Watts AERCO 58015-04 Technical Instructions
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Watts AERCO 58015-04 Technical Instructions

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Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
TECHNICAL INSTRUCTIONS
Benchmark
This kit applies to units with an Ignitor and a separate gas injector.
For units with an Ignitor-Injector (P/N 58023), see Kit 58025-04 and TID-0065.
ITEM 1
Igniter
P/N GP-122435-S
ITEM 6
ITEM 7
Burner Gasket
Condensate
P/N 81030
Trap O-Ring
P/N 84017
Latest Release: 10/12/2017 (Replaces TSB-2009-15)
The information contained in this manual is subject to change without notice from AERCO
International, Inc. AERCO makes no warranty of any kind with respect to this material, including,
but not limited to, implied warranties of merchantability and fitness for a particular application.
AERCO International is not liable for errors appearing in this manual, nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of these
materials.
/12/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
10
Technical Instruction Document
®
3.0LN 24-Month Maintenance Kit# 58015-04
Maintenance Kit 58015-04 Contents
ITEM 2
ITEM 3
Flame
Flame Detector
Detector
Gasket
P/N 66034
P/N 81048
ITEM 8
Condensate Trap
Orifice Gasket
P/N 81092
DISCLAIMER
ITEM 4
Gas Injector
Gasket
P/N 81047
ITEM 9
ITEM 10
Exhaust
Burner Housing
Manifold Orifice
Gasket
Gasket
P/N 81019
P/N 81098
TID-0135_0C
ITEM 5
Exhaust
Manifold Seal
P/N 49102
ITEM 11
LWCO Kit
P/N 69126
Page 1 of 20

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  • Page 1 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C TECHNICAL INSTRUCTIONS ® Benchmark 3.0LN 24-Month Maintenance Kit# 58015-04 This kit applies to units with an Ignitor and a separate gas injector. For units with an Ignitor-Injector (P/N 58023), see Kit 58025-04 and TID-0065. Maintenance Kit 58015-04 Contents ITEM 5 ITEM 1...

  • Page 2: Table Of Contents

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Table of Contents INTRODUCTION ......................3 CONTENTS OF KIT 58015-04 ..................3 TOOLS, TEST EQUIPMENT & MATERIALS REQUIRED ..........3 3.1 Tools ........................3 3.2 Test Equipment ......................3 3.3 Materials ........................4 PRELIMINARY INSPECTION PROCEDURES ..............

  • Page 3: Introduction

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C INTRODUCTION This Technical Instruction Document provides the procedures to perform waterside and fireside inspections of the heat exchangers contained in Benchmark 3.0LN and 3.0LN Dual-Fuel Boilers. The replacement parts required to perform the waterside and fireside inspections on the Benchmark 3.0LN and 3.0LN Dual-Fuel Boilers are provided in the 24 - Month Inspection Kit, part number 58015-04, listed and described in section 2.

  • Page 4: Materials

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Materials Expendable materials required to perform the procedures described in this document are not included in the 24 -Month Inspection Kits. These materials may include such items as: • Pipe joint compound •...

  • Page 5: Waterside Inspection Of Benchmark 3.0 Heat Exchanger

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Figure 1. Benchmark 3.0 Low NOx (LN) Boiler WATERSIDE INSPECTION OF BENCHMARK 3.0 HEAT EXCHANGER Benchmark 3.0LN units contain both a primary heat exchanger and a secondary heat exchanger, as shown in Figure 2. Perform the waterside inspection as follows: Ensure that the preliminary set-up and disassembly procedures in section 4 have been performed to provide access to the unit‘s heat exchangers.
  • Page 6 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C EXHAUST MANIFOLD PRIMARY HEAT SECONDARY EXCHANGER HEAT EXCHANGER DRAIN VALVE ACCESS ACCESS PORT PORT Figure 2. Benchmark 3.0LN - (Right Side View) WATER INLET CONNECTION EXHAUST MANIFOLD HOT WATER OUTLET CONNECTION INLET DRAIN...

  • Page 7: Fireside Inspections & Component Replacements

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C FIRESIDE INSPECTIONS & COMPONENT REPLACEMENTS Benchmark 3.0LN heat exchanger fireside inspections include removal of the burner and exhaust manifold assembly from the boiler. In addition, the 24 Month Inspection Kit includes the recommended replacement parts for annual maintenance, which should also be performed at this time.
  • Page 8 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C 10. If there is an extension ring around the burner, remove it. 11. Remove the burner and two (2) burner gaskets by pulling straight up. Figure 6 shows an exploded view of the Benchmark 3.0LN burner assembly. HEAT AIR/FUEL EXCHANGER...

  • Page 9: Burner Reassembly

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C 6.1.2 Burner Reassembly Referring to Figure 6, below, reassemble the burner assembly as described below. The following parts from the kit will be used during this procedure: • Burner Gasket P/N 81030 (2) •...

  • Page 10: Igniter Replacement

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C 3. Place the new burner housing gasket (P/N 81019) on top of the blower, ensuring is positioned correctly in relation to the burner housing’s mounting holes. 4. Position the burner housing on the blower and the burner flange, aligning it with both burner and blower.

  • Page 11: Flame Detector Replacement

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C 6.1.4 Flame Detector Replacement Flame detector (P/N 66034) and gasket (P/N 81048) are used on Benchmark 3.0 Low NOx units. Complete the instructions below to replace these parts. Refer to Figure 7 to locate the flame detector installation location. Install the replacement flame detector and gasket in the location shown.
  • Page 12 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Inspect and clean the exhaust manifold as necessary. Replace the exhaust manifold seal (P/N 49102) with the new seal provided in the kit. Install the adhesive-backed seal in the recess of the exhaust manifold flange (Figure 9) so that the adhesive side is in contact with the exhaust manifold.
  • Page 13 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C EXHAUST MANIFOLD PRIMARY SECONDARY HEAT HEAT EXCHANGER MANIFOLD EXCHANGER MOUNTING BOLTS (3) STARTER SECTION BOLTS (4) FLOAT EXHAUST MANIFOLD ORIFICE ORIFICE GASKET GASKET (81098) VIEW A - A VIEW B - B Figure 8.

  • Page 14: External Condensate Trap Maintenance

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C 6.1.6 External Condensate Trap Maintenance NOTE Benchmark 3.0LN boilers actually contain two condensate traps. One is an integral part of the unit’s exhaust manifold. This trap is inspected and serviced during the exhaust manifold inspection procedures described in section 6.1.2.
  • Page 15 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Figure 10. Condensate Trap P/N 24060 CONNECTING MANIFOLD CONDENSATE TRAP ADAPTER CLAMP FLOOR DRAIN DRAIN PIPE 1" I.D. 3/4" NPT HOSE NIPPLES Figure 11. Connecting Manifold Condensate Drain Location /12/2017 AERCO International, Inc.

  • Page 16: Replacing The Lwco Probe/Capacitor Assembly

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Replacing the LWCO Probe/Capacitor Assembly The replacement LWCO probe sensor comes with a capacitor assembly attached. This procedure replaces an old probe assembly with a new probe assembly (P/N 69126). 1.

  • Page 17: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C LWCO Probe Rear Panel Plastic Acorn Nut Capacitor Assembly (Covered By Large Shrink Tubing) Hot Water Connector Outlet Pipe (to Shell Harness) LWCO Probe Terminal Figure 13: LWCO Probe Location (BMK3000 Shown) 6.3.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger.
  • Page 18 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C 3. Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on left in Figure 15. 4. Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed from the C-More controller) as shown on right in Figure 15.

  • Page 19: Final Reassembly And Testing

    Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C FINAL REASSEMBLY AND TESTING Upon completion of all waterside and fireside inspections, reassemble the unit and perform the tests specified in sections 7.1 and 7.2. Reassembly and Set-Up Following Completion of Inspections Following completion of the all required inspections and replacements, perform the following reassembly and setup procedures: Ensure that the heat exchanger has been filled and the water supply and return valves...
  • Page 20 Benchmark 3.0LN 24-Month Maintenance Kit 58015-04 Technical Instruction Document TID-0135_0C Change Log: Description Changed By Date Rev B: 06/03/2016 Chris Blair DIR 335: Clarified reassembly order in section 6.1.2, added water bubble test to section 7.2 Rev C: 10/12/2017 Chris Blair DIR 335: Changed “Blower Plenum”...

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