltage Chart (Balco) TEMP (°F) RES (OHMS) VOLTS* 779.0 1.93 797.5 1.96 816.3 1.99 835.4 2.02 854.8 2.05 874.6 2.07 894.7 2.10...
  • Page 126 Benchmark 1500 - 2000 Boilers APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 127: Appendix D: Boiler Default Settings

    Benchmark 1500 - 2000 Boilers APPENDIX D – BOILER DEFAULT SETTINGS Appendix D: BOILER DEFAULT SETTINGS Appendix D: Boiler Default Settings MENU & OPTION FACTORY DEFAULT Setup Menu Password Language English Unit of Temp Fahrenheit Comm Address Baud Rate 9600...
  • Page 128 Benchmark 1500 - 2000 Boilers APPENDIX D – BOILER DEFAULT SETTINGS Appendix D: Boiler Default Settings MENU & OPTION FACTORY DEFAULT Configuration Menu (Cont.) Setpt Limit Band (If Setpt Limiting = Enabled) 5°F Network Timeout 30 seconds Hi DB Setpt En...

  • Page 129: Appendix E: Recommended Periodic Testing

    Benchmark 1500 - 2000 Boilers APPENDIX E – RECOMMENDED PERIODIC TESTING Appendix E: RECOMMENDED PERIODIC TESTING WARNING Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage.
  • Page 130 Benchmark 1500 - 2000 Boilers APPENDIX E – RECOMMENDED PERIODIC TESTING This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 131: Appendix F: Indoor/Outdoor Reset Ratio Charts

    Benchmark 1500 - 2000 Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Appendix F: INDOOR/OUTDOOR RESET RATIO CHARTS Table F-1: Header Temperature for a Building Reference Temperature of 50F RESET RATIO Temp -10F -15F -20F Table F-2: Header Temperature for a Building Reference Temperature of 60F...
  • Page 132 Benchmark 1500 - 2000 Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-3: Header Temperature for a Building Reference Temperature of 65F RESET RATIO Temp Table F-4: Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp...
  • Page 133 Benchmark 1500 - 2000 Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-5: Header Temperature for a Building Reference Temperature of 75F RESET RATIO Temp -10F -15F Table F-6: Header Temperature for a Building Reference Temperature of 80F RESET RATIO...
  • Page 134 Benchmark 1500 - 2000 Boilers APPENDIX F – INDOOR/OUTDOOR RESET RATIO CHARTS Table F-7: Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 184 OMM-0097_0C Ph.: 800-526-0288...

  • Page 135: Appendix G: Dimensional And Clearance Drawings

    Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Appendix G: DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-936 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 135 of 184 Ph.: 800-526-0288...
  • Page 136 Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-995 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 137 Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: AP-A-898 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 137 of 184 Ph.: 800-526-0288 GF-142...
  • Page 138 Benchmark 1500 - 2000 Boilers APPENDIX G – DIMENSIONAL AND CLEARANCE DRAWINGS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 139: Appendix H: Part Drawings

    12V POWER SUPLY 69161-1 DIN RAIL GAS TRAIN 65120 TERMINAL BLOCK: DIN MOUNTED: BLK TERMINAL BLOCK: DIN MOUNTED: 22188 BMK 1500 STANDARD GAS TRAIN ASSY 65121 TERMINAL GROUND BLOCK: DIN 22199 BMK 1500-2000 DBB GAS TRAIN 65122 MOUNTED 65118 FUSE TERMINAL: DIN MOUNTED...
  • Page 140 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 - 2000 Part List – Continued Item# Part # Description Item# Part # Description SHEET METAL/PANEL ASSEMBLY OTHER ACCESSORIES & PARTS PRESSURE/TEMP GAUGE 37117 BACK PANEL: LEFT 87 ...
  • Page 141 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500-2000 Part List AERCO 10/31/2013 International, Inc. Blauvelt, NY 10913 29313 rev B – 29337 rev B Sheet 3 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 142 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500/2000 Burner-Air/Fuel Valve Assembly P/N 24378 & 24388 See full part lists below AERCO Benchmark 1500-2000 Part List 10/31/2013 International, Inc. Blauvelt, NY 10913 29313 rev B – 29337 rev B Sheet 4 of 7 AERCO International, Inc.
  • Page 143 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500/2000 Benchmark 1500/2000 Standard FM Gas Train Double Block & Bleed Gas Train P/N 22188 P/N 22199 See full part lists below See full part lists below Benchmark 1500-2000 Part List...
  • Page 144 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS AERCO Benchmark 1500-2000 Part List 10/31/2013 International, Inc. Blauvelt, NY 10913 29313 rev B – 29337 rev B Sheet 6 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 145 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Power I/O Box P/N # 24386 Benchmark 1500-2000 Part List AERCO 10/31/2013 International, Inc. Blauvelt, NY 10913 29313 rev B – 29337 rev B Sheet 7 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 146 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 - 2000 Standard Gas Train – p/n 22188 rev B Item Qty Part # Description Item Part # Description 123542 FLANGE 2" 125# 2"NPT 18 63109 GAS TRAIN HARNESS 93069 BUSHING: REDUCING 1-1/2"...
  • Page 147 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500/2000 DBB Gas Train – p/n 22199 rev A Item Qty Part # Description Item Part # Description 123542 FLANGE 2" 125# 2"NPT 124142 VALVE: SSOV: DOUBLE BODY: 2" NPT BUSHING: REDUCING 1-1/2"...
  • Page 148 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS AERCO Benchmark 1500/2000 DBB Gas Train 10/31/2013 International, Inc. Blauvelt, NY 10913 22199 rev A Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 149 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 – 2000 Burner Assembly, p/n 24378 – 24388 rev A Item Qty Part # Description Item Part # Description 69078 BLOWER: AMETEK 12.3" 81100 GASKET: BLOWER 12.3" 43090...
  • Page 150 Benchmark 1500 - 2000 Boilers APPENDIX H – PART DRAWINGS Benchmark 1500 – 2000 Burner Assembly AERCO 10/18/2013 International, Inc. Blauvelt, NY 10913 24378 – 24388 rev A Sheet 2 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 151: Appendix I: Wiring Diagrams

    Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Appendix I: WIRING DIAGRAMS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 151 of 184 Ph.: 800-526-0288 GF-142...
  • Page 152 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 153 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68050 page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 153 of 184 Ph.: 800-526-0288 GF-142...
  • Page 154 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 155 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68050 page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 155 of 184 Ph.: 800-526-0288 GF-142...
  • Page 156 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 157 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number: 68060 rev A page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 157 of 184 Ph.: 800-526-0288 GF-142...
  • Page 158 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 159 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68061 rev A page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 159 of 184 Ph.: 800-526-0288 GF-142...
  • Page 160 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 161 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68061 rev A page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 161 of 184 Ph.: 800-526-0288 GF-142...
  • Page 162 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 163 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68062 rev A page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 163 of 184 Ph.: 800-526-0288 GF-142...
  • Page 164 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 165 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number N 68062 rev A page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 165 of 184 Ph.: 800-526-0288 GF-142...
  • Page 166 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 167 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68063 rev A page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 167 of 184 Ph.: 800-526-0288 GF-142...
  • Page 168 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 169 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS Drawing Number 68063 rev A page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 169 of 184 Ph.: 800-526-0288 GF-142...
  • Page 170 Benchmark 1500 - 2000 Boilers APPENDIX I – WIRING DIAGRAMS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 171: Appendix J: Piping Drawings

    Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Appendix J: PIPING DRAWINGS Drawing Number: SD-A-989 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 171 of 184 Ph.: 800-526-0288 GF-142...
  • Page 172 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-990 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 173 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-991 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 173 of 184 Ph.: 800-526-0288 GF-142...
  • Page 174 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-992 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...
  • Page 175 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-993 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 175 of 184 Ph.: 800-526-0288 GF-142...
  • Page 176 Benchmark 1500 - 2000 Boilers APPENDIX J – PIPING DRAWINGS Drawing Number: SD-A-994 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 177: Appendix K: C-More Control Panel Views

    P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure K-1: Benchmark Control Panel Exploded View BENCHMARK CONTROL PANEL EXPLODED VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0C Page 177 of 184 Ph.: 800-526-0288...
  • Page 178 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure K-2: Benchmark Control Panel Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 184 OMM-0097_0C Ph.: 800-526-0288 GF-142...

  • Page 179: Appendix L: Recommended Spares

    Benchmark 1500 - 2000 Boilers APPENDIX L – RECOMMENDED SPARES Appendix L: RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix H for the locations of the recommended and optional spare parts listed in the following Tables. Table L-1: Recommended Emergency Spare Parts...
  • Page 180 Benchmark 1500 - 2000 Boilers Change Log: Date Description Changed By 10/15/2013 Rev A: Initial release Curtis Harvey Rev B: Added in the technical ref docs, tables, drawings, 11/12/2013 diagrams. And etc. Revised pressure regulator Curtis Harvey requirements. Rev C: 934-5: Revised the regulator requirements.

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