Watts AERCO Benchmark BMK 1500DF User Manual
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Watts AERCO Benchmark BMK 1500DF User Manual

Natural gas, propane gas, or dual fuel fired modulating, condensing boilers
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Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America
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
Initial Release: 01/02/2018
OMM-0132_A
GF-206-LA
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-0131 (GF-205-LA)
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-LA
,
:
(NG/P)
Page 1 of 162
01/02/2018

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  • Page 1 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America GF-206-LA USER MANUAL (2 of 2) 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 SEE ALSO: Benchmark Installation and Startup Guide OMM-0131 (GF-205-LA) APPLIES TO MODELS:...

  • Page 2: Table Of Contents

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America CONTENTS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018 GF-206-LA-LA...

  • Page 5: Foreword

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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. All these models, under standard calibration, meet 20 parts per million (ppm) NOx requirements, and the Benchmark 750 through 2000 are capable of complying with the U.S.’s most stringent NOx requirements of 9 ppm.
  • Page 6 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 1: SAFETY PRECAUTIONS 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 Operation, Service & Maintenance Guide-Latin America SECTION 1: SAFETY PRECAUTIONS 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION 2.2 C-MORE CONTROLLER DESCRIPTION All Benchmark boilers utilize the C-More Controller shown in Figure 2-1. This panel 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION * Only if BST (Boilier Sequencing Technology) is enabled. BST is described in detail in Section 6 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0131 (GF-205-LA). 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION TABLE 2-4: CONFIGURATION Menu AVAILABLE CHOICES OR LIMIT 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION 2.8.2 BMK 1500/2000 COMBUSTION CAL Menus TABLE 2-7a: COMBUSTION CAL Menu: BMK 1500/2000 SINGLE FUEL – NATURAL GAS DEFAULT MENU ITEM DISPLAY MINIMUM MAXIMUM BMK 1500 BMK 2000 CAL Voltage 16% 1.80 –...

  • Page 23: Bmk 2500/3000 Combustion Cal Menus

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION 2.8.3 BMK 2500/3000 COMBUSTION CAL Menus TABLE 2-8a: COMBUSTION CAL Menu: BMK 2500/3000 SINGLE FUEL – NATURAL GAS DEFAULT MENU ITEM DISPLAY MINIMUM MAXIMUM BMK 2500 BMK 3000 CAL Voltage 16% 2.20 –...

  • Page 24: Bst (Boiler Sequencing Technology) Menu

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 25 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION TABLE 2-9: BST Menu AVAILABLE CHOICES OR LIMIT MENU ITEM DISPLAY DEFAULT Minimum Maximum Header Temp Addr Header Temp Point BST Outdoor Sens Disabled Enabled Disabled Outdr Tmp Source Outdoor Temp Network Outdoor Temp...
  • Page 26 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION TABLE 2-9: BST Menu AVAILABLE CHOICES OR LIMIT MENU ITEM DISPLAY DEFAULT Minimum Maximum BST Deadband Hi BST Deadband Lo Deadband En Time 120 Sec 30 Sec BST FR Up Rate BST Bldg Ref Tmp 40°F (4.4°C) 230°F (110°C)

  • Page 27: Calibration Menu

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 LIMIT MENU ITEM DISPLAY...
  • Page 28 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 2: OPERATION TABLE 2-10: CALIBRATION Menu AVAILABLE CHOICES OR LIMIT MENU ITEM DISPLAY DEFAULT Minimum Maximum A/F Sensitivity Power Reset Automatic or Manual Automatic Water Temp Reset Automatic or Manual Automatic Gas Press Reset Automatic or Manual Manual...

  • Page 29: Section 3: Modes Of Operation

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 (Removed from Boiler) BLOWER A/F VALVE...
  • Page 40 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE Igniter-Injector Maintenance Procedure Instructions STAGED IGNITION COMPRESSION SOLENOID FITTING & ELBOW FLAME BLOWER DETECTOR & GASKET PLENUM O2 SENSOR FLEX GAS & WASHER HOSE NIPPLE FLAME OBSERVATION INJECTOR-IGNITOR PORT ASSY WITH INDEXING (CLOCKING) WASHERS...
  • Page 42 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 DETECTOR...

  • Page 43: Flame Detector

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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, above). 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE BMK 750/1000 Burner Inspection Instructions FRONT REAR 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 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE BMK 750/1000 Burner Inspection Instructions 11. Disconnect the gas train from the air/fuel valve by removing the four (4) 1/2” bolts and nuts (Figure 4-4a). 12. Disconnect the flex hose from the air/fuel valve by loosening the hose clamp. 13.

  • Page 47: Bmk 1500 - 3000 Burner Inspection

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE 4.6.2 BMK 1500 – 3000 BURNER INSPECTION The following parts will be required for reassembly after burner inspection: Burner Inspection Parts Part Number Description BMK 1500/2000 BMK 2500/3000 Burner Upper Release Gasket 81183 81173...
  • Page 48 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 AIR/FUEL VALVE...
  • Page 49 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE BMK 1500-3000 Burner Inspection Instructions BLOWER 3/8”-16 PLENUM HEX NUTS 5/16” x 1-3/4” BOLTS, (8 each) 5/16” WASHERS & NYLOCK NUTS (4 each) BLOWER A/F VALVE PLENUM GAS INLET PIPE BLOWER PROOF...
  • Page 50 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE BMK 1500-3000 Burner Inspection Instructions 14. Remove and replace the burner gasket(s) (see Figure 4-6, below). IMPORTANT! ALL THREE gaskets provided for maintenance MUST be installed during this procedure, as shown in Figure 4-6, even if there is only one existing gasket being replaced.

  • Page 51: Condensate Drain Trap

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Controller as described below. Low Water Cutoff (LWCO) - Standard C-More Test Instructions 1.

  • Page 56: Spark Monitor (Ac Current Transducer)

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America SECTION 4 – MAINTENANCE 4.12 SPARK MONITOR (AC CURRENT TRANSDUCER) The spark monitor (P/N 61034) evaluates the strength of the current between the ignition transformer and igniter-injector. Wire# 140, connected to the ignition transformer (see Figure 4- 12), passes through the monitor’s orifice.

  • Page 57: Section 5: Troubleshooting Guide

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America SECTION 5 – TROUBLESHOOTING GUIDE (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018 GF-206-LA-LA...
  • Page 59 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 current overload.
  • Page 60 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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) rotate to ignition position.
  • Page 67 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America 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) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 162 OMM-0132_A Ph.: 800-526-0288...

  • Page 71: Appendix A: Boiler Menu Item Descriptions

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 This is the setpoint temperature to which the control is set...
  • Page 72 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS TABLE A-3: CONFIGURATION Menu Item Descriptions MENU OPTIONS DESCRIPTION Specifies the amount of time to wait, up to 120 seconds, Aux Start On Dly between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the boiler.
  • Page 76 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 the setpoint temperature and the actual outlet temperature.
  • Page 78 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 4.4 of the Benchmark 750 –...
  • Page 79 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS 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 calibrated at Stepper Fbk...
  • Page 80 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS TABLE A-6: CALIBRATION Menu Item Descriptions MENU OPTION DESCRIPTION Supply Gas Pressure Allows adjustment of the Supply Gas Pressure level from 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% in 0.1% Gas Plate dp In Adj increments.
  • Page 81 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS TABLE A-6: CALIBRATION Menu Item Descriptions MENU OPTION DESCRIPTION – Inlet Wtr Offset Range: -20 to + 20 (either ºF or °C) – Outlet Wtr Offset Range: -20 to + 20 (either ºF or °C) 24 hr Max Cycles Maximum cycles in 24 hour period.
  • Page 82 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX A: BOILER MENU DESCRIPTIONS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018 GF-206-LA-LA...

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

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES Appendix B: STARTUP, STATUS, & FAULT MESSAGES TABLE B-1: 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 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES TABLE B-2: 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 Operation, Service & Maintenance Guide-Latin America APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES TABLE B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION LOW WATER The Low Water Cutoff board is indicating low water level. LEVEL NETWORK COMM The RS-485 network information is not present or is corrupted. FAULT % OUT OF RANGE % has gone below 3% or above 8%.
  • Page 86 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018 GF-206-LA-LA...

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

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 -17.2...
  • Page 88 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018 GF-206-LA-LA...

  • Page 89: Appendix D: Recommended Periodic Testing

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 Operation, Service & Maintenance Guide-Latin America APPENDIX D – RECOMMENDED PERIODIC TESTING Recommended Periodic Testing ITEM FREQUENCY ACTION BY REMARKS Operating controls Annually Operator See section 2.2. See section 5.8 in the Benchmark 750 – 3000 Low air flow Monthly Operator Installation and Startup Guide, OMM-0131...

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

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 -15.0...
  • Page 92 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 -23.3...
  • Page 93 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 -17.8...
  • Page 94 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 -9.4...

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

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 43086...
  • 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 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST Benchmark 750/1000 Gas Trains FM Gas Train 22140-1 Propane Gas Train 22140-3 DBB Gas Train 22140-2 LEFT-REAR VIEW FRONT VIEW RIGHT-REAR VIEW Benchmark 750/1000 Part List 09/28/2017 AERCO International, Inc.
  • Page 98 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST Benchmark 750/1000 Burner – Air/Fuel Valve Assembly P/N 24276-TAB Full Diagram Below BURNER–AIR/FUEL VALVE ASSEMBLY – EXPLODED VIEW Benchmark 750/1000 Part List 09/28/2017 AERCO International, Inc.
  • Page 99 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST Benchmark 750/1000 Part List 09/28/2017 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.
  • Page 100 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST 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 BMK 750 28321-TAB rev F 10913 Sheet 6 of 6 BMK 1000 28253-TAB rev F...
  • Page 101 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST 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 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST Benchmark 750/1000 DBB Gas Train – P/N 22140-2 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 103 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST BMK 750/1000 PROPANE Gas Train – P/N 22140-3 Item Qty Part # Description Item Qty Part # Description 95026 THREADED FLANGE: 1.25" NPT 125# 92006-3 VALVE: FULL PORT BALL 1/2"...
  • Page 104 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX F – BENCHMARK 750/1000 PART LIST 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 105: Appendix G: Benchmark 1500/2000 Part List

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Appendix G: BENCHMARK 1500/2000 PART LIST Benchmark 1500/1500DF & Benchmark 2000/2000DF Part List Item # Qty Part # Description 65121 TERMINAL BLOCK: DIN MOUNTED: WHT TERMINAL GROUND BLOCK: DIN EXHAUST MANIFOLD 65122...
  • Page 106 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 107 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500/1500DF, 2000/2000DF Part List 10/02/2017 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.
  • Page 108 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500/2000 Burner-Air/Fuel Valve Assembly P/N 24378, 24378-1 & 24378-2 Full part lists below Benchmark 1500/1500DF, 2000/2000DF Part List 10/02/2017 AERCO International, Inc. Benchmark 1500 29313-TAB rev G Blauvelt, NY 10913 Sheet 4 of 9 Benchmark 2000 29337-TAB rev G...
  • Page 109 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500/2000 Benchmark 1500/2000 Standard FM Gas Train Double Block & Bleed Gas Train P/N 22188 P/N 22199 See full part lists below See full part lists below Benchmark 1500/1500DF, 2000/2000DF Part List 10/02/2017 AERCO...
  • Page 110 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500DF/2000DF DUAL FUEL Gas Train P/N 22198 consists of: • 22188-1 NATURAL GAS gas train • 22197 PROPANE train Full gas train part lists are shown below NATURAL GAS Gas Train P/N 22188-1...
  • Page 111 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500DF/2000DF DUAL FUEL Gas Train P/N 22201 consists of: • 22199-1 NATURAL GAS gas train • 22200 PROPANE train Full gas train part lists are shown below NATURAL GAS Gas Train P/N 22199-1...
  • Page 112 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST REAR VIEW TOP VIEW FRONT VIEW LEFT SIDE VIEW Benchmark 1500/1500DF, 2000/2000DF Part List 10/02/2017 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.
  • Page 113 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST PARTIAL FRONT VIEW Benchmark 1500/1500DF, 2000/2000DF Part List 10/02/2017 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.
  • Page 114 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500-2000 Natural Gas Standard Gas Train – P/N 22188 Item Qty Part # Description Item Qty Part # Description 123542 FLANGE 2" 125# 2"NPT 97087-20 FLEX HOSE, 20"...
  • Page 115 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500-2000 Natural Gas DBB Gas Train – P/N 22199 Item Qty Part No Description Item Qty Part No Description 123542 FLANGE 2" 125# 2" NPT 124094 UNION, 3/4"...
  • Page 116 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500DF – 2000DF NATURAL GAS Gas Train – P/N 22188-1 Item Qty. Part No. Description Item Qty. Part No. Description 123542 FLANGE 2" 125# 2" NPT 93382 2'' NPT CAP 64048...
  • Page 117 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500DF – 2000DF PROPANE Gas Train – P/N 22197 Item Qty. Part No. Description Item Qty. Part No. Description 92036 VALVE, SSOV 1" NPT 99017 SNUBBER, PRESSURE, 1/4"...
  • Page 118 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500DF – 2000DF DBB NATURAL GAS Train – P/N 22199-1 Item Qty Part No. Description Item Qty Part No. Description 123542 FLANGE 2" 125# 2" NPT 9-291 UNION, 1"...
  • Page 119 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500DF – 2000DF DBB PROPANE Gas Train – P/N 22200 Item Qty Part # Description Item Qty Part # Description 64048 ACTUATOR, SSOV W/ REGULATOR 92036 VALVE, SSOV 1"...
  • Page 120 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX G – BENCHMARK 1500/2000 PART LIST Benchmark 1500/2000 Burner Assembly – P/N 24378-TAB Item Part # Description Item Part # Description 69078 BLOWER: AMETEK 12.3" 81166 BURNER GASKET 43090 AIR FUEL VALVE PLENUM 66026 IGNITOR-INJECTOR LEAN OXYGEN SENSOR...

  • Page 121: Appendix H: Benchmark 2500/3000 Part List

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H: BENCHMARK 2500/3000 PART LIST Appendix H: BENCHMARK 2500/3000 PART LIST Benchmark 2500/2500 DF & Benchmark 3000/3000 DF Part List Item # Qty Part # Description 93230 SNUBBER - AIR/FUEL VALVE 64081 ECU, O SENSOR...
  • Page 122 125 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 123 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500/2500DF & 3000/3000DF Part List 10/09/2017 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.
  • Page 124 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 2500/2500DF & 3000/3000DF Part List 10/09/2017 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 4 of 9...
  • Page 125 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 3000 Benchmark 3000 Standard FM Gas Train Double Block & Bleed Gas Train P/N 22171 P/N 22173 See full drawing below See full drawing below Benchmark 2500 Benchmark 2500 Standard FM Gas Train...
  • Page 126 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST NATURAL PROPANE INLET INLET NATURAL PROPANE INLET INLET Natural Gas Natural Gas P/N 22177 P/N 22177-1 Propane Propane P/N 22178 P/N 22178-1 Benchmark 3000 Dual Fuel Benchmark 3000 Dual Fuel FM Gas Train Double Block &...
  • Page 127 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST NATURAL NATURAL PROPANE INLET PROPANE INLET INLET INLET Natural Gas Natural Gas P/N 22209-1 P/N 22210-1 Propane Propane P/N 22209-2 P/N 22210-2 Benchmark 2500 Dual Fuel Benchmark 2500 Dual Fuel FM Gas Train Double Block &...
  • Page 128 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST REAR VIEW TOP VIEW LEFT SIDE VIEW FRONT VIEW Benchmark 2500/2500DF & 3000/3000DF Part List 10/09/2017 AERCO International, Inc. Blauvelt, NY Benchmark 2500 28536-TAB rev E 10913 Sheet 8 of 9 Benchmark 3000 28382-TAB rev F...
  • Page 129 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST PARTIAL FRONT VIEW – FRONT PANEL REMOVED Benchmark 2500/2500DF & 3000/3000DF Part List 10/09/2017 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.
  • Page 130 ACTUATOR: SSOV W/ 64048 REGULATOR 60032 SWITCH: GAS PRESSURE 1-20" W.C. 12951-2 BUSHING: CONTROL BOX 92143 1/4" BALL VALVE: WATTS 124136 VALVE: SSOV 2" NPT 9-294 UNION: 2" NPT 300# 97087-12 FLEX GAS TUBING 12" AERCO Benchmark 3000 FM Gas Train 01/17/2017 International, Inc.
  • Page 131 PIPE PLUG: 1/4" NPT: STEEL 124142 VALVE: SSOV: DOUBLE BODY: 2" NPT 97087-16 TUBING: FLEXIBLE GAS 12" ACTUATOR: SSOV W/ REGULATOR 92143 1/4" BALL VALVE: WATTS 64048 27086-1 ACTUATOR: SSOV W/O P.O.C. SWITCH 9-294 UNION: 2" NPT 300# 99015 DAMPING ORIFICE: SSOV 60020 SWITCH: GAS PRESSURE 2-20"...
  • Page 132 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 FM Gas Train – P/N 22190 Item Qty Part # Description Item Qty Part # Description 123542 FLANGE 2" 125# 2"NPT 92077 1/4" NPT MXF BRASS BALL VALVE 92006-7 VALVE: BALL BRASS 1-1/2"...
  • Page 133 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 Natural Gas DBB Gas Train – P/N 22211 Item Qty Part # Description Item Qty Part # Description 123542 FLANGE 2" 125# 2"NPT 99017 SNUBBER: PRESSURE: 1/4"...
  • Page 134 ACTUATOR: SSOV W/O P.O.C. 27086-1 60020 SWITCH: GAS PRESSURE 2-20" W.C. SWITCH 9-22 PIPE PLUG: 1/4" NPT: STEEL 92143 1/4" BALL VALVE: WATTS 93382 2'' NPT CAP AERCO Benchmark 3000DF Gas Train – NATURAL GAS 01/03/2017 International, Inc. Blauvelt, NY 10913...
  • Page 135 9-22 PIPE PLUG: 1/4" NPT: STEEL 60020 SWITCH: GAS PRESSURE 2-20" W.C. 99017 SNUBBER: PRESSURE: 1/4" 92143 1/4" BALL VALVE: WATTS 93382 2'' NPT CAP 97087-12 FLEX HOSE 12” 99015 DAMPING ORIFICE: SSOV AERCO Benchmark 3000 DF Gas Train – PROPANE 01/03/2017 International, Inc.
  • Page 136 PIPE PLUG: 1/4" NPT: STEEL 60020 SWITCH: GAS PRESSURE 2-20" W.C. 93382 2'' NPT CAP 92143 1/4" BALL VALVE: WATTS AERCO 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.
  • Page 137 Description 124142 VALVE: SSOV: DOUBLE BODY: 2" NPT 95030 FLANGE: SSOV 2" NPT ACTUATOR: SSOV W/ REGULATOR 92143 1/4" BALL VALVE: WATTS 64048 27086-1 ACTUATOR: SSOV W/O P.O.C. SWITCH 60032 SWITCH: GAS PRESSURE 2-20" W.C. 9-22 PIPE PLUG: 1/4" NPT: STEEL 60020 SWITCH: GAS PRESSURE 2-20"...
  • Page 138 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 Dual Fuel FM Gas Train, Natural Gas – P/N 22210-1 Item Part # Description Item Part # Description 123542 FLANGE 2" 125# 2" NPT 9-22 PIPE PLUG: 1/4"...
  • Page 139 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 Dual Fuel FM Gas Train – Propane – P/N 22210-2 Item Description Item Qty P/N Description 124150 VALVE: SSOV 1-1/2" NPT 9-22 PIPE PLUG: 1/4" NPT: STEEL ACTUATOR: SSOV W/ REGULATOR 12951-2 BUSHING: CONTROL BOX...
  • Page 140 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 DF DBB Gas Train – NATURAL GAS – P/N 22209-1 Item Qty Part # Description Item Qty Part # Description 123542 FLANGE 2" 125# 2"NPT 95029 FLANGE: SSOV 1 1/2"...
  • Page 141 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America APPENDIX H – BENCHMARK 2500/3000 PART LIST Benchmark 2500 DF DBB Gas Train – PROPANE – P/N 22209-2 Item Qty Part # Description Item Qty Part # Description ACTUATOR: SSOV W/ REGULATOR 99015 DAMPING ORIFICE: SSOV 64048...
  • Page 142 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 See Table 3 PHASE BLOWER Replacement Kit...

  • Page 143: Appendix I: Wiring Diagrams

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 143 of 162 OMM-0122_0C Ph.: 800-526-0288...
  • Page 144 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 144 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 145 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 145 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 146 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 146 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 147 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 147 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 148 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 148 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 149 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 149 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 150 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 150 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 151 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 151 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 152 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 152 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 153 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 153 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 154 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 154 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 155 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 155 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 156 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 156 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...
  • Page 157 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 157 of 162 OMM-0122_0C Ph.: 800-526-0288 11/29/2017...
  • Page 158 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 158 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...

  • Page 159: Appendix J: C-More Controller Views

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 POWER SUPPLY BOARD...
  • Page 160 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 161: Appendix K: Recommended Spares

    Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America 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 162 Benchmark 750-3000 Operation, Service & Maintenance Guide-Latin America Change log: Date Description Changed By 01/02/2018 Rev A: Initial release Chris Blair © AERCO International, Inc., 2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 162 OMM-0132_A Ph.: 800-526-0288 01/02/2018...

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