Aerco BMK 1500 Operation And Service Manual
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Aerco BMK 1500 Operation And Service Manual

Benchmark platinum series
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BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE
OPERATION, SERVICE, and MAINTENANCE GUIDE
Natural Gas, Propane Gas, or Dual Fuel Fired Modulating, Condensing Boilers
750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers
Latest Update: 03/15/2017
OMM-0116_0A
GF-201
USER MANUAL
®
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
(2 of 2)
SEE ALSO: Benchmark Platinum
Installation and Startup Guide
OMM-0115 (GF-200)
APPLIES TO MODELS:
Natural Gas:
Dual-Fuel
• BMK 750
• BMK 1500DF
• BMK 1000
• BMK 2000DF
• BMK 1500
• BMK 2500DF
• BMK 2000
• BMK 3000DF
• BMK 2500
• BMK 3000
Propane:
• BMK 750P
• BMK 2500P
• BMK 1000P
• BMK 3000P
• BMK 1500P
• BMK 2000P
Applies to Serial Numbers:
G-17-0001 and above.
GF-201
,
:
(NG/P)
Page 1 of 178
03/15/2017

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  • Page 1 • BMK 1000P • BMK 3000P • BMK 1500P • BMK 2000P Applies to Serial Numbers: G-17-0001 and above. Latest Update: 03/15/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 1 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 2: Table Of Contents

    3.7.2 Combination Control System Setup and Startup .................... 38 SECTION 4: AERTRIM OPERATION ..............39 4.1 AERTRIM INTRODUCTION ......................... 39 4.2 AERTRIM ACTIVATION ........................39 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 2 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 3 APPENDIX G: BENCHMARK 1500/2000 PART LISTS .......... 121 APPENDIX H: BENCHMARK 2500/3000 PART LISTS .......... 137 APPENDIX I: WIRING DIAGRAMS ..............159 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 3 of 178 Ph.: 800-526-0288...
  • Page 4 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE CONTENTS APPENDIX J: C-MORE CONTROL PANEL VIEWS ..........175 APPENDIX K: RECOMMENDED SPARES ............177 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 5: Foreword

    FORWARD FOREWORD The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas and propane fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
  • Page 6 (1 BTU/hr = 0.29 W) Combination Control Panel Combination Control System C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Cubic Feet per Hour (1 CFH = 0.028 m...
  • Page 7 Primary Micro-Controller (PMC) board, contained in the C-More Part Number Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 7 of 178 Ph.: 800-526-0288 GF-201...
  • Page 8 W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 9: Section 1: Safety Precautions

    In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers.

  • Page 10: Emergency Shutdown

    Startup Guide, OMM-0115 (GF-200) be performed to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.

  • Page 11: Important - For Massachusetts Installations

    The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 11 of 178 Ph.: 800-526-0288...
  • Page 12 ……………….[End of Extracted Information From 248 CMR 5.08 (2)]………………… AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 13: Section 2: Operation

    All of the installation procedures in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0115 (GF-200) must be completed before attempting to start the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 13 of 178 Ph.: 800-526-0288...

  • Page 14: Control Panel Description

    Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section. Figure 2-1: Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 15 TEST/RESET Pressing RESET resets the water level monitor circuit. switches • Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 15 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 16 20 segment red LED bargraph continuously shows the Air/Fuel VALVE POSITION Valve position in 5% increments from 0 to 100% Bargraph AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017...

  • Page 17: Control Panel Menus

    The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 17 of 178 Ph.: 800-526-0288...
  • Page 18 Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for a list and descriptions of startup, status and error messages. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 19: Operating Menu

    = 100) does not appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More Control Panel’s front face. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 19 of 178 Ph.: 800-526-0288...

  • Page 20: Setup Menu

    E, G, H, R, N or A Unit Year Unit Serial # 9999 Current software Software Ver 0.00 Ver 9.99 version AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 21: Configuration Menu

    100°F 60°F (If Outdoor Sensor = (-1.1°C) (37.8°C) (15.6°C) Enabled) Setpt Lo Limit 40°F (4.4°C) Setpt Hi Limit 60°F (15.6°C) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 21 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 22 # 7 is set to Enabled. CAUTION! DO NOT change the Analog Output menu item from its default setting (Valve Position 0-10V). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 23: Tuning Menu

    SET Valve Position 100% Blower Output Monitor Blower Output Voltage 0.00 0.00 Set Stdby Volt 10.0 V 2.00 2.00 Oxygen Level AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 23 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 24: Bmk 1500/2000 Combustion Cal Menus

    * The default values for Natural Gas on Dual Fuel units are different than the default values for Natural Gas on Single Fuel units. These values do NOT apply to single fuel units. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 25: Bmk 2500/3000 Combustion Cal Menus

    * The default values for Natural Gas on Dual Fuel units are different than the default values for Natural Gas on Single Fuel units. These values shown DO NOT APPLY to single fuel units. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 25 of 178 Ph.: 800-526-0288...

  • Page 26: Bst (Boiler Sequencing Technology) Menu

    Network Network Head Temp Source Network FFWD Temp FFWD Temp Mdbus Temp Units Degrees C or Degrees F Degrees C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 27 1°F (-17.2°C) 120°F (48.9°C) 100°F (37.8°C) BST Intgral Gain 0.00 2.00 0.50 BST Deriv Time 0.00 Min 2.00 Min 0.10 Min AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 27 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 28 BST Max Addr SSD Address SSD Poll Control 1000 Err Threshold SSD Temp Format Degrees Points Degrees BST Upld Timer 9999 sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 29: Calibration Menu

    0.0% Flow In Adj Supply Gas Pressure In Adj -5.0% 5.0% 0.0% Gas Plate dp In Adj -5.0% 5.0% 0.0% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 29 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 30 Depends on unit type/size Min Spark Amps 0.0 Amps 2.5 Amps 0.10 Amps Max Spark Amps 0.0 Amps 2.5 Amps 0.40 Amps AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 30 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 31: Section 3: Modes Of Operation

    I/O Box. Refer to Section 2.10: AC Electrical Power Wiring of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0115 (GF-200) for additional information on wiring. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 31 of 178 Ph.: 800-526-0288...

  • Page 32: Indoor/Outdoor Startup

    The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted. See Appendix A for descriptions of temperature-related functions, and Sections 2.4 – 2.10 for their range of values and factory defaults.

  • Page 33: Setting The Setpoint

    Remote Setpoint Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network Refer to section 2.3: Control Panel Menus for detailed instructions on changing menu options. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 33 of 178 Ph.: 800-526-0288...

  • Page 34: Remote Setpoint Field Wiring

    While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. See Appendix A for descriptions of temperature-related functions, and Sections 2.4 –...

  • Page 35: Direct Drive Field Wiring

    To change back to the Direct Drive mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 35 of 178 Ph.: 800-526-0288...

  • Page 36: Aerco Control System (Acs)

    Section 6 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0115 (GF-200). The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible.

  • Page 37: Combination Control System (Ccs)

    Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay...

  • Page 38: Combination Control System Field Wiring

    These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Sections 2.4 –...

  • Page 39: Section 4: Aertrim Operation

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 39 of 178 Ph.: 800-526-0288...

  • Page 40: Operation Details

    Fixed Key in the Configuration Menu (item 34 in Section 2.6). 2. Contact AERCO Sales Administration with the recorded information. They will provide you with a license key. 3. Once you have obtained the license key, navigate to the O Trim Key in the Configuration menu in the C-More and enter the key.
  • Page 41 Target O value. This process repeats until the target oxygen range is achieved or the unit reaches the allowable blower voltage limit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 41 of 178 Ph.: 800-526-0288...

  • Page 42: Aertrim Auto Calibration

    Sensor OOR Maintenance Required” will be displayed, and the trim function is disabled. (OOR is used throughout this manual for Out Of Range) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 43: Aertrim Menu Items

    Enables or Disables all warnings from AERtrim system *This item is in the top level operating menu **This item is in the configuration menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 43 of 178 Ph.: 800-526-0288...

  • Page 44: Aertrim Menu Values And Defaults

    Default 1.75 2.85 2.10 1.95 2.60 2.55 2.35 3.60 3.10 3.00 3.90 3.50 3.80 4.75 4.60 100% 4.75 6.00 5.60 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 45 Default 1.20 2.85 2.10 1.95 2.60 2.55 2.35 3.60 3.10 3.00 3.90 3.50 3.80 4.75 4.60 100% 4.75 6.00 5.60 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 45 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 46 Default 1.40 3.30 1.80 1.90 4.60 2.30 2.30 5.70 2.50 2.50 5.70 2.90 2.70 6.30 3.80 100% 6.00 10.00 7.90 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 47 Default 1.90 4.00 1.40 2.70 7.70 3.80 3.00 7.70 4.30 3.30 7.70 5.40 4.00 9.60 6.40 100% 6.00 10.00 9.50 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 47 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 48 Default 1.90 2.90 2.20 3.00 4.90 4.10 3.70 5.90 4.80 4.20 6.40 5.30 5.20 8.40 6.80 100% 6.50 9.20 8.50 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 49 Default 2.60 4.90 2.80 3.60 7.00 4.60 4.60 8.00 5.00 5.00 9.20 5.50 6.10 10.00 6.90 100% 7.60 10.00 9.10 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 49 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 50: Aertrim Maintenance And Troubleshooting

    Table 4-2 will be displayed when you view the Trim State menu item in the O2 Trim menu. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 51 FR Rng Err Fire Rate is not within track range None – Steady State has not been during trim operation achieved AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 51 of 178 Ph.: 800-526-0288 GF-201...
  • Page 52 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE SECTION 4 – AERTRIM OPERATION (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 53: Section 5: Maintenance

    Table 5-1. For a complete inspection check list see ASME CSD-1 chart. In order to perform the maintenance tasks specified in Table 5-1, the following maintenance kits are available through your local AERCO Sales Representative: •...

  • Page 54: Igniter-Injector

    BURNER PLATE SOLENOID FLAME DETECTOR O2 SENSOR BURNER STAGED IGNITION ASSEMBLY IGNITER-INJECTOR Figure 5-1a: BMK 750/1000 Burner Assembly (Removed from Boiler) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 55 IGNITOR-INJECTOR SWITCH AIR/FUEL ASSEMBLY VALVE BURNER FLAME DETECTOR FLAME OBSERVATION PORT Figure 5-1c: BMK 2500/3000 Burner Assembly (Removed from Boiler) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 55 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 56 LEAN O2 SENSOR & WASHER FLAME DETECTOR & BURNER PLATE GASKET FLANGE Figure 5-2b: BMK 1500/2000 Igniter-Injector & Flame Detector Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 57 Reconnect the igniter-injector cable. Reinstall the shroud on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 57 of 178 Ph.: 800-526-0288...
  • Page 58 POSITION O2 SENSOR INJECTOR TUBE INSIDE THIS ARC FLAME OBSERVATION INJECTOR TUBE PORT IGNITER-INJECTOR Figure 5-3c. BMK 2500/3000 Igniter-Injector Orientation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 59: Flame Detector

    If the AERtrim technology system is functioning, it should be inspected at the same time as sensor maintenance. See Section 4: AERtrim Operation, above, for instructions. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 59 of 178 Ph.: 800-526-0288...

  • Page 60: Safety Device Testing

    Illustrations for the burner inspection procedure for all BMK Platinum models are presented first, starting on the next page, followed by the written instructions. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 61: Bmk 750/1000 Burner Inspection

    2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 61 of 178 Ph.: 800-526-0288...
  • Page 62 19. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange. This completes the Benchmark 750/1000 burner inspection. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 63: Bmk 1500 - 3000 Burner Inspection

    GAS INLET PIPE AIR/FUEL VALVE MANUAL SHUT- OFF VALVE BLOCKED INLET SWITCH FILTER TRAIN Figure 5-5b: BMK 1500/2000 Burner Assembly Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 63 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 64 PROOF MANUAL SWITCH SHUT-OFF VALVE AIR/FUEL VALVE BLOCKED INLET SWITCH FILTER TRAIN Figure 5-5d: BMK 2500/3000 Burner Assembly Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 65 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 Figures 5-5a & 5-5b (BMK 1500/2000) or Figures 5-5c & 5-5d (BMK 2500/3000). 10. You must either rig a support for the blower to hold it in place or remove the blower from the unit and set it aside for later reassembly.
  • Page 66 16. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange. This completes the Benchmark 1500/3000 burner inspection. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 67: Condensate Drain Trap

    FLOAT INLET OUTLET O-Rings EXPLODED CROSS-SECTION VIEW 3/4" NPT Port Figure 5-7: External Condensate Trap – Cross-Section & Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 67 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 68: Air Filter Cleaning And Replacement

    4. Using a flat-tip screwdriver or 5/16” nut driver, loosen the clamp securing the filter to the inlet flange of the air/fuel valve. Remove the filter and clamp. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 69: Water Cutoff (Lwco) Capacitor Integrity Test

    Shrink Tubing) Hot Water Connector Outlet Pipe (to Shell Harness) LWCO Probe Terminal Figure 5-9: LWCO Probe Location (BMK1500 Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 69 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 70: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    19-PIN SHELL HARNESS CABLE CONNECTOR LWCO PROBE ASSEMBLY CONNECTOR Figure 5-11: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 71: Low Water Cutoff (Lwco) - Standard C-More Test

    4. Perform initial startup per Section 4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0115 (GF-200). 5. Perform safety device testing and scheduled maintenance procedures per Sections 5 and 6 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 71 of 178 Ph.: 800-526-0288...

  • Page 72: Spark Monitor (Ac Current Transducer)

    I/O board’s Spark Signal terminals, red wire to the positive (+) terminal and black to negative (-). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 73: Section 6: Troubleshooting Guide

    The front panel of the C-More Control Box contains an RS232 port. This port is used only by factory- trained personnel to monitor onAER communications via a portable computer. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 73 of 178 Ph.: 800-526-0288...
  • Page 74 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE SECTION 6 – TROUBLESHOOTING GUIDE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 75 Air/Fuel Valve dial. Hard light. Check igniter-injector for soot or erosion of electrode. Check injector solenoid valve to insure proper open/close operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 75 of 178 Ph.: 800-526-0288...
  • Page 76 Probable causes from 3 to 16 for AIRFLOW See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT FAULT DURING IGNITION applies for this fault. DURING IGNITION. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 77 120VAC at the valve input terminals. If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 77 of 178 Ph.: 800-526-0288...
  • Page 78 (C) and normally closed (NC) terminals with the unit not firing. Replace the switch if continuity does not exist. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 79 Press CLEAR button and restart unit. If fault persists, contact IGN BOARD PMC board and Ignition/Stepper (IGST) board. qualified Service Personnel. COMM FAULT AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 79 of 178 Ph.: 800-526-0288 GF-201...
  • Page 80 Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF Defective IGST Board. every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 81 MODBUS Check network connections. If fault persists, contact qualified Unit not seeing information from Modbus network. COMMFAULT Service Personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 81 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 82 Check resistance of sensor to determine if it is within specification. SENSOR Incorrect Sensor. Ensure that the correct sensor is installed. FAULT AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017...
  • Page 83 SSOV switch closed for 15 seconds during run. Replace or adjust micro-switch in SSOV actuator. If fault persists, SSOV FAULT replace actuator. DURING RUN AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 83 of 178 Ph.: 800-526-0288 GF-201...
  • Page 84 Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 85: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards are Rev. E the 70% Valve Position in Control Box are outdated. or higher. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 85 of 178 Ph.: 800-526-0288...
  • Page 86 BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 8-1: SSOV Actuator With Gas Pressure Adjustment (SKP25) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 87: Appendix A: Boiler Menu Item Descriptions

    Displays the elapsed time between 120VAC being applied to SSOV Time to OPN the Gas Valve and confirmation of gas valve opening (POC). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 87 of 178 Ph.: 800-526-0288...
  • Page 88 Displays total run time of unit in hours. Fault Log Displays information on the last 20 faults. Manual Valve Pos Selects valve position. Available in Manual mode only! AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017...

  • Page 89: Table A-2: Setup Menu Item Descriptions

    4-digit serial # on the Code Plate, e.g., G-12- Software Version Identifies the current software version of the control box. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 89 of 178 Ph.: 800-526-0288...

  • Page 90: Table A-3: Configuration Menu Item Descriptions

    °C) setting to allow the unit to run. Max Valve Position Sets the maximum allowable valve position for the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017...
  • Page 91 Valve Position In reaches the Start Level value (Calibration menu item 37). There will not be a one minute delay when firing at the 29% Valve Position level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 91 of 178 Ph.: 800-526-0288...
  • Page 92 When set to Enabled, the AERtrim menu options appears. O2 Trim Menu When set to Enabled, the BST menu options appears. BST Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 93: Table A-4: Tuning Menu Item Descriptions

    Range = 0 - 240 seconds Default = 20 seconds Timer Allows Tuning menu options to be reset to their Factory Reset Defaults? Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 93 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 94: Table A-5: Combustion Calibration Menu Item Descriptions

    Permits the Standby Voltage to be set from 0 to 4.00 Volts. Permits the combustion oxygen level to be displayed (0% to Oxygen Level 25%) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 95: Table A-6: Calibration Menu Item Descriptions

    Allows adjustment of the analog input from -5.0% to +5.0%. Allows adjustment of the water Flow Rate Input from Flow In Adj -5.0% to +5.0%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 95 of 178 Ph.: 800-526-0288...
  • Page 96 – FFWD Temp Offset Range: -20 to + 20 (either ºF or °C) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 97 Min Spark Amps transformer input. Allows the adjustment of the maximum spark current required at the spark Max Spark Amps transformer input. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 97 of 178 Ph.: 800-526-0288 GF-201...
  • Page 98 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX A: BOILER MENU DESCRIPTIONS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 99: Appendix B: Startup, Status, & Fault Messages

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 99 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 100: Table B-2: Fault Messages

    The Line (Hot) and Neutral wires are reversed. OUT OF PHASE LOW WATER The Low Water Cutoff board is indicating low water level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 101 A failure has been detected in one of the relays that control the SSOV. FAILURE STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to the desired position. FAILURE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 101 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 102 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017...

  • Page 103: Appendix C: Sensor Resistance/Voltage Chart

    1260.0 2.47 87.8 1285.6 2.50 93.3 1311.4 2.52 98.9 1337.7 2.54 104.4 1364.2 2.56 1391.0 2.58 115.6 1418.2 121.1 1445.7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 103 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 104 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 105: Appendix D: Recommended Periodic Testing

    Perform a slow drain test in accordance with Slow drain test Semi-Annually Operator ASME Boiler and Pressure Vessel Code, Section IV. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 105 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 106 See section 5.8. Annually Verify oxygen level is between 3% and 8% Oxygen (O ) Level Monthly Operator during boiler operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 107: Appendix E: Indoor/Outdoor Reset Ratio Charts

    RESET RATIO Air Temp °F °C 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 -26.1 -28.9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 107 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 108 Air Temp °F °C 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 -26.1 -28.9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 109 Air Temp °F °C 26.7 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 109 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 110 Air Temp °F °C 32.2 29.4 26.7 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 111: Appendix F: Benchmark 750/1000 Part Lists

    Benchmark 750 – 1000 Part List 01/25/2017 AERCO International, Inc. Blauvelt, NY 10913 28321-TAB rev D – 28253-TAB rev D Sheet 1 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 111 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 112 Benchmark 750 – 1000 Part List 01/25/2017 AERCO International, Inc. Blauvelt, NY 10913 28321-TAB rev D – 28253-TAB rev D Sheet 2 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 113 Benchmark 750 – 1000 Part List 01/25/2017 AERCO International, Inc. Blauvelt, NY 10913 28321-TAB rev D – 28253-TAB rev D Sheet 3 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 113 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 114 Benchmark 750 – 1000 Part List 01/25/2017 AERCO International, Inc. Blauvelt, NY 10913 28321-TAB rev D – 28253-TAB rev D Sheet 4 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 115 Benchmark 750 – 1000 Part List 01/25/2017 AERCO International, Inc. Blauvelt, NY 10913 28321-TAB rev D – 28253-TAB rev D Sheet 5 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 115 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 116 Benchmark 750 – 1000 Part List AERCO International, 01/25/2017 Inc. Blauvelt, NY 10913 28321-TAB rev D – 28253-TAB rev D Sheet 6 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 117 DAMPING ORIFICE: SSOV Benchmark 750-1000 FM Gas Train AERCO International, 09/15/2015 Inc. Blauvelt, NY 10913 22140-1 rev F Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 117 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 118 TUBE: FLEXIBLE GAS 20" " (50.8 cm) LG Benchmark 750-1000 DBB Gas Train AERCO International, 10/15/2015 Inc. Blauvelt, NY 10913 22140-2 rev E Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 119 Benchmark AERCO 750-1000 Gas Train – Propane 10/28/2015 International, Inc. Blauvelt, NY 10913 22140-3 rev G Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 119 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 120 A/F VALVE ASSY BMK 750/1000 PROPANE Benchmark 750-1000 Burner Assembly 10/28/2015 AERCO International, Inc. Blauvelt, NY 10913 24276 rev J Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 121: Appendix G: Benchmark 1500/2000 Part Lists

    Benchmark 1500/1500DF, 2000/2000DF Part List 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 1 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 121 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 122 Benchmark 1500/1500DF, 2000/2000DF Part List 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 2 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 123 Benchmark 1500/1500DF, 2000/2000DF Part List 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 3 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 123 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 124 Benchmark 1500/1500DF, 2000/2000DF Part List 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 4 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 125 Benchmark 1500/1500DF, 2000/2000DF Part List 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 5 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 125 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 126 Benchmark 1500/1500DF, 2000/2000DF Part List 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 6 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 127 Benchmark 1500/1500DF, 2000/2000DF Part List AERCO 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 7 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 127 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 128 Benchmark 1500/1500DF, 2000/2000DF Part List AERCO 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 8 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 129 Benchmark 1500/1500DF, 2000/2000DF Part List AERCO 01/03/2017 International, Inc. Blauvelt, NY 10913 29313-TAB rev E, 29337-TAB rev E Sheet 9 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 129 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 130 HIGH GAS PRESSURE SWITCH 4.7" W.C. Benchmark 1500-2000 Gas Train AERCO 05/28/2015 International, Inc. Blauvelt, NY 10913 22188 rev E Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 131 ACTUATOR, SSOV W/O P.O.C. SWITCH AERCO Benchmark 1500-2000 DBB Gas Train 11/10/2015 International, Inc. Blauvelt, NY 10913 22199 rev F Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 131 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 132 AERCO Benchmark 1500 - 2000 Burner Assembly 09/22/2015 International, Inc. Blauvelt, NY 10913 24378-TAB rev F Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 133 Benchmark 1500DF-2000DF Gas Train AERCO 05/05/2015 NATURAL GAS International, Inc. Blauvelt, NY 10913 22188-1 rev C, component of 22198 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 133 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 134 AERCO 09/17/2015 PROPANE Gas Train International, Inc. Blauvelt, NY 10913 22197 rev D, component of 22198 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 135 DBB NATURAL GAS Gas Train International, Inc. Blauvelt, NY 10913 22199-1 rev D, component of 22201 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 135 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 136 10/16/2015 DBB PROPANE Gas Train International, Inc. Blauvelt, NY 10913 22200 rev E, component of 22201 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 137: Appendix H: Benchmark 2500/3000 Part Lists

    Benchmark 2500/2500DF, 3000/3000DF Part List 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 1 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 137 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 138 Benchmark 2500/2500DF, 3000/3000DF Part List 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 2 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 139 Benchmark 2500/2500DF, 3000/3000DF Part List AERCO 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 3 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 139 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 140 Benchmark 2500/2500DF, 3000/3000DF Part List AERCO 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 4 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 141 Benchmark 2500/2500DF, 3000/3000DF Part List AERCO 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 5 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 141 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 142 Benchmark 2500/2500DF, 3000/3000DF Part List 12/15/2016 International, Inc. Blauvelt, NY 10913 Whole Boiler 28536-TAB – 28382-TAB Sheet 6 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 143 Benchmark 2500/2500DF, 3000/3000DF Part List 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 7 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 143 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 144 Benchmark 2500/2500DF, 3000/3000DF Part List 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 8 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 145 Benchmark 2500/2500DF, 3000/3000DF Part List 12/15/2016 International, Inc. Blauvelt, NY 10913 28536-TAB rev C, 28382-TAB rev D Sheet 9 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 145 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 146 AERCO Benchmark 3000 FM Gas Train 01/17/2017 International, Inc. Blauvelt, NY 10913 P/N 22171 rev J Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 147 Benchmark 3000 DBB Gas Train – Natural Gas 01/04/2017 International, Inc. Blauvelt, NY 10913 22173 rev K Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 147 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 148 Benchmark 2500 FM Gas Train AERCO 07/21/2016 International, Inc. Blauvelt, NY 10913 22190 – rev D Page 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 149 Benchmark 2500 Natural Gas DBB Gas Train 07/22/2016 International, Inc. Blauvelt, NY 10913 22211 rev E Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 149 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 150 Benchmark 3000DF Gas Train – NATURAL GAS 01/03/2017 International, Inc. Blauvelt, NY 10913 Sheet 1 of 1 22177 rev F, component of 22174 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 151 Benchmark 3000 DF Gas Train – PROPANE 01/03/2017 International, Inc. Blauvelt, NY 10913 22178 rev F, component of 22174 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 151 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 152 Benchmark 3000DF DBB Gas Train – NATURAL GAS 01/03/2017 International, Inc. Blauvelt, NY 10913 22177-1 rev F, component of 22183 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 153 Benchmark 3000 DF DBB Gas Train – PROPANE 01/05/2017 International, Inc. Blauvelt, NY 10913 22178-1 rev E, component of 22183 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 153 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 154 Benchmark 2500 DF FM Gas Train – AERCO 02/19/2016 Natural Gas International, Inc. Blauvelt, NY 10913 Sheet 1 of 2 22210-1 rev B, component of 22210 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 155 Benchmark 2500 DF FM Gas Train – AERCO 02/19/2016 PROPANE International, Inc. Blauvelt, NY 10913 22210-2 rev B, component of 22210 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 155 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 156 Benchmark 2500DF DBB Gas Train – AERCO 02/19/2016 NATURAL GAS International, Inc. Blauvelt, NY 10913 Sheet 1 of 1 22209-1 rev C, component of 22209 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...
  • Page 157 Benchmark 2500 DF DBB Gas Train AERCO 03/23/2016 PROPANE International, Inc. Blauvelt, NY 10913 22209-2 rev C, component of 22209 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 157 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 158 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX H – BENCHMARK 2500/3000 PART LISTS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 159: Appendix I: Wiring Diagrams

    BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Appendix I: WIRING DIAGRAMS Benchmark 750/1000 – Drawing Number: 68038 rev G Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 159 of 178 Ph.: 800-526-0288...
  • Page 160 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 750/1000 – Drawing Number: 68038 rev G Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 161 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 – Drawing Number 68050 rev C page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 161 of 178 Ph.: 800-526-0288...
  • Page 162 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 – Drawing Number 68050 rev C page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 163 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 DBB – Drawing Number 68071 rev C page 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 163 of 178 Ph.: 800-526-0288...
  • Page 164 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 DBB – Drawing Number 68071 rev C page 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 165 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 3000 208 VAC – Diagram 68040 rev F, Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 165 of 178 Ph.: 800-526-0288...
  • Page 166 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 3000 208 VAC – Drawing Number: 68040 rev F, Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 167 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 3000 460 VAC – Drawing Number: 68041 rev F Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 167 of 178 Ph.: 800-526-0288...
  • Page 168 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 3000 460 VAC – Drawing Number: 68041 rev E Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 169 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 2500 208 VAC – Drawing Number: 68060 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 169 of 178 Ph.: 800-526-0288...
  • Page 170 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 2500 208 VAC – Drawing Number: 68060 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 171 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 208 VAC DBB – Drawing Number: 68062 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 171 of 178 Ph.: 800-526-0288...
  • Page 172 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 208 VAC DBB – Drawing Number: 68062 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 178 OMM-0116_0A Ph.: 800-526-0288...
  • Page 173 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 460 VAC DBB – Drawing Number: 68063 rev B Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 173 of 178 Ph.: 800-526-0288...
  • Page 174 BMK 750-3k Platinum Boiler OPERATION, SERVICE, and MAINTENANCE GUIDE APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 460 VAC DBB – Drawing Number: 68063 rev B Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 178 OMM-0116_0A Ph.: 800-526-0288...

  • Page 175: Appendix J: C-More Control Panel Views

    P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure J-1 – Benchmark Series Control Panel - Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 175 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...
  • Page 176 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure J-2: Benchmark Control Panel Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

  • Page 177: Appendix K: Recommended Spares

    BMK 750/1000: 46023 BMK 1500: 46042 Burner BMK 2000: 46044 BMK 2500: 46039 BMK 3000: 46038 61026 Lean Oxygen Sensor AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0116_0A Page 177 of 178 Ph.: 800-526-0288 GF-201 03/15/2017...

  • Page 178: Omm-0116_0A Aerco International, Inc. • 100 Oritani Dr. • Blauvelt, Ny 10913

    CHANGE LOG: DATE DESCRIPTION CHANGED BY Curtis Harvey, 03/15/2017 Rev A: Initial release Chris Blair © AERCO International, Inc., 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 178 OMM-0116_0A Ph.: 800-526-0288 03/15/2017 GF-201...

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