Watts AERCO Benchmark OMM-0127 Operation And Maintenance Manual
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Watts AERCO Benchmark OMM-0127 Operation And Maintenance Manual

Natural gas fired modulating & condensing boilers
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Operation and Maintenance Manual
Benchmark
Natural Gas Fired
Modulating & Condensing Boilers
Models 750 through 3000
Other documents for this product include:
OMM-0127, GF-205-K Installation & Startup Manual
TAG-0019, GF-2070 Boiler Application Guide
TAG-0022, GF-2050 Vent-Combustion Air Guide
TAG-0047, GF-2030 Benchmark Gas Guide
TAG-0048, GF-2060 Benchmark Power Guide
Applies to serial number:
G-19-0001 and above
U.S. Patent #: 9,243,848
Korea Patent #: 10-1755141
Disclaimer
The information contained in this manual is subject to change without notice
from AERCO International, Inc. AERCO makes no warranty of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or consequential
damages occurring in connection with the furnishing, performance, or use of
these materials
OMM-0128 • GF-206-K • 5/9/2019
®
Boilers – Korea

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  • Page 1 Operation and Maintenance Manual ® Benchmark Boilers – Korea Natural Gas Fired Modulating & Condensing Boilers Models 750 through 3000 Other documents for this product include: OMM-0127, GF-205-K Installation & Startup Manual TAG-0019, GF-2070 Boiler Application Guide TAG-0022, GF-2050 Vent-Combustion Air Guide TAG-0047, GF-2030 Benchmark Gas Guide TAG-0048, GF-2060 Benchmark Power Guide Applies to serial number:...

  • Page 2: Table Of Contents

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA CONTENTS TABLE OF CONTENTS FOREWORD ...................... 5 SECTION 1: SAFETY PRECAUTIONS ..............9 1.1 WARNINGS & CAUTIONS ........................9 1.2 EMERGENCY SHUTDOWN ......................... 10 1.3 PROLONGED SHUTDOWN ......................... 10 SECTION 2: OPERATION ................. 11 2.1 INTRODUCTION ...........................
  • Page 3 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA CONTENTS 4.4 O SENSOR 43 4.5 SAFETY DEVICE TESTING ......................... 44 4.6 BURNER INSPECTION ........................44 4.6.1 BMK 750/1000 BURNER INSPECTION ......................44 4.6.2 BMK 1500 – 3000 BURNER INSPECTION ......................47 4.7 CONDENSATE DRAIN TRAP ......................
  • Page 4 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA CONTENTS (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 4 of 146...

  • Page 5: Foreword

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA FORWARD FOREWORD The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas 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 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING A (Amp) Ampere AERCO Control System, AERCO’s boiler management systems ADDR Address AGND Analog Ground ALRM Alarm ANSI American National Standards Institute, ASME American Society of Mechanical Engineers Auxiliary Building Automation System, often used interchangeably with EMS (see below)
  • Page 7 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Header Hexadecimal Number (0 – 9, A – F) Horse Power Heat Exchanger Hertz (Cycles Per Second) I.D. Inside Diameter Ignition IGST Board Ignition/Stepper Board, contained in the C-More Controller INTLK (INTL’K) Interlock Input/Output...
  • Page 8 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref) Reference RES.

  • Page 9: Section 1: Safety Precautions

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION SECTION 1: SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.

  • Page 10: Emergency Shutdown

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 1.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit. NOTE: The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

  • Page 11: Section 2: Operation

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION SECTION 2: OPERATION 2.1 INTRODUCTION The information in this section provides a guide to the operation of the Benchmark Boiler using the C-More Controller mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel.

  • Page 12: C-More Controller Description

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.2 C-MORE CONTROLLER DESCRIPTION All Benchmark boilers utilize the C-More Controller shown in Figure 2-1. It contains all of the controls, indicators and displays necessary to operate, adjust and troubleshoot the boiler. These operating controls, indicators and displays are listed and described in Table 2-1.
  • Page 13 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION TABLE 2-1: Controls, Indicators, and Displays (ref. Figure 2-1) CONTROL, INDICATOR ITEM FUNCTION or DISPLAY LED STATUS INDICATORS Four Status LEDs indicate the current operating status as follows: COMM = Lights when RS232 communication is occurring –...
  • Page 14 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION TABLE 2-1: Controls, Indicators, and Displays (ref. Figure 2-1) CONTROL, INDICATOR ITEM FUNCTION or DISPLAY MENU KEYPAD Six (6) keys which provide the following functions for the C-More Controller menus: Steps through the main menu categories shown in Figure 2-2.

  • Page 15: C-More Controller Menus

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.3 C-MORE CONTROLLER MENUS The C-More Controller incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of five major menu categories which are applicable to this manual.
  • Page 16 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION * Only if BST (Boiler Sequencing Technology) is enabled. BST is described in detail in Section 6 of the Benchmark 750 – 3000 Boiler Installation and Startup Guide, OMM-0127 (GF-205-K). Figure 2-2: Menu Structure NOTE: The following sections provide brief descriptions of the options contained in each menu.

  • Page 17: Operating Menu

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.4 OPERATING Menu The Operating menu displays a number of key operating parameters for the unit. All items in this menu except O2 Monitor (item 15) are “Read-Only” and cannot be changed. This menu can be accessed without entering a password.

  • Page 18: Setup Menu

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.5 SETUP Menu The Setup menu permits the operator to enter the unit password (159) which is required to change the menu options. To prevent unauthorized use, the password will time-out after 1 hour. Therefore, the correct password must be reentered when required.

  • Page 19: Configuration Menu

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.6 CONFIGURATION Menu The Configuration menu permits adjustment of the Internal Setpoint (Setpt) temperature regardless of whether the valid password has been entered. Setpt is required for operation in the CONSTANT SETPOINT mode.
  • Page 20 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION TABLE 2-4: CONFIGURATION Menu AVAILABLE CHOICES OR LIMITS MENU ITEM DISPLAY DEFAULT Minimum Maximum Setpt Hi Limit Setpt Lo Limit 210°F (98.9°C) 180°F (82.2°C) Temp Hi Limit 40°F (4.4° 210°F (98.9°...

  • Page 21: Tuning Menu

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.7 TUNING Menu The Tuning menu items are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by factory-trained personnel. A full description of each item appears in Appendix A-4.

  • Page 22: Bmk 1500/2000 Combustion Cal Menus

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.8.2 BMK 1500/2000 COMBUSTION CAL Menus TABLE 2-7: COMBUSTION CAL Menu: BMK 1500/2000 DEFAULTS MENU ITEM DISPLAY MINIMUM MAXIMUM BMK 1500 BMK 2000 CAL Voltage 16% 1.80 – 0.25 10.00 CAL Voltage 18%...

  • Page 23: Bst (Boiler Sequencing Technology) Menu

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.9 BST (Boiler Sequencing Technology) Menu The BST menu must be enabled in order to be displayed and accessed. The BST Menu item, located at the end of the Configuration menu (item 37 in Table 2-4), must be set to Enabled. The BST menu contains all of the items required to configure, operate and monitor the functionality of the BST System.
  • Page 24 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION TABLE 2-9: BST Menu AVAILABLE CHOICES OR LIMITS MENU ITEM DISPLAY DEFAULT Minimum Maximum Head Temp Source Network FFWD Temp FFWD Temp Mdbus Temp Units Degrees C or Degrees F Degrees C Header Temp Addr Header Temp Point...
  • Page 25 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION TABLE 2-9: BST Menu AVAILABLE CHOICES OR LIMITS MENU ITEM DISPLAY DEFAULT Minimum Maximum BST Setpt Lo Limit 40°F (4.4°C) BST Setpt HI Limit 60°F (15.5°C) BST Setpt HI Limit BST Setpt Lo Limit 220°F (104.4°C) 195°F (90.6°C)

  • Page 26: Calibration Menu

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION 2.10 CALIBRATION MENU The Calibration menu is used by factory trained service personnel to adjust or reset the parameters listed below. A full description of each item appears in Appendix A-6. TABLE 2-10: Calibration Menu AVAILABLE CHOICES OR LIMITS MENU ITEM DISPLAY...
  • Page 27 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION TABLE 2-10: Calibration Menu AVAILABLE CHOICES OR LIMITS MENU ITEM DISPLAY DEFAULT Minimum Maximum Gas Press Reset Automatic or Manual Manual Min Off Time 0 Min 15 Min 1 Min Heatr Tuning Dsp Enabled or Disabled...
  • Page 28 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 2: OPERATION (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 28 of 146...

  • Page 29: Section 3: Modes Of Operation

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION SECTION 3: MODES OF OPERATION 3.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The following sections provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation.

  • Page 30: Indoor/Outdoor Startup

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION 3.2.4 Indoor/Outdoor Startup Startup in the INDOOR/OUTDOOR RESET mode is accomplished as follows: NOTE: A design engineer typically provides design outdoor air temperature and supply header temperature data.

  • Page 31: Setting The Setpoint

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION 3.3.1 Setting the Setpoint The setpoint temperature of the unit is adjustable from 40°F to 240°F (4.4°C to 115.6°C). To set the unit for operation in the CONSTANT SETPOINT mode, you must set menu items Internal Setpt and Boiler Mode in the Configuration menu as follows: TABLE 3-1: Constant Setpoint Mode Settings MENU OPTION...

  • Page 32: Remote Setpoint Field Wiring

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be entered in the Setup menu. Refer to Modbus Communication Manual GF-114 for additional information.

  • Page 33: Direct Drive Field Wiring

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION NOTE: If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the CPU Board located in the C-More Controller. Contact your local AERCO representative for details.

  • Page 34: Aerco Control System (Acs)

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION 3.6 AERCO CONTROL SYSTEM (ACS) NOTE: ACS is for installations with 9 or more boilers. It utilizes only RS-485 signaling to the boiler. Installations with 1 to 8 boilers can use Boiler Sequencing Technology (BST), as described in Section 6 of the Benchmark 750 –...

  • Page 35: Combination Control System (Ccs)

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION 3.7 COMBINATION CONTROL SYSTEM (CCS) NOTE: Only ACS can be utilized for the Combination Control System. A Combination Control System (CCS) is one that uses multiple boilers to cover both space- heating and domestic hot water needs.

  • Page 36: Combination Control System Field Wiring

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 3 – MODES OF OPERATION 3.7.1 Combination Control System Field Wiring Wiring for this system is between the ACS, the ACS Relay Box, and the terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above.

  • Page 37: Section 4: Maintenance

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE SECTION 4: Maintenance 4.1 MAINTENANCE SCHEDULE All Benchmark boilers require regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 4-1.

  • Page 38: Igniter-Injector

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.2 IGNITER-INJECTOR The igniter-injector (Kit P/N 58023) is located on the burner plate at the top of the boiler. In addition to providing the ignition spark required to light the burner, the igniter-injector also contains a gas injector tube which connects to the staged ignition assembly.
  • Page 39 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE BLOWER A/F VALVE BLOWER PLENUM PLENUM IGNITER- INJECTOR ASSEMBLY BLOCKED INLET SWITCH LEAN O SENSOR AIR/FUEL FLAME VALVE PLENUM FLANGE/ DETECTOR BURNER TOP PLATE FLAME BURNER OBSERVATION PORT Figure 4-1b: BMK 1500/2000 Burner Assembly BLOWER...
  • Page 40 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE The igniter-injector may be hot, therefore, care should be exercised to avoid burns. It is easier to remove the igniter-injector from the unit after the unit has cooled to room temperature. To inspect/replace the Igniter: Igniter-Injector Maintenance Procedure Instructions 1.
  • Page 41 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE Igniter-Injector Maintenance Procedure Instructions STAGED IGNITION COMPRESSION SOLENOID FITTING & ELBOW FLAME DETECTOR & BLOWER PLENUM GASKET O2 SENSOR FLEX GAS & WASHER HOSE NIPPLE FLAME OBSERVATION INJECTOR-IGNITOR PORT ASSY WITH INDEXING...
  • Page 42 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE Igniter-Injector Maintenance Procedure Instructions BLOWER POSITION BURNER PLATE INJECTOR TUBE INSIDE THIS ARC INJECTOR TUBE IGNITER-INJECTOR Figure 4-3a: BMK 750/1000 Igniter-Injector Orientation POSITION INJECTOR TUBE INJECTOR TUBE INSIDE THIS ARC IGNITER-INJECTOR FLAME...

  • Page 43: Flame Detector

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.3 FLAME DETECTOR The flame detector (kit P/N 24356-1) is located on the burner plate at the top of the unit (see Figure 4-1a through 4-1c and 4-2a through 4-2c). The flame detector may be hot. Allow the unit to cool sufficiently before removing the flame detector.

  • Page 44: Safety Device Testing

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1, require that these tests be performed on a scheduled basis.
  • Page 45 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE BMK 750/1000 Burner Inspection Instructions REAR FRONT BLOWER BURNER PLATE 3/16”–16 HEX NUTS (8) BLOWER PROOF SWITCH IGNITER-INJECTOR BLOCKED INLET STAGED IGNITION SWITCH ASSEMBLY 1/2" BOLTS & NUTS (4) (GAS TRAIN-to-A/F AIR FILTER VALVE)
  • Page 46 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE BMK 750/1000 Burner Inspection Instructions 9. Disconnect the unit wiring harness connectors from the air/fuel valve and blower motor. 10. Disconnect the wire leads connected to the Blower Proof switch and Blocked Inlet switch (Figure 4-4a and Figure 4-4b).

  • Page 47: Bmk 1500 - 3000 Burner Inspection

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.6.2 BMK 1500 – 3000 BURNER INSPECTION The following parts are required for reassembly after burner inspection: Burner Inspection Parts Part No. Description BMK 1500/2000 BMK 2500/3000 81183 Burner Upper Release Gasket 81173...
  • Page 48 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE BMK 1500-3000 Burner Inspection Instructions BLOWER 5/16” x 1-3/4” BOLTS, 5/16” PLENUM WASHERS & NYLOCK NUTS (4 each) BLOWER 3/8”-16 HEX NUTS A/F VALVE PLENUM (8 each) BLOWER PROOF SWITCH GAS INLET PIPE...
  • Page 49 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE BMK 1500-3000 Burner Inspection Instructions BLOWER PLENUM 5/16” x 1-3/4” BOLTS, 3/8”-16 5/16” WASHERS & HEX NUTS NYLOCK NUTS (8 each) (4 each) BLOWER GAS INLET PIPE A/F VALVE PLENUM BLOWER...
  • Page 50 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE BMK 1500-3000 Burner Inspection Instructions 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. 11.

  • Page 51: Condensate Drain Trap

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.7 CONDENSATE DRAIN TRAP Benchmark boilers contain a condensate trap (P/N 24441), located external to the unit and attached to the drain connection from the exhaust manifold at the rear of the unit (shown in Figure 2-6a and 2-6b of the Benchmark 750 –...

  • Page 52: Air Filter Cleaning And Replacement

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.8 AIR FILTER CLEANING and REPLACEMENT The Benchmark boiler is equipped with an air filter which should be cleaned and re-oiled every 12 months and replaced every 24 months. The air filter is located at the air fuel valve inlet, as shown in Figure 4-8.

  • Page 53: Water Cutoff (Lwco) Capacitor Integrity Test

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE Air Filter Cleaning and Replacement Instructions 5. The filter may be cleaned in hot soapy water to remove oil and dirt. It should then be thoroughly dried and then sprayed with a light coating of K&N® Air Filter Oil (or equivalent specifically formulated for air filters) prior to reinstallation.

  • Page 54: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.9.1 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. Perform the capacitor electrical short test as described below. Low Water Cutoff –...

  • Page 55: Low Water Cutoff (Lwco) - Standard C-More Test

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.9.2 Low Water Cutoff (LWCO) - Standard C-More Test Perform the standard Low Water Cutoff test using the C-More controls as described below. Low Water Cutoff (LWCO) - Standard C-More Test Instructions 1.

  • Page 56: Placing The Boiler Back In Service After Aprolonged Shutdown

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 4 – MAINTENANCE 4.11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown (one year or more), the following procedures must be followed: Placing The Boiler Back In Service After A Prolonged Shutdown Instructions 1.

  • Page 57: Section 5: Troubleshooting Guide

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE SECTION 5: TROUBLESHOOTING GUIDE 5.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in Benchmark 750 through 3000 boilers. The troubleshooting procedures contained herein are presented in tabular form on the following pages.
  • Page 58 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 58 of 146...
  • Page 59 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Blower stopped running due to thermal or Check combustion blower for signs of excessive heat or high current overload.
  • Page 60 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Blower not running or running too slow. Start the unit. If the blower does not run check the blower solid state relay for input and output voltage.
  • Page 61 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Delayed Interlock Jumper not properly installed Check to insure jumper is properly installed across the delayed or missing.
  • Page 62 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Worn Flame Detector or cracked ceramic. Remove and inspect the Flame Detector for signs of wear or cracked ceramic.
  • Page 63 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Faulty Water temperature switch. Test the temperature switch to insure it trips at its actual water temperature setting.
  • Page 64 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Air/Fuel Valve not rotating. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position.
  • Page 65 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Interlock jumper not installed or removed. Check for a jumper properly installed across the interlock terminals in the I/O box.
  • Page 66 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication A/F Valve rotated open to purge and did not Start the unit. The Air/Fuel Valve should rotate to the purge (open) PRG SWTCH rotate to ignition position.
  • Page 67 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication Combustion Calibration incorrect. Check Combustion Analyzer and recalibrate the boiler. O2 % OUT OF Blocked inlet air duct or louver. Unblock air inlet and measure open area for combustion air to the RANGE room.
  • Page 68 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE TABLE 5-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Indication SSOV relay failed on IGST board. Press CLEAR button and restart unit. If fault persists, replace Ignition/Stepper (IGST) Board.

  • Page 69: Additional Faults Without Specific Fault Messages

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE 5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 5-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 5-2: Boiler Troubleshooting With No Fault Message Displayed Observed Incident Probable Causes Corrective Action...
  • Page 70 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA SECTION 5 – TROUBLESHOOTING GUIDE DAMPING ORIFICE BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 5-1: SSOV Actuator With Gas Pressure Adjustment (SKP25) OMM-0128 • GF-206-K •...

  • Page 71: Appendix A: Boiler Menu Item Descriptions

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION Appendix A: BOILER MENU ITEM DESCRIPTIONS TABLE A-1: Operating Menu Item Descriptions See Section 2-4 OPERATING Menu for a range of choices and the default values. TABLE A-1: OPERATING Menu Item Descriptions MENU OPTIONS DESCRIPTION...
  • Page 72 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-1: OPERATING Menu Item Descriptions MENU OPTIONS DESCRIPTION Fault Log Displays information on the last 20 faults. 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.
  • Page 73 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-2: Setup Menu Item Descriptions See Section 2-5 SETUP Menu for a range of choices and the default values. TABLE A-2: SETUP Menu Item Descriptions MENU OPTIONS DESCRIPTION Allows Level 1 or Level 2 password to be entered.
  • Page 74 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-3: Configuration Menu Item Descriptions See Section 2-6 CONFIGURATION Menu for a range of choices and the default values. The Configuration menu settings are Factory-Set in accordance with the requirements specified with each individual order.
  • Page 75 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-3: CONFIGURATION Menu Item Descriptions MENU OPTIONS DESCRIPTION This is the maximum allowable outlet temperature, up to 210°F (98.9 . Any temperature above this setting will turn off the °C) Temp Hi Limit unit.
  • Page 76 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-3: CONFIGURATION Menu Item Descriptions MENU OPTIONS DESCRIPTION Deadband High and Deadband Low settings create an “Outlet Temperature” Zone in which no Valve Position corrections will be attempted.
  • Page 77 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-4: Tuning Menu Item Descriptions See Section 2-7 TUNING Menu for a range of choices and the default values. TABLE A-4: TUNING Menu Item Descriptions MENU OPTIONS DESCRIPTION Generates a fire rate based on the error that exists between...
  • Page 78 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-5: Combustion Calibration Menu Item Descriptions See Section 2-8 COMBUSTION CAL Menu for a range of choices and the default values. NOTE: The Level 2 Password must be entered to view the options in the Combustion Cal menu. This Menu is used during the Combustion Calibration procedures described in Section 4-3 of the Benchmark 750 –...
  • Page 79 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-6: Calibration Menu Item Descriptions See Section 2-10 CALIBRATION Menu for a range of choices and the default values. TABLE A-6: CALIBRATION Menu Item Descriptions MENU OPTION DESCRIPTION Allows the Air/Fuel Valve stepper motor feedback current to be...
  • Page 80 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-6: CALIBRATION Menu Item Descriptions MENU OPTION DESCRIPTION In Adj -5.0% to +5.0% in 0.1 % increments. Allows adjustment of the Gas Plate dp level from -5.0% to +5.0% Gas Plate dp In Adj in 0.1% increments.
  • Page 81 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION TABLE A-6: CALIBRATION Menu Item Descriptions MENU OPTION DESCRIPTION – Outdr Air Offset Range: -20 to + 20 (either ºF or °C) – Inlet Air Offset Range: -20 to + 20 (either ºF or °C) –...
  • Page 82 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX A: BOILER MENU DESCRIPTION (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 82 of 146...

  • Page 83: Appendix B: Startup, Status, & Fault Messages

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES Appendix B: STARTUP, STATUS, & FAULT MESSAGES Startup and Status Messages TABLE B-1: Startup and Status Messages MESSAGE DESCRIPTION DEMAND DELAY Displayed if Demand Delay is active. XX sec DISABLED Displayed if ON/OFF switch is set to OFF.

  • Page 84: Fault Messages

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES Fault Messages TABLE B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT The Blower Proof switch opened during purge, or air inlet is blocked. DURING PURGE AIRFLOW FAULT The Blower Proof switch opened during ignition.
  • Page 85 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES TABLE B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION % OUT OF RANGE % has gone below 3% or above 8%. OUTDOOR TEMP The temperature measured by the Outdoor Air Sensor is out of range.
  • Page 86 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 86 of 146...

  • Page 87: Appendix C: Sensor Resistance/Voltage Chart

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART Appendix C: SENSOR RESISTANCE/VOLTAGE CHART TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART (BALCO) TEMPERATURE RES (OHMS) VOLTS* °F °C 779.0 1.93 -34.4 797.5 1.96 -28.9 816.3 1.99 -23.3 835.4 2.02...
  • Page 88 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 88 of 146...

  • Page 89: Appendix D: Recommended Periodic Testing

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX D – RECOMMENDED PERIODIC TESTING Appendix D: RECOMMENDED PERIODIC TESTING WARNING! Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage.
  • Page 90 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX D – RECOMMENDED PERIODIC TESTING Recommended Periodic Testing ITEM FREQUENCY ACTION BY REMARKS See Section 5.4 in the Benchmark 750 – Low water level cut Weekly Operator 3000 Boiler Installation and Startup Guide off and alarm Guide, OMM-0127 (GF-205-K).

  • Page 91: Appendix E: Indoor/Outdoor Reset Ratio Charts

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS Appendix E: INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature = 50°F (10.0°C) AIR TEMP RESET RATIO °F °C 10.0 -1.1 -3.9 -6.7 -9.4 -12.2...
  • Page 92 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature = 65°F (18.3°C) AIR TEMP RESET RATIO °F °C 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6...
  • Page 93 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature = 75°F (23.9°C) AIR TEMP RESET RATIO °F °C 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0...
  • Page 94 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature = 90°F (32.2°C) AIR TEMP 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...

  • Page 95: Appendix F: Benchmark 750/1000 Part List

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LIST Appendix F: BENCHMARK 750/1000 PART LIST Benchmark 750 and Benchmark 1000 Part List Item # Qty Part # Description TERMINAL BLOCK: DIN MOUNTED: 65121 EXHAUST MANIFOLD TERMINAL GROUND BLOCK: DIN 65122...
  • Page 96 Description 30 PSI 50 PSI 75 PSI 100 PSI 150 PSI 60 PSI 125 PSI 160 PSI Number Apollo Conbraco Apollo Watts Watts Watts Watts Kunkle 24286 6” Exhaust Kit 24441 Condensate Trap Assy. 92006-5 1” Ball Valve 123675-2 Tridicator...
  • Page 97 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LISTS Benchmark 750/1000 Gas Trains LEFT-REAR VIEW FRONT VIEW RIGHT-REAR VIEW Benchmark 750/1000 Part List 09/28/2017 AERCO International, Inc. Blauvelt, NY Benchmark 750 P/N 28321-TAB rev F 10913 Sheet 3 of 6 Benchmark 1000 P/N 28253-TAB rev F...
  • Page 98 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LISTS Benchmark 750/1000 Burner – Air/Fuel Valve Assembly P/N 24276-TAB Full Diagram Below Benchmark 750/1000 Part List 09/28/2017 AERCO International, Inc. Blauvelt, NY Benchmark 750 P/N 28321-TAB rev F 10913 Sheet 4 of 6 Benchmark 1000 P/N 28253-TAB rev F...
  • Page 99 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LISTS Benchmark 750/1000 Part List 09/28/2017 AERCO International, Inc. Blauvelt, NY Benchmark 750 P/N 28321-TAB rev F 10913 Sheet 5 of 6 Benchmark 1000 P/N 28253-TAB rev F OMM-0128 •...
  • Page 100 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LISTS TOP VIEW REAR VIEW LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW Benchmark 750/1000 Part List 09/28/2017 AERCO International, Inc. Blauvelt, NY Benchmark 750 P/N 28321-TAB rev F 10913 Sheet 6 of 6 Benchmark 1000 P/N 28253-TAB rev F...
  • Page 101 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LISTS Benchmark 750/1000 FM Gas Train – P/N 22140-1 Item Qty Part # Description Item Part # Description 95026 1.25"NPT 125#: THREADED FLANGE 92006-5 VALVE: BALL 1" NPT 92036 VALVE: SSOV 1"...
  • Page 102 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX F – BENCHMARK 750/1000 PART LISTS Benchmark 750/1000 Burner, Blower, Air/Fuel Valve Assy. – P/N 24276-TAB Item Qty Part # Description Item Part # Description 42140 PLATE: BURNER 53033 WASHER: CLOCKING 81143 GASKET: BURNER 46026...

  • Page 103: Appendix G: Benchmark 1500/2000 Part List

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LIST Appendix G: BENCHMARK 1500/2000 PART LIST Benchmark 1500 and Benchmark 2000 Part List Item # Qty Part # Description TERMINAL GROUND BLOCK: DIN 65122 MOUNTED EXHAUST MANIFOLD 65118...
  • Page 104 58088-C150 150 PSI (1034 kPa) KIT (CONBRACO) 92023-7 123675-7 58087-7 125 PSI (862 kPa) 123620-W125 123675-6 58088-W30 30 PSI (207 kPa) KIT (WATTS) 92023-8 123675-5 58087-8 160 PSI (1103 kPa) 123620-K160 123675-7 58088-W50 50 PSI (345 kPa) KIT (WATTS) 92023-9...
  • Page 105 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS Benchmark 1500/2000 Part List 10/02/2017 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 3 of 7 Benchmark 2000 29337-TAB rev G OMM-0128 •...
  • Page 106 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS Benchmark 1500/2000 Burner-Air/Fuel Valve Assembly P/N 24378 & 24378-1 Full part lists below Benchmark 1500/2000 Part List 10/02/2017 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 4 of 7 Benchmark 2000 29337-TAB rev G...
  • Page 107 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS Benchmark 1500/2000 Gas Train P/N 22240 See full part lists below YELLOW RUN LIGHT 1. OFF during normal operation 2. ON during valve proving operation 3.
  • Page 108 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS REAR VIEW TOP VIEW FRONT VIEW LEFT SIDE VIEW Benchmark 1500/2000 Part List 10/02/2017 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 6 of 7 Benchmark 2000 29337-TAB rev G OMM-0128 •...
  • Page 109 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS Benchmark 1500/2000 Part List 10/02/2017 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 7 of 7 Benchmark 2000 29337-TAB rev G OMM-0128 •...
  • Page 110 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS Benchmark 1500/2000 Natural Gas Gas Train – 22240 Item Qty Part # Description Item Part # Description 123542 FLANGE 2" 125# 2" NPT 92077 1/4"...
  • Page 111 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS AERCO Benchmark 1500/2000 Gas Train 04/17/2017 International, Inc. P/N 22240 rev D Blauvelt, NY 10913 Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support •...
  • Page 112 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX G – BENCHMARK 1500/2000 PART LISTS Benchmark 1500/2000 Burner Assembly – P/N 24378-TAB Item Qty Part # Description Item Qty Part # Description 69078 BLOWER: AMETEK 12.3" 81166 BURNER GASKET 43090 AIR FUEL VALVE PLENUM 66026...

  • Page 113: Appendix H: Benchmark 2500/3000 Part List

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Appendix H: BENCHMARK 2500/3000 PART LIST Benchmark 2500 and Benchmark 3000 Part List Item # Qty Part # Description 65120 TERMINAL BLOCK: DIN MOUNTED: BLK 65121 TERMINAL BLOCK: DIN MOUNTED: WHT EXHAUST MANIFOLD...
  • Page 114 125 PSI (862 kPa) KIT (CONBRACO) 92016-6 123675-6 58048-C150 150 PSI (1034 kPa) KIT (CONBRACO) 92016-7 123675-7 24441 123540 58048-W50 50 PSI (345 kPa) KIT (WATTS) 92016-8 123675-5 58048-W60 60 PSI (414 kPa) KIT (WATTS) 92016-9 123675-6 58048-W75 75 PSI (517 kPa) KIT (WATTS) 92016-10...
  • Page 115 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500/3000 Part List 10/09/2017 AERCO International, Inc. Benchmark 2500 28536-TAB rev E Blauvelt, NY 10913 Sheet 3 of 8 Benchmark 3000 28382-TAB rev F OMM-0128 •...
  • Page 116 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 Gas train P/N 22244 Full part lists below Benchmark 3000 Gas train P/N 22215 Full part lists below Benchmark 2500/3000 Part List 10/09/2017 AERCO International, Inc.
  • Page 117 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST The Benchmark 2500 and 3000 gas trains (P/N 22244 and 22215) contain a Valve Proving device (P/N 24629-2). This device monitors the gas pressure on both sides of the Actuator. If the pressure difference falls below a fixed value, indicating the failure of the Actuator or leakage in the gas line, it triggers the shutdown of the boiler.
  • Page 118 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500/3000 Burner - Air/Fuel Valve Assembly P/N 26015-TAB & 26014-TAB Full part lists below Benchmark 2500/3000 Part List 10/09/2017 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 6 of 8...
  • Page 119 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST REAR VIEW TOP VIEW LEFT SIDE VIEW FRONT VIEW Benchmark 2500/3000 Part List 10/09/2017 AERCO International, Inc. Benchmark 2500 28536-TAB rev E Blauvelt, NY 10913 Sheet 7 of 8 Benchmark 3000 28382-TAB rev F OMM-0128 •...
  • Page 120 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST PARTIAL FRONT VIEW – FRONT PANEL REMOVED Benchmark 2500/3000 Part List 10/09/2017 AERCO International, Inc. Benchmark 2500 28536-TAB rev E Blauvelt, NY 10913 Sheet 8 of 8 Benchmark 3000 28382-TAB rev F OMM-0128 •...
  • Page 121 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 Natural Gas Gas Train – P/N 22244 Item Qty Part # Description Item Qty Part # Description 123542 FLANGE 2" 125# 2" NPT 63063 RELAY 64048...
  • Page 122 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST AERCO Benchmark 2500 Gas Train 04/17/2017 International, Inc. P/N 22244 rev F Blauvelt, NY 10913 Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support •...
  • Page 123 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 3000 Natural Gas Gas Train – P/N 22215 Item Qty Part # Description Item Qty Part # Description 123542 FLANGE 2" 125# 2 “NPT 123540 VALVE: BALL 2"...
  • Page 124 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST AERCO Benchmark 3000 Gas Train 04/17/2017 International, Inc. P/N 22215 rev H Blauvelt, NY 10913 Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support •...
  • Page 125 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST Burner Assembly: BMK 2500 P/N 26015-TAB, BMK 3000 P/N 26014-TAB Item Qty Part # Description Item Qty Part # Description 43091 BLOWER PLENUM (MACHINING) 60011-5 BLOWER PROOF SWITCH, BMK 2500 460 VAC BLOWER Replacement Kit...
  • Page 126 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX H – BENCHMARK 2500/3000 PART LIST (This page intentionally blank) OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 126 of 146...

  • Page 127: Appendix I: Wiring Diagrams

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Appendix I: WIRING DIAGRAMS Benchmark 750/1000 – Drawing Number: 68038 rev H Sheet 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 127 of 146...
  • Page 128 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 750/1000 – Drawing Number: 68038 rev H Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 128 of 146...
  • Page 129 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 – Drawing Number 68050 rev D page 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 129 of 146...
  • Page 130 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 – Drawing Number 68050 rev D page 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 130 of 146...
  • Page 131 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 DBB – Drawing Number 68071 rev D page 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 131 of 146...
  • Page 132 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 1500/2000 DBB – Drawing Number 68071 rev D page 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 132 of 146...
  • Page 133 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 3000 208 VAC – Diagram 68040 rev G, Sheet 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 133 of 146...
  • Page 134 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 3000 208 VAC – Drawing Number: 68040 rev G, Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 134 of 146...
  • Page 135 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 3000 460 VAC – Drawing Number: 68041 rev G Sheet 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 135 of 146...
  • Page 136 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 3000 460 VAC – Drawing Number: 68041 rev G Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 136 of 146...
  • Page 137 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 2500 208 VAC – Drawing Number: 68060 rev D Sheet 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 137 of 146...
  • Page 138 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 2500 208 VAC – Drawing Number: 68060 rev D Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 138 of 146...
  • Page 139 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 208 VAC DBB – Drawing Number: 68062 rev D Sheet 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 139 of 146...
  • Page 140 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 208 VAC DBB – Drawing Number: 68062 rev D Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 140 of 146...
  • Page 141 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 460 VAC DBB – Drawing Number: 68063 rev C Sheet 1 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 141 of 146...
  • Page 142 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX I – WIRING DIAGRAMS Benchmark 2500/3000 460 VAC DBB – Drawing Number: 68063 rev C Sheet 2 of 2 OMM-0128 • GF-206-K • 5/9/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 142 of 146...

  • Page 143: Appendix J: C-More Controller Views

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX J – C-MORE CONTROLLER VIEWS Appendix J: C-MORE CONTROLLER VIEWS CONNECTOR BOARD P/N 124366 LOW WATER CUTOFF BOARD P/N 124363 PMC BOARD P/N 124364 DISPLAY BOARD P/N 124365 GREEN LED P/N 124948 ENCLOSURE P/N 124951...
  • Page 144 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX J – C-MORE CONTROLLER VIEWS INTERLOCK HARNESS CONNECTOR (16 PIN) TO INPUT/OUTPUT (I/O) BOX SHELL HARNESS CONNECTOR (19 PIN) GAS TRAIN HARNESS CONNECTOR (9 PIN) A/F VALVE HARNESS CONNECTOR (16 PIN) EXT.

  • Page 145: Appendix K: Recommended Spares

    Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA APPENDIX K – RECOMMENDED SPARE PARTS Appendix K: RECOMMENDED SPARES NOTE: Refer to the Parts List Illustrations in Appendix F – H for the locations of the recommended and optional spare parts listed in the following tables. TABLE K-1: Recommended Emergency Spare Parts DESCRIPTION BMK 750/1000...
  • Page 146 Benchmark 750-3000 Boiler Operation & Maintenance Manual - KOREA Change Log: Date Description Changed By Rev C: DIR 17-070: Removed manufacturer name from high gas pressure switch 11/29/2017 PIR 1459: Updated enclosure panels in Appendix F, H and H. Chris Blair (reference 17-076) DIR 17-080: Verified and corrected part numbers in Appendix F through G.

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