Aerco Benchmark BMK 750 User Manual
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Aerco Benchmark BMK 750 User Manual

Benchmark series natural gas, propane gas, or dual fuel fired modulating, condensing boilers
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See also: User Manual
Benchmark 750-3000 Boiler Operation, Service & 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: 11/29/2017
OMM-0122_0C
GF-206
USER MANUAL
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
(2 of 2)
SEE ALSO: Benchmark
Installation and Startup Guide
OMM-0121 (GF-205)
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-17-2400 and above.
GF-206
,
:
(NG/P)
Page 1 of 164
11/29/2017

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  • Page 1 • BMK 1000P • BMK 3000P • BMK 1500P • BMK 2000P Applies to Serial Numbers: G-17-2400 and above. Latest Update: 11/29/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 1 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...

  • Page 2: Table Of Contents

    3.7.2 Combination Control System Setup and Startup .................... 38 SECTION 4: MAINTENANCE ................39 4.1 MAINTENANCE SCHEDULE ....................... 39 4.2 IGNITER-INJECTOR ..........................40 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 2 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 3 APPENDIX H: BENCHMARK 2500/3000 PART LIST ........... 123 APPENDIX I: WIRING DIAGRAMS ..............145 APPENDIX J: C-MORE CONTROLLER VIEWS ............ 161 APPENDIX K: RECOMMENDED SPARES ............163 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 3 of 164 Ph.: 800-526-0288...
  • Page 4 Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide CONTENTS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • 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 BTUs per Hour (1 BTU/hr = 0.29 W) Combination Control Panel Combination Control System A control system developed by AERCO and currently used in all C-More Controller Benchmark, Innovation and KC1000 Series product lines. Cubic Feet per Hour (1 CFH = 0.028 m...
  • Page 7 Part Number Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) Point-to-Point (usually over RS232 networks) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 7 of 164 Ph.: 800-526-0288 GF-206...
  • 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 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • 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-0121 (GF-205) 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-0122_0C Page 11 of 164 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 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 13: Section 2: Operation

    All of the installation procedures in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) must be completed before attempting to start the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 13 of 164 Ph.: 800-526-0288...

  • Page 14: C-More Controller Description

    Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section. Figure 2-1: C-More Controller Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 164 OMM-0122_0C 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-0122_0C Page 15 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • 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 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...

  • Page 17: C-More Controller 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-0122_0C Page 17 of 164 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 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 19: Operating Menu

    An additional parameter associated with the Operating menu, (Min = 0, Max = 100) does not appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More Controller’s front face. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 19 of 164 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 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • 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-0122_0C Page 21 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • 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 164 OMM-0122_0C 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-0122_0C Page 23 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...

  • 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 164 OMM-0122_0C 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-0122_0C Page 25 of 164 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 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • 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-0122_0C Page 27 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 28 Unit 2 is Off Unit 4 is Not Available Unit 5 is Lead On Unit 6 is Lag Off 1 BST Units 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...

  • Page 29: Calibration Menu

    -5.0% 5.0% 0.0% Gas Plate dp In Adj -5.0% 5.0% 0.0% mA Out Adj -1.0 mA 1.0 mA 0.0 mA AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 29 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • 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 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • 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-0121 (GF-205) for additional information on wiring. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 31 of 164 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: C-More Controller Menus for detailed instructions on changing menu options. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 33 of 164 Ph.: 800-526-0288 GF-206...

  • 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-0122_0C Page 35 of 164 Ph.: 800-526-0288...

  • Page 36: Aerco Control System (Acs)

    Section 6 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205). 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: Maintenance

    For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 4-1. For a complete inspection check list see ASME CSD-1 chart. The following maintenance kits are available through your local AERCO Sales Representative: Model Kit P/N...

  • Page 40: Igniter-Injector

    STAGED IGNITION BURNER PLATE SOLENOID FLAME DETECTOR O2 SENSOR BURNER IGNITER-INJECTOR Figure 4-1a: BMK 750/1000 Burner Assembly (Removed from Boiler) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 41 IGNITOR-INJECTOR SWITCH AIR/FUEL ASSEMBLY VALVE BURNER FLAME DETECTOR FLAME OBSERVATION PORT Figure 4-1c: BMK 2500/3000 Burner Assembly (Removed from Boiler) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 41 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 42 LEAN O2 SENSOR & WASHER FLAME DETECTOR & BURNER PLATE GASKET FLANGE Figure 4-2b: BMK 1500/2000 Igniter-Injector & Flame Detector Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 43 Reconnect the igniter-injector cable. Reinstall the shroud on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 43 of 164 Ph.: 800-526-0288...
  • Page 44 POSITION O2 SENSOR INJECTOR TUBE INSIDE THIS ARC FLAME OBSERVATION INJECTOR TUBE PORT IGNITER-INJECTOR Figure 4-3c. BMK 2500/3000 Igniter-Injector Orientation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 45: Flame Detector

    6. Reinstall the O sensor and crush washer on the burner plate. 7. Reconnect the sensor lead wire. Reinstall the shroud on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 45 of 164 Ph.: 800-526-0288...

  • Page 46: Safety Device Testing

    NOTE: Illustrations for the burner inspection procedure for all BMK models are presented first, starting on the next page, followed by the written instructions. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 47: 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-0122_0C Page 47 of 164 Ph.: 800-526-0288...
  • Page 48 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 48 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 49: Bmk 1500 - 3000 Burner Inspection

    GAS INLET PIPE AIR/FUEL VALVE MANUAL SHUT- OFF VALVE BLOCKED INLET SWITCH FILTER TRAIN Figure 4-5b: BMK 1500/2000 Burner Assembly Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 49 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 50 PROOF MANUAL SWITCH SHUT-OFF VALVE AIR/FUEL VALVE BLOCKED INLET SWITCH FILTER TRAIN Figure 4-5d: BMK 2500/3000 Burner Assembly Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 51 Figure 4-3b or Figure 4-3c. Torque the igniter-injector to 14 - 15 ft-lbs. (19.0 - 20.3 Nm). (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 51 of 164 Ph.: 800-526-0288...
  • Page 52 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 52 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 53: Condensate Drain Trap

    FLOAT INLET OUTLET O-Rings EXPLODED CROSS-SECTION VIEW 3/4" NPT Port Figure 4-7: External Condensate Trap – Cross-Section & Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 53 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...

  • Page 54: 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 54 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 55: Water Cutoff (Lwco) Capacitor Integrity Test

    Shrink Tubing) Hot Water Connector Outlet Pipe (to Shell Harness) LWCO Probe Terminal Figure 4-9: LWCO Probe Location (BMK1500 Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 55 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...

  • Page 56: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    19-PIN SHELL HARNESS CABLE CONNECTOR LWCO PROBE ASSEMBLY CONNECTOR Figure 4-11: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 57: 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-0121 (GF-205). 5. Perform safety device testing and scheduled maintenance procedures per Sections 4 and 5 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 57 of 164 Ph.: 800-526-0288...

  • Page 58: 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 58 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 59: Section 5: Troubleshooting Guide

    The front panel of the C-More Controller 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-0122_0C Page 59 of 164 Ph.: 800-526-0288...
  • Page 60 Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide SECTION 5 – TROUBLESHOOTING GUIDE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 61 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-0122_0C Page 61 of 164 Ph.: 800-526-0288...
  • Page 62 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 62 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 63 120VAC at the valve input terminals. If 120VAC is not present, the IGST board in the C-More Controller may be defective. Refer fault to qualified service personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 63 of 164 Ph.: 800-526-0288...
  • Page 64 (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 64 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 65 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-0122_0C Page 65 of 164 Ph.: 800-526-0288 GF-206...
  • Page 66 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 66 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 67 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-0122_0C Page 67 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 68 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 68 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 69 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-0122_0C Page 69 of 164 Ph.: 800-526-0288 GF-206...
  • Page 70 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 70 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 71: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards are Rev. E Air/Fuel Valve “hunting” at in C-More Controller are or higher. the 70% Valve Position outdated. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 71 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 72 BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 5-1: SSOV Actuator With Gas Pressure Adjustment (SKP25) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 73: Appendix A: Boiler Menu Item Descriptions

    Displays the current going to the ignition transformer. Run Cycles Displays the total number of run cycles. Displays total run time of unit in hours. Run Hours AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 73 of 164 Ph.: 800-526-0288 GF-206...
  • Page 74 An additional parameter associated with the Operating menu, Manual Valve Pos (Min = 0, Max = 100) does not appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More Controller’s front face. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 75: 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 C-More Controller. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 75 of 164 Ph.: 800-526-0288...

  • Page 76: Table A-3: Configuration Menu Item Descriptions

    Specifies the amount of time, up to 30 minutes, to keep the Pump Delay Timer pump running after the unit turns off. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 77 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-0122_0C Page 77 of 164 Ph.: 800-526-0288...
  • Page 78 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 78 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 79: 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-0122_0C Page 79 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...

  • Page 80: 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 80 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 81: 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-0122_0C Page 81 of 164 Ph.: 800-526-0288...
  • Page 82 – FFWD Temp Offset Range: -20 to + 20 (either ºF or °C) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 83 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-0122_0C Page 83 of 164 Ph.: 800-526-0288 GF-206...
  • Page 84 Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide APPENDIX A: BOILER MENU DESCRIPTIONS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 85: 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-0122_0C Page 85 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...

  • Page 86: Table B-2: Fault Messages

    INTERLOCK The Remote Interlock is open. OPEN LINE VOLTAGE The Line (Hot) and Neutral wires are reversed. OUT OF PHASE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 87 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-0122_0C Page 87 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 88 Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 89: 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-0122_0C Page 89 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 90 Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 91: Appendix D: Recommended Periodic Testing

    See section 5.5 in the Benchmark 750 – 3000 High water temp. Annually Service Technician Installation and Startup Guide, OMM-0121 safety control test (GF-205). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C Page 91 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 92 See section 4.7. 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 92 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 93: Appendix E: Indoor/Outdoor Reset Ratio Charts

    AIR TEMP RESET RATIO °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-0122_0C Page 93 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 94 RESET RATIO °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 94 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 95 RESET RATIO °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-0122_0C Page 95 of 164 Ph.: 800-526-0288 GF-206 11/29/2017...
  • Page 96 RESET RATIO °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 96 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 97: Appendix F: Benchmark 750/1000 Part List

    AERCO International, Inc. Blauvelt, NY BMK 750 28321-TAB rev F 10913 Sheet 1 of 6 BMK 1000 28253-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 98 AERCO International, Inc. Blauvelt, NY BMK 750 28321-TAB rev F 10913 Sheet 2 of 6 BMK 1000 28253-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 99 AERCO International, Inc. Blauvelt, NY BMK 750 28321-TAB rev F 10913 Sheet 3 of 6 BMK 1000 28253-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 99 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 100 AERCO International, Inc. Blauvelt, NY BMK 750 28321-TAB rev F 10913 Sheet 4 of 6 BMK 1000 28253-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 101 AERCO International, Inc. Blauvelt, NY BMK 750 28321-TAB rev F 10913 Sheet 5 of 6 BMK 1000 28253-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 101 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 102 AERCO International, Inc. Blauvelt, NY BMK 750 28321-TAB rev F 10913 Sheet 6 of 6 BMK 1000 28253-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 103 DAMPING ORIFICE: SSOV Benchmark 750-1000 FM Gas Train 04/11/2017 AERCO International, Inc. Blauvelt, NY 10913 22140-1 rev G Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 103 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 104 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 104 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 105 AERCO Benchmark 750/1000 Gas Train – Propane 04/11/2017 International, Inc. Blauvelt, NY 10913 22140-3 rev H Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 105 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 106 A/F VALVE ASSY BMK 750/1000 PROPANE Benchmark 750/1000 Burner Assembly 08/15/2017 AERCO International, Inc. Blauvelt, NY 10913 24276-TAB Rev K Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 107: Appendix G: Benchmark 1500/2000 Part List

    AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 1 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 108 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 2 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 109 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 3 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 109 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 110 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 4 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 111 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 5 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 112 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 6 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 113 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 7 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 113 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 114 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 8 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 115 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 9 of 9 Benchmark 2000 29337-TAB rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 116 HIGH GAS PRESSURE SWITCH 4.7" W.C. AERCO Benchmark 1500-2000 Gas Train 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 116 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 117 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 Page 117 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 118 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 Page 118 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 119 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 119 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 120 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 Page 120 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 121 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 121 of 164 OMM-0122_0C Ph.: 800-526-0288 10/25/2017 GF-206...
  • Page 122 61024 60011-2 AERCO Benchmark 1500/2000 Burner Assembly 08/09/2017 International, Inc. Blauvelt, NY 10913 24378-TAB rev G Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 123: Appendix H: Benchmark 2500/3000 Part List

    AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 1 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 123 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 124 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 2 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 125 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 3 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 125 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 126 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 4 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 127 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 5 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 127 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 128 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 6 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 129 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 7 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 129 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 130 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 8 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 131 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 9 of 9 Benchmark 3000 28382-TAB rev F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 131 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 132 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 132 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 133 Benchmark 3000 DBB Gas Train – Natural AERCO 01/04/2017 International, Inc. Blauvelt, NY 10913 22173 rev K Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 133 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 134 Benchmark 2500 FM Gas Train 07/21/2016 AERCO International, Inc. Blauvelt, NY 10913 22190 – rev D Page 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 135 Benchmark 2500 Natural Gas DBB Gas Train 07/22/2016 International, Inc. Blauvelt, NY 10913 22211 rev E Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 135 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 136 Benchmark 3000DF Gas Train – NATURAL GAS 01/03/2017 International, Inc. Blauvelt, NY 10913 22177 rev F, component of 22174 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 137 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 Page 137 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 138 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 138 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 139 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 Page 139 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 140 Benchmark 2500 DF FM Gas Train – Natural Gas 02/19/2016 International, Inc. Blauvelt, NY 10913 22210-1 rev B, component of 22210 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 141 Benchmark 2500 DF FM Gas Train – PROPANE 02/19/2016 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 Page 141 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 142 Benchmark 2500DF DBB Gas Train – AERCO 02/19/2016 NATURAL GAS International, Inc. Blauvelt, NY 10913 22209-1 rev C, component of 22209 Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 143 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 Page 143 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 144 International, Inc. BMK 2500 – 26015-TAB rev E Blauvelt, NY 10913 Sheet 1 of 1 BMK 3000 – 26014-TAB rev K AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...

  • Page 145: Appendix I: Wiring Diagrams

    Benchmark 750-3000 Boiler Operation, Service & 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 Page 145 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 146 Benchmark 750-3000 Boiler Operation, Service & 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 146 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 147 Benchmark 750-3000 Boiler Operation, Service & 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 Page 147 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 148 Benchmark 750-3000 Boiler Operation, Service & 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 148 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 149 Benchmark 750-3000 Boiler Operation, Service & 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 Page 149 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 150 Benchmark 750-3000 Boiler Operation, Service & 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 150 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 151 Benchmark 750-3000 Boiler Operation, Service & 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 Page 151 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 152 Benchmark 750-3000 Boiler Operation, Service & 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 152 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 153 Benchmark 750-3000 Boiler Operation, Service & 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 Page 153 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 154 Benchmark 750-3000 Boiler Operation, Service & 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 154 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 155 Benchmark 750-3000 Boiler Operation, Service & 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 Page 155 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 156 Benchmark 750-3000 Boiler Operation, Service & 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 156 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 157 Benchmark 750-3000 Boiler Operation, Service & 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 Page 157 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 158 Benchmark 750-3000 Boiler Operation, Service & 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 158 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 159 Benchmark 750-3000 Boiler Operation, Service & 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 Page 159 of 164 OMM-0122_0C Ph.: 800-526-0288...
  • Page 160 Benchmark 750-3000 Boiler Operation, Service & 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 160 of 164 OMM-0122_0C Ph.: 800-526-0288...

  • Page 161: Appendix J: C-More Controller Views

    PUSH BUTTON P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure J-1 – C-More Controller - Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 161 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 162 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure J-2: C-More Controller Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...

  • Page 163: Appendix K: Recommended Spares

    BMK 750/1000 46026 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 Page 163 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017 GF-206...
  • Page 164 Chris Blair (Reference 17-076) DIR 17-080: Verified and corrected part numbers in Appendix F through G. © AERCO International, Inc., 2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 164 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...

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