Benchmark 750-3000 Boiler Operation, Service

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
GF-206
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-0121 (GF-205)
APPLIES TO MODELS:
Natural Gas:
Dual-Fuel (NG/P):
• 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.
Latest Update: 11/29/2017
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 1 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ............................................................... 11
SECTION 2: OPERATION ................................................................................. 13
2.1 INTRODUCTION................................................................................................................................... 13
2.2 C-MORE CONTROLLER DESCRIPTION ............................................................................................ 14
2.3 C-MORE CONTROLLER MENUS ........................................................................................................ 17
2.3.1 Menu Navigation and Processing Procedure ..................................................................................................17
2.4 OPERATING MENU ............................................................................................................................. 19
2.5 SETUP MENU ....................................................................................................................................... 20
2.6 CONFIGURATION MENU .................................................................................................................... 21
2.7 TUNING MENU ..................................................................................................................................... 23
2.8 COMBUSTION CAL MENU .................................................................................................................. 23
2.8.1 BMK 750/1000 COMBUSTION CAL Menu .......................................................................................................23
2.8.2 BMK 1500/2000 COMBUSTION CAL Menus ...................................................................................................24
2.8.3 BMK 2500/3000 COMBUSTION CAL Menus ...................................................................................................25
2.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU ....................................................................... 26
2.10 CALIBRATION MENU......................................................................................................................... 29
SECTION 3: MODES OF OPERATION ............................................................... 31
3.1 INTRODUCTION................................................................................................................................... 31
3.2 INDOOR/OUTDOOR RESET MODE ................................................................................................... 31
3.2.1 Reset Ratio ......................................................................................................................................................31
3.2.2 Building Reference Temperature ....................................................................................................................31
3.2.3 Outdoor Air Temperature Sensor Installation ................................................................................................31
3.2.4 Indoor/Outdoor Startup .................................................................................................................................32
3.3 CONSTANT SETPOINT MODE ........................................................................................................... 32
3.3.1 Setting the Setpoint ........................................................................................................................................33
3.4 REMOTE SETPOINT MODES ............................................................................................................. 33
3.4.1 Remote Setpoint Field Wiring .........................................................................................................................34
3.4.2 Remote Setpoint Startup ................................................................................................................................34
3.5 DIRECT DRIVE MODES....................................................................................................................... 34
3.5.1 Direct Drive Field Wiring .................................................................................................................................35
3.5.2 Direct Drive Startup ........................................................................................................................................35
3.6 AERCO CONTROL SYSTEM (ACS) .................................................................................................... 36
3.6.1 ACS External Field Wiring................................................................................................................................36
3.6.2 ACS Setup and Startup ....................................................................................................................................36
3.7 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 37
3.7.1 Combination Control System Field Wiring ......................................................................................................38
3.7.2 Combination Control System Setup and Startup ............................................................................................38
SECTION 4: MAINTENANCE ............................................................................ 39
4.1 MAINTENANCE SCHEDULE ............................................................................................................... 39
4.2 IGNITER-INJECTOR ............................................................................................................................ 40
Page 2 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
CONTENTS
4.3 FLAME DETECTOR ............................................................................................................................. 45
4.4 O2 SENSOR .......................................................................................................................................... 45
4.5 SAFETY DEVICE TESTING ................................................................................................................. 46
4.6 BURNER INSPECTION ........................................................................................................................ 46
4.6.1 BMK 750/1000 BURNER INSPECTION .............................................................................................................47
4.6.2 BMK 1500 – 3000 BURNER INSPECTION .........................................................................................................49
4.7 CONDENSATE DRAIN TRAP .............................................................................................................. 53
4.8 AIR FILTER CLEANING AND REPLACEMENT .................................................................................. 54
4.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST............................................................... 55
4.9.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ...........................................................................56
4.9.2 Low Water Cutoff (LWCO) - Standard C-More Test ........................................................................................57
4.10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD ................................................................... 57
4.11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ....................... 57
4.12 SPARK MONITOR (AC CURRENT TRANSDUCER) ......................................................................... 58
SECTION 5: TROUBLESHOOTING GUIDE ......................................................... 59
5.1 INTRODUCTION................................................................................................................................... 59
5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................... 71
APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ............................................. 73
TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS ......................................................................... 73
TABLE A-2: SETUP MENU ITEM DESCRIPTIONS ................................................................................... 75
TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS ................................................................ 76
TABLE A-4: TUNING MENU ITEM DESCRIPTIONS ................................................................................. 79
TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS ............................................. 80
TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS ....................................................................... 81
APPENDIX B: STARTUP, STATUS, & FAULT MESSAGES ...................................... 85
TABLE B-1: STARTUP AND STATUS MESSAGES .................................................................................. 85
TABLE B-2: FAULT MESSAGES ............................................................................................................... 86
APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART........................................ 89
APPENDIX D: RECOMMENDED PERIODIC TESTING ............................................ 91
APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS .................................. 93
APPENDIX F: BENCHMARK 750/1000 PART LIST ............................................... 97
APPENDIX G: BENCHMARK 1500/2000 PART LIST ........................................... 107
APPENDIX H: BENCHMARK 2500/3000 PART LIST ........................................... 123
APPENDIX I: WIRING DIAGRAMS ................................................................... 145
APPENDIX J: C-MORE CONTROLLER VIEWS .................................................... 161
APPENDIX K: RECOMMENDED SPARES ........................................................... 163
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 3 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
CONTENTS
(This page intentionally blank)
Page 4 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
FORWARD
FOREWORD
The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas and
propane fueled boilers are modulating and condensing units. They represent a true industry
advance that meets the needs of today's energy and environmental concerns. Designed for
application in any closed loop hydronic system, the Benchmark's modulating capability relates
energy input directly to fluctuating system loads. These BMK models provide extremely high
efficiency operation and are ideally suited for modern low temperature, as well as, conventional
heating systems.
The Benchmark models operate within the following input and output ranges:
IMPORTANT!
Unless otherwise specified, all measurements apply to both natural gas and propane models.
Benchmark Boiler Intake and Output Ranges
MODEL
INPUT RANGE (BTU/HR.)
MINIMUM
MAXIMUM
OUTPUT RANGE (BTU/HR.)
MINIMUM
MAXIMUM
BMK 750
50,000 (14.6 kW)
750,000 (220 kW)
47,750 (14 kW)
716,250 (210 kW)
BMK 1000
50,000 (14.6 kW)
1,000,000 (293 kW)
48,300 (14.15 kW)
968,000 (284 kW)
BMK 1500
75,000 (22 kW)
1,500,000 (440 kW)
64,500 (18.9 kW)
1,395,000 (409 kW)
BMK 2000
100,000 (29.3 kW)
2,000,000 (586 kW)
86,000 (25.2 kW)
1,860,000 (545 kW)
BMK 2500
167,000 (48.9 kW)
2,500,000 (732 kW)
144,000 (42.2 kW)
2,395,000 (702 kW)
BMK 3000
200,000 (58.6 kW)
3,000,000 (879 kW)
174,000 (51.0 kW)
2,874,000 (842 kW)
The output of the boiler is a function of the unit’s firing rate (valve position) and return water
temperature.
When installed and operated in accordance with this Instruction Manual, these boilers comply
with the NOx emission standards outlined in: South Coast Air Quality Management District
(SCAQMD), Rule 1146.2. In addition, the BMK 750 & 1000 comply with the Bay Area Air
Quality Management District regulation 9, Rule 7.
Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting
flexibility with minimum installation space requirements. These boilers are Category II and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:
• Room Combustion Air:
o Vertical Discharge
o Horizontal Discharge
• Ducted Combustion Air:
o Vertical Discharge
o Horizontal Discharge
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 5 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
A (Amp)
Ampere
ACS
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
AUX
Auxiliary
BAS
Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate
Symbol rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BMK (Benchmark)
AERCO’s Benchmark series boilers
BMS or BMS II
AERCO Boiler Management Systems
BLDG (Bldg)
Building
BST
AERCO on-board Boiler Sequencing Technology
BTU
British Thermal Unit. A unit of energy approximately equal to the
heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)
BTU/HR
BTUs per Hour (1 BTU/hr = 0.29 W)
CCP
Combination Control Panel
CCS
Combination Control System
C-More Controller
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CFH
Cubic Feet per Hour (1 CFH = 0.028 m3/hr)
CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
CNTL
Control
CPU
Central Processing Unit
DBB
Double Block and Bleed, a gas trains containing 2 Safety Shutoff
Valves (SSOVs) and a solenoid operated vent valve.
DIP
Dual In-Line Package, a type of switch
ECU
Electronic Control Unit (O2 sensor)
EMS
Energy Management System; often used interchangeably with BAS
FM
Factory Mutual. Used to define boiler gas trains.
GF-xxxx
Gas Fired (an AERCO document numbering system)
GND
Ground
Page 6 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
HDR
Header
Hex
Hexadecimal Number (0 – 9, A – F)
HP
Horse Power
HX
Heat Exchanger
Hz
Hertz (Cycles Per Second)
I.D.
Inside Diameter
IGN
Ignition
IGST Board
Ignition/Stepper Board, contained in the C-More Controller
INTLK (INTL’K)
Interlock
I/O
Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
IP
Internet Protocol
ISO
International Organization for Standardization
Lbs.
Pounds (1 lb = 0.45 kg)
LED
Light Emitting Diode
LN
Low Nitrogen Oxide
MA (mA)
Milliampere (1 thousandth of an ampere)
MAX (Max)
Maximum
MBH
MIN (Min)
1000 BTUs per Hour
Minimum
Modbus®
A serial, half-duplex data transmission protocol developed by AEG
Modicon
NC (N.C.)
Normally Closed
NO (N.O.)
Normally Open
NOx
Nitrogen Oxide
NPT
National Pipe Thread
O2
Oxygen
O.D.
Outside Diameter
OMM & O&M
Operation and Maintenance Manual
onAER
AERCO’s on-line remote monitoring system
PCB
Printed Circuit Board
PMC Board
Primary Micro-Controller (PMC) board, contained in the C-More
P/N
Part Number
POC
PPM
Proof of Closure
Parts per Million
PSI
Pounds per Square Inch (1 PSI = 6.89 kPa)
PTP
Point-to-Point (usually over RS232 networks)
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 7 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
P&T
Pressure and Temperature
ProtoNode
Hardware interface between BAS and a boiler or water heater
PVC
Poly Vinyl Chloride, a common synthetic plastic
PWM
Pulse Width Modulation
REF (Ref)
Reference
RES.
Resistive
RS232
(or EIA-232)
A standard for serial, full-duplex (FDX) transmission of data based
on the RS232 Standard
RS422
(or EIA-422)
A standard for serial, full-duplex (FDX) transmission of data based
on the RS422 Standard
RS485
(or EIA-485)
A standard for serial, half-duplex (HDX) transmission of data based
on the RS485 Standard
RTN (Rtn)
Return
SETPT (Setpt)
Setpoint Temperature
SHLD (Shld)
Shield
SPDT
Single Pole Double Throw, a type of switch
SSOV
Safety Shut Off Valve
TEMP (Temp)
Temperature
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network
in order to prevent reflections that may cause invalid data in the
communication
Tip-N-Tell
A device that indicates if a package was tipped during shipping
UL
A business that tests and validates products
VAC
Volts, Alternating Current
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, also Variable Frequency Drive
W
Watt
W.C.
Water Column, a unit of pressure (1 W.C. = 249 Pa)
µA
Micro amp (1 millionth of an ampere)
Page 8 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
See section 1.4 for important information regarding installation of units within the
Commonwealth of Massachusetts.
IMPORTANT!
This Instruction Manual is an integral part of the product and must be maintained in legible
condition. It must be given to the user by the installer and kept in a safe place for future
reference.
WARNING!
•
Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.
•
Fluids under pressure may cause injury to personnel or damage to equipment when
released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully
decrease all trapped pressures to zero before performing maintenance.
•
Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
•
The exhaust vent pipe of the unit operates under a positive pressure and therefore must be
completely sealed to prevent leakage of combustion products into living spaces.
•
Electrical voltages up to 120 VAC may be used in this equipment. Therefore the cover on
the unit’s power box (located behind the front panel door) must be installed at all times,
except during maintenance and servicing.
•
A three-pole switch must be installed on the electrical supply line of the unit. The switch
must be installed in an easily accessible position to quickly and safely disconnect electrical
service. Do not affix switch to unit sheet metal enclosures.
CAUTION!
•
Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
•
DO NOT use this boiler if any part has been under water. Call a qualified service technician
to inspect and replace any part that has been under water.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 9 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
MANUAL GAS SHUT-OFF VALVE
VALVE
OPEN
VALVE
CLOSED
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures and safety device test
procedures, described in Section 4 and 5, respectively of the Benchmark 750 – 3000 Installation
and Startup Guide, OMM-0121 (GF-205) be performed to verify all system-operating
parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler
and close the manual gas valve located upstream the unit. The installer must identify the
emergency shut-off device.
Page 10 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 1: SAFETY PRECAUTIONS
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Requirements For Massachusetts Installations
Boiler Installations within the Commonwealth of Massachusetts must conform to the
following requirements:
•
Boiler must be installed by a plumber or a gas fitter who is licensed within the
Commonwealth of Massachusetts.
•
Prior to unit operation, the complete gas train and all connections must be leak
tested using a non-corrosive soap.
•
The vent termination must be located a minimum of 4 feet above grade level. If
side-wall venting is used, the installation must conform to the following
requirements extracted from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
building or structure used in whole or in part for residential purposes, including those owned or
operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a
crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the
exterior of the building at a minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 11 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 1: SAFETY PRECAUTIONS
Requirements For Massachusetts Installations
4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas
fueled equipment shall not approve the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed in accordance with the
provisions of 248 CMR 5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in
the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a
room or structure separate from the dwelling, building or structure used in whole or in
part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When
the manufacturer of Product Approved side wall horizontally vented gas equipment provides a
venting system design or venting system components with the equipment, the instructions
provided by the manufacturer for installation of the equipment and the venting system shall
include:
1. Detailed instructions for the installation of the venting system design or the venting
system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled
equipment does not provide the parts for venting the flue gases, but identifies "special venting
systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of
the installation.
……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………
Page 12 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Operation prior to initial startup by factory
trained personnel may void the equipment warranty. In addition, the following WARNINGS and
CAUTIONS must be observed at all times.
WARNING!
•
•
ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 VAC (BMK 750 – 2000) and
208 or 460 VAC (BMK 2500/3000) and 24 volts AC. It must be serviced only by factory
certified service technicians.
DO NOT ATTEMPT TO DRY FIRE THE UNIT. Starting the unit without a full water level
can seriously damage the unit and may result in injury to personnel or property damage.
This situation will void any warranty.
CAUTION!
All of the installation procedures in the Benchmark 750 – 3000 Installation and Startup Guide,
OMM-0121 (GF-205) must be completed before attempting to start the unit.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 13 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
Additional information on these items is provided in the individual operating procedures and
menu descriptions provided in this section.
2
1
3
4
12
5
11
6
10
7
8
9
Figure 2-1: C-More Controller Front View
Page 14 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
TABLE 2-1: Controls, Indicators, And Displays (ref. Figure 2-1)
ITEM
CONTROL, INDICATOR
or DISPLAY
FUNCTION
LED STATUS INDICATORS
Four Status LEDs indicate the current operating status as follows:
COMM =
1
Lights when RS232 communication is occurring – see Item 4.
MANUAL =
Lights when the valve position (fire rate) is being controlled using the front
panel keypad. This mode of operation is for service technician use only.
REMOTE =
Lights when the unit is being controlled by an external signal from an Energy
Management System.
DEMAND =
Lights when there is a demand for heat.
OUTLET
TEMPERATURE
Display
3–Digit, 7–Segment LED display continuously displays the outlet
water temperature. The °F or °C LED next to the display lights to
indicate whether the displayed temperature is in degrees Fahrenheit
or degrees Celsius. The °F or °C blinks when operating in the
DEADBAND mode.
On a BST Manager, display flashes & shows header temperature.
3
VFD Display
Vacuum Fluorescent Display (VFD) consists of 2 lines each capable
of displaying up to 16 alphanumeric characters. The information
displayed includes:
• Startup Messages
• Fault Messages
• Operating Status Messages
• Menu Selection
• BST Messages
4
RS232 Port
This port is used only by factory-trained personnel to monitor
onAER communications, in combination with the RS232 Adaptor
Cable (P/N 124675).
5
FAULT Indicator
Red FAULT LED indicator lights when a boiler alarm condition
occurs. An alarm message will appear in the VFD.
6
CLEAR Key
Turns off the FAULT indicator and clears the alarm message if the
alarm is no longer valid. Lockout type alarms will be latched and
cannot be cleared by simply pressing this key. Troubleshooting
may be required to clear these types of alarms.
7
READY Indicator
Lights when ON/OFF switch is set to ON and when all Pre-Purge
conditions have been satisfied.
8
ON/OFF switch
Enables and disables boiler operation.
2
9
LOW WATER
LEVEL
TEST/RESET
switches
OMM-0122_0C
GF-206
•
•
•
•
Allows operator to test operation of the water level monitor.
Pressing TEST opens the water level probe circuit and
simulates a Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 15 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
TABLE 2-1: Controls, Indicators, And Displays (ref. Figure 2-1)
ITEM
CONTROL, INDICATOR
or DISPLAY
FUNCTION
MENU KEYPAD
Six (6) keys which provide the following functions for the C-More Controller menus:
10
MENU
Steps through the main menu categories shown in Figure 2-2. The menu
categories wrap around in the order shown.
BACK
Allows you to go back to the previous menu level without changing any
information. Continuously pressing this key will bring you back to the
default status display in the VFD. Also, this key allows you to go back to
the top of a main menu category.
▲
(UP)
Arrow
When in one of the main menu categories (Figure 2-2), pressing the ▲
arrow key will select the displayed menu category. If the CHANGE key was
pressed and the menu item is flashing, pressing the ▲ arrow key will
increment the selected setting.
▼
(DOWN)
Arrow
When in one of the main menu categories (Figure 2-2), pressing this key
will select the displayed menu category. If the CHANGE key was pressed
and the menu item is flashing, pressing the ▼ arrow key will decrement the
selected setting.
Permits a setting to be changed (edited). When the CHANGE key is
pressed, the displayed menu item will begin to flash. Pressing the ▲ or ▼
CHANGE arrow key when the item is flashing will increment or decrement the
displayed setting.
ENTER
Saves the modified menu settings in memory.
flashing.
The display will stop
11
AUTO/MAN switch
This switch toggles the boiler between the AUTOMATIC and
MANUAL modes of operation. When in the MANUAL (MAN) mode,
the front panel controls are enabled and the MANUAL status LED
lights. Manual operation is for service only.
When in the AUTOMATIC (AUTO) mode, the MANUAL status LED
will be off and the front panel controls disabled.
12
VALVE POSITION
Bargraph
20 segment red LED bargraph continuously shows the Air/Fuel
Valve position in 5% increments from 0 to 100%
Page 16 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. These categories are shown in Figure 2-2. Each of the menus
shown, contain options which permit operating parameters to be viewed or changed. The
menus are protected by password levels to prevent unauthorized use.
Prior to entering the correct password, the options contained in the Operation, Setup,
Configuration and Tuning menu categories can be viewed. However, with the exception of
Internal Setpoint Temperature (Configuration menu), none of the viewable menu options can be
changed.
Once the valid level 1 password (159) is entered, the options listed in the Setup, Configuration
and Tuning menus can be viewed and changed, if desired. The Combustion Cal menu is
protected by the level 2 password (6817), which is used in initial startup (see Section 4: Initial
Startup of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205)), to
perform combustion calibration prior to service use.
2.3.1 Menu Navigation and Processing Procedure
Accessing and initiating each menu and option is accomplished using the menu keys shown in
Figure 2-1. Therefore, it is imperative that you be thoroughly familiar with the following basic
steps before attempting to perform specific menu procedures:
Menu Navigation and Processing Procedure Instructions
1. The C-More Controller will normally be in the Operating menu and the VFD will display the
current unit status. Pressing the ▲ or ▼ arrow key will display the other available data
items in the Operating menu.
2. Press the MENU key. The display will show the Setup menu, which is the next menu
category shown in Figure 2-2. This menu contains the Password option which must be
entered if other menu options will be changed.
3. Continue pressing the MENU key until the desired menu is displayed.
4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the
selected menu will be displayed.
5. Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.
Pressing the ▲ arrow key will display the available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence.
The menu options will wrap-around after the first or last available option is reached.
6. To change the value or setting of a displayed menu option, press the CHANGE key. The
displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the
available menu option choices for the option to be changed. The menu option choices do
not wrap around.
7. To select and store a changed menu item, press the ENTER key.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 17 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
* Only if BST is enabled. BST is described in detail in Section 6 of the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121 (GF-205).
Figure 2-2: Menu Structure
NOTE:
The following sections provide brief descriptions of the options contained in each menu.
Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B
for a list and descriptions of startup, status and error messages.
Page 18 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
A full description of each item appears in Appendix A-1.
TABLE 2-2: OPERATING Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMIT
1
Active Setpoint
Minimum
40°F (4.4°C)
Maximum
240°F (116°C)
2
Outlet Temp
30°F (-1.1°C)
240°F (116°C)
3
Inlet Temp
30°F (-1.1°C)
240°F (116°C)
4
Air Temp
-70°F (-56.7°C)
245°F (118°C)
5
Outdoor Temp
-70°F (-56.7°C)
130°F (54.4°C)
6
Valve Position In
0%
100%
7
Valve Position Out
8
FFWD Temp
0%
30°F (-1.1°C)
100%
240°F (115.6°C)
9
Exhaust Temp
10
Flame Strength
11
Min Flame Str
12
O2 Monitor
13
Appears Only If
Enabled in:
Configuration Menu
Configuration Menu
Configuration Menu
Displays current exhaust temperature
0%
100%
Not Used
Enable
Disable
Oxygen Level
0%
21%
14
Ignition Time
0.00
10.00
15
SSOV Time to OPN
0.00
10.00
16
Spark Current
0 amps
2.5 amps
17
Run Cycles
0
999,999,999
18
Run Hours
0
999,999,999
19
Fault Log
0
19
O2 Monitor = Enabled
An additional parameter associated with the Operating menu, (Min = 0, Max = 100) does not
appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More
Controller’s front face.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 19 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. In addition to permitting
password entries, the Setup menu is also used to enter date and time, and units of temperature
measurements. A view-only software version display is also provided to indicate the current CMore Controller software version.
A full description of each item appears in Appendix A-2.
TABLE 2-3: SETUP Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMIT
Minimum
Maximum
0
9999
DEFAULT
1
Password
2
Language
3
Time
12:00 am
11:59 pm
12:00
4
Date
01/01/00
12/31/99
01/01/00
5
Unit of Temp
6
Comm Address
0
7
Baud Rate
2400, 4800, 9600, 19.2K
9600
8
onAER Mode
Ethernet or SD Card
Ethernet
9
Min Upload Timer
10
Unit Alpha
11
Unit Year
12
Unit Serial #
13
Software
Page 20 of 164
11/29/2017
0
English
English
Fahrenheit or Celsius
Fahrenheit
127
0
0
9,999 Sec
0
E, G, H, R, N or A
A
0
99
0
0
9999
0
Ver 0.00
Ver 9.99
Current software
version
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. The remaining options in this menu require the valid
password to be entered, prior to changing existing entries. This menu contains a number of
other configuration settings which may or may not be displayed, depending on the current
operating mode setting.
A full description of each item appears in Appendix A-3.
NOTE:
The Configuration menu settings are Factory-Set in accordance with the requirements specified
for each individual order. Under normal operating conditions, no changes will be required.
TABLE 2-4: CONFIGURATION Menu
MENU ITEM DISPLAY
1
Internal Setpt
2
Unit Type
3
Unit Size
(Only displays sizes
available for the unit)
AVAILABLE CHOICES OR LIMIT
Minimum
Maximum
40°F (4.4°C)
240°F (115.6°C)
DEFAULT
130°F (54.4°C)
BMK Blr Std, BMK Blr Std Dual,
BMK Blr LN, BMK Blr LN Dual
BMK Boiler LN
750 MBH (220 kW), 1000 MBH (293
kW), 1500 MBH (439.6 kW), 2000 MBH
(586.1 kW), 2500 MBH (732.6 kW), 3000
MBH (879.2 kW)
750 MBH (220 kW),
Natural Gas or Propane
Natural Gas in
standard and dual fuel
models, Propane in
propane only models
4
Fuel Type
5
Boiler Mode
Constant Setpoint, Remote Setpoint,
Direct Drive, Combination,
Outdoor Reset
Constant Setpoint
6
Remote Signal
(If Mode = Remote
Setpoint, Direct Drive
or Combination)
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
PWM Input (Legacy BMS), Network
4 – 20 mA,
1-5V
7
Outdoor Sensor
Enabled or Disabled
Disabled
8
* Bldg Ref Temp
(If Mode = Outdoor
Reset)
40°F
(4.4°C)
230°F
(110°C)
70°F
(21.1°C)
9
* Reset Ratio
(If Mode = Outdoor
Reset)
0.1
9.9
1.2
10
* System Start Tmp
(If Outdoor Sensor =
Enabled)
30°F
(-1.1°C)
100°F
(37.8°C)
60°F
(15.6°C)
11
Setpt Lo Limit
40°F (4.4°C)
Setpt Hi Limit
60°F (15.6°C)
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 21 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
TABLE 2-4: CONFIGURATION Menu
MENU ITEM DISPLAY
12
Setpt Hi Limit
13
Temp Hi Limit
14
AVAILABLE CHOICES OR LIMIT
Minimum
Maximum
Setpt Lo Limit
210°F (98.9°C)
DEFAULT
180°F (82.2°C)
40°F (4.4°C)
210°F (98.9°C)
195°F (90.6°C)
Max Valve Position
40%
100%
100%
15
Pump Delay Timer
0 min.
30 min.
0 min.
16
Aux Start On Dly
0 sec.
120 sec.
0 sec.
17
Failsafe Mode
Shutdown or Constant Setpt
Constant Setpt
18
Analog Output
Off, Setpoint, Outlet Temp, Valve Pos 420mA, valve Pos 0-10v
19
Low Fire Timer
Valve Pos 0-10v
(Do NOT change)
2 sec.
20
Setpt Limiting
21
Setpt Limit Band
0°F (0°C)
10°F (5.5°C)
5°F (2.75°C)
22
Network Timeout
5 sec.
999 sec.
30 sec.
23
Shutoff Dly Temp
0°F (0°C)
25°F (13.75°C)
10°F (5.5°C)
24
Demand Offset
0°F (0°C)
25°F (13.75°C)
10°F (5.5°C)
25
Deadband High
0°F (0°C)
25°F (13.75°C)
5°F (2.75°C)
26
Deadband Low
0°F (0°C)
25°F (13.75°C)
5°F (2.75°C)
27
IGST Version
28
IGN Time Setting
29
Slow Shutdown
30
Slow Sht Duration
31
Slow Sht Threshold
32
O2 Warnings
33
O2 Trim ID
34
Fixed ID
35
O2 Trim Key
36
O2 Trim Menu
Enabled or Disabled
Disabled
37
BST Menu
Enabled or Disabled
Disabled
2 sec.
600 sec.
Enabled or Disabled
Disabled
V2.02
Displays current IGST version
Displays 4 sec. or 7 sec. depending on wiring harness installed
Enabled or Disabled
Disabled
0 sec.
9,999 sec.
60 sec.
40%
100%
60
Enabled or Disabled
Disabled
Displays 4 digit AERtrim ID
Displays unit’s fixed 4 digit ID
Displays AERtrim 4 digit license key
*NOTE
The Bldg Ref Temp and Reset Ratio menu Items are only displayed when the Outdoor Sensor,
item # 7 is set to Enabled.
CAUTION!
DO NOT change the Analog Output menu item from its default setting (Valve Position 0-10V).
Page 22 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
TABLE 2-5: TUNING Menu
MENU ITEM DISPLAY
1
Prop Band
2
Integral Gain
3
Derivative Time
4
Warmup Prop Band
5
Warmup Int Gain
6
Warmup PID timer
7
Reset Defaults?
MINIMUM
MAXIMUM
DEFAULT
1°F (0.55°C)
120°F (66°C)
70°F (38.5°C)
0.00
2.00
1.00
0.0 min
2.00 min
0.0min
1°F (0.55°C)
120°F (66°C)
95 °F (52°C)
0.00
2.00
0.50
240 sec.
20 sec.
0 sec.
Yes, No, Are You Sure?
No
2.8 COMBUSTION CAL Menu
The Combustion Cal (Calibration) menu is protected by the level 2 password (6817) which must
be entered to view or change the menu items shown in Table 2-6, 2-7 and 2-8. These menu
items are used to vary the speed of the unit’s blower motor based on air temperature and air
density at prescribed Air/Fuel Valve positions (% open). This is accomplished by providing a DC
drive voltage to the motor, which then adjusts the rotational speed of the blower to maximize
combustion efficiency and ensure the unit conforms to the Nitrogen Oxide (NOx) and Carbon
Monoxide (CO) emissions specified in the combustion calibration instructions in Section 4.4 of
the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).
CAL Voltage values are factory adjusted for each unit prior to shipping, and so may differ from
the defaults shown in the tables below. A full description of each item appears in Appendix A-5.
2.8.1 BMK 750/1000 COMBUSTION CAL Menu
TABLE 2-6: COMBUSTION CAL Menu: BMK 750/1000
MINIMUM
MAXIMUM
CAL Voltage 18%
0.25
2
CAL Voltage 30%
0.25
3
CAL Voltage 45%
4
5
MENU ITEM DISPLAY
DEFAULT
Natural gas
Propane
10.00
2.10
2.10
10.00
2.55
2.55
0.25
10.00
3.10
3.10
CAL Voltage 60%
0.25
10.00
3.50
3.50
CAL Voltage 80%
0.25
10.00
4.60
4.60
6
CAL Voltage 100%
0.25
10.00
5.60
5.60
7
SET Valve Position
0%
100%
0%
0%
8
Blower Output
0.00
0.00
9
Set Stdby Volt
0V
10.0 V
2.00
2.00
10
Oxygen Level
0%
25%
0.0
0.0
1
OMM-0122_0C
GF-206
Monitor Blower Output Voltage
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 23 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
MENU ITEM DISPLAY
1
MINIMUM
MAXIMUM
0.25
10.00
CAL Voltage 16%
CAL Voltage 18%
DEFAULT
BMK 1500
BMK 2000
1.80
–
–
1.40
2
CAL Voltage 30%
0.25
10.00
2.30
3.80
3
CAL Voltage 40%
0.25
10.00
2.50
4.30
4
CAL Voltage 50%
0.25
10.00
2.90
5.40
5
CAL Voltage 70%
0.25
10.00
3.80
6.40
6
CAL Voltage 100%
0.25
10.00
7.90
9.50
7
SET Valve Position
0%
100%
8
Blower Output
9
Set Stdby Volt
10
Oxygen Level
Variable
Displays current value
0
10.00 V
2.00 V
2.00 V
Displays current value
TABLE 2-7b: COMBUSTION CAL Menu: BMK 1500/2000
DUAL FUEL
DEFAULT
MENU ITEM DISPLAY
MINIMUM
MAXIMUM
NATURAL GAS *
PROPANE
BMK 1500
BMK 2000
BMK 1500
BMK 2000
CAL Voltage: 16%
0.25
10.00
1.50
2.10
–
–
CAL Voltage: 18%
0.25
10.00
–
–
1.20
2.10
2
CAL Voltage 30%
0.25
10.00
2.60
4.50
2.30
3.50
3
CAL Voltage 40%
0.25
10.00
3.20
4.50
2.80
3.90
4
CAL Voltage 50%
0.25
10.00
3.30
4.50
3.00
4.10
5
CAL Voltage 70%
0.25
10.00
4.10
4.80
3.50
4.10
6
CAL Voltage 100%
0.25
10.00
8.30
9.80
7.70
8.90
7
SET Valve Position
0
100
8
Blower Output
9
Set Stdby Volt
2.00
2.00
10
Oxygen Level
1
Variable
Displays current value
0
10.0
2.00
2.00
Displays current value
* The default values for Natural Gas on Dual Fuel units are different than the default values for
Natural Gas on Single Fuel units. These values do NOT apply to single fuel units.
Page 24 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
MENU ITEM DISPLAY
1
CAL Voltage 16%
CAL Voltage 14%
MINIMUM
MAXIMUM
0.25
10.00
DEFAULT
BMK 2500
BMK 3000
2.20
–
–
2.80
2
CAL Voltage 30%
0.25
10.00
4.10
4.60
3
CAL Voltage 40%
0.25
10.00
4.80
5.00
4
CAL Voltage 50%
0.25
10.00
5.30
5.50
5
CAL Voltage 70%
0.25
10.00
6.80
6.90
6
CAL Voltage 100%
0.25
10.00
8.50
9.10
7
SET Valve Position
0%
100%
8
Blower Output
9
Set Stdby Volt
10
Oxygen Level
Variable
Displays current value
0
10.00 V
2.00 V
2.00 V
Displays current value
TABLE 2-8b: COMBUSTION CAL Menu: BMK 2500/3000 DUAL FUEL
DEFAULT
MENU ITEM DISPLAY
MINIMUM
MAXIMUM
NATURAL GAS *
PROPANE
BMK 2500
BMK 3000
BMK 2500
BMK 3000
CAL Voltage: 14%
0.25
10.00
–
2.40
–
–
CAL Voltage: 16%
0.25
10.00
2.15
–
–
–
CAL Voltage: 18%
0.25
10.00
–
–
2.00
2.30
CAL Voltage: 20%
0.25
10.00
2.10
–
–
–
CAL Voltage: 22%
0.25
10.00
–
–
2.00
–
2
CAL Voltage 30%
0.25
10.00
3.90
5.40
3.30
4.40
3
CAL Voltage 45%
0.25
10.00
5.60
6.60
4.60
5.40
4
CAL Voltage 65%
0.25
10.00
–
7.00
–
5.70
CAL Voltage 70%
0.25
10.00
6.60
–
5.60
–
CAL Voltage 75%
0.25
10.00
–
–
–
–
CAL Voltage 85%
0.25
10.00
–
8.00
–
7.00
6
CAL Voltage 100%
0.25
10.00
8.50
8.70
7.90
8.60
7
SET Valve Position
0
100
8
Blower Output
9
Set Stdby Volt
10
Oxygen Level
1
5
Variable
Displays current value
0
10.0
2.00
2.00
2.00
2.00
Displays current value
* The default values for Natural Gas on Dual Fuel units are different than the default values for
Natural Gas on Single Fuel units. These values shown DO NOT APPLY to single fuel units.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 25 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. There are over 50 items in this menu, and selecting any
particular item from the list, for inspection or modification, could be time consuming. As a result,
the BST menu has been segmented into FIVE logical groups based on functionality.
The five Item groups are:
1.
2.
3.
4.
5.
BST Monitor Items
*BST SETUP MENU*
*OPERATE MENU*
*TEMP CTRL MENU*
*BST COMM MENU*
These displayed item groups are displayed in UPPER CASE letters, and are bounded by an
asterisk * in order to readily identify them within the item list.
The Items contained in group 1 (BST Monitor Items) are always displayed within the menu, as
these items are critical for proper system operation. Therefore, the BST Monitor Items Header
itself is not displayed.
The Items contained in groups 2-5 are not displayed unless that particular item group has been
enabled from the C-More keypad.
TABLE 2-9: BST Menu
AVAILABLE CHOICES OR LIMIT
MENU ITEM DISPLAY
1
Minimum
Off
BST Mode
Maximum
BST Client
BST Manager
DEFAULT
Off
2
BST Setpoint
BST Setpt Lo Limit
3
Header Temp
Read Only – current Header temperature in °F
4
BST Fire Rate
0
100%
Fire rate %
5
BST Ave Fire Rate
0
100%
Avg Fire Rate %
6
BST Outdoor Temp
7
Units Available
0
8
Units Present
8
Units Ignited
0
8
Units firing
9
BST Valve State
0 (CLOSED)
1 (OPEN)
0
10
1 BST Comm Errors 8
0
9
0
11
1 BST Units 8
0 – 8 (see * NOTE below)
0
Read Only – current outdoor temperature in °F
Disabled
12
*BST SETUP MENU*
13
BST Setpoint Mode
Constant Setpoint
14
BST Remote Signl
4-20 mA/1-5 VDC
15
Head Temp Source
16
Mdbus Temp Units
Page 26 of 164
11/29/2017
BST Setpt Hi Limit
Network
Enabled
Remote
Outdoor
Setpoint
Reset
0-20 mA/0-5
Network
VDC
FFWD Temp
Degrees C or Degrees F
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
130°F (54.4°C)
N/A
N/A
Disabled
Constant Setpt
Network
FFWD Temp
Degrees C
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
TABLE 2-9: BST Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMIT
Minimum
Maximum
DEFAULT
17
Header Temp Addr
0
255
240
18
Header Temp Point
0
255
14
19
BST Outdoor Sens
Disabled
Enabled
Disabled
20
Outdr Tmp Source
Outdoor Temp
Network
Outdoor Temp
21
Outdoor Tmp Addr
0
255
240
22
Outdoor Tmp Pnt
0
255
Yes
215
NOTE! A Modbus
temperature transmitter
must be installed in
conjunction with this
feature.
23
BST Auto Mstr
24
BST Auto Timer
10 sec
25
Remote Intlk Use
Boiler Shutdown
26
One Boiler Mode
27
1 Blr Threshold
28
Setpoint Setback
Disable
Enable
Disable
29
Setback Setpoint
BST Setpt Lo Limit
BST Setpt HI Limit
130°F (54.4°C)
30
Setback Start
12:00am
11:59pm
12.00am
31
Setback End
12:00am
11:59pm
12.00am
32
Rate Threshold
1°F (0.55°C)
30°F (16.5°C)
15°F (8.25°C)
33
*OPERATE MENU*
Disabled
Enabled
Disabled
34
BST Next On VP
16%
100%
50%
35
BST Max Boilers
1
8
8
36
BST On Delay
30 sec
300 sec
60 sec
37
BST On Timeout
15 sec
300 sec
60 Sec
38
Valve Override
39
Valve Off Delay
40
BST Sequencing
41
Select Lead Unit
0
127
0
42
Select Lag Unit
0
127
0
43
Lead/Lag Hours
25 hours
225 hours
72 hours
No
Off
10
120 sec
System Shutdown
On-Outlet
On-Avg Temp
Temp
35
Off
Closed
Open
0
Run Hours
15 min
Unit Size
Select Lead
No
30 sec
System Shutdown
Off
25
Off
1 min
Run Hours
44
*TEMP CTRL MENU*
Disabled
Enabled
Disabled
45
BST Temp Hi Limit
40°F (4.4°C)
210°F (98.9°C)
210°F (98.9°C)
46
BST Setpt Lo Limit
40°F (4.4°C)
BST Setpt HI Limit
60°F (15.5°C)
47
BST Setpt HI Limit
BST Setpt Lo Limit
220°F (104.4°C)
195°F (90.6°C)
48
BST Prop Band
1°F (-17.2°C)
120°F (48.9°C)
100°F (37.8°C)
49
BST Intgral Gain
0.00
2.00
0.50
50
BST Deriv Time
0.00 Min
2.00 Min
0.10 Min
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 27 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
TABLE 2-9: BST Menu
AVAILABLE CHOICES OR LIMIT
MENU ITEM DISPLAY
Minimum
Maximum
DEFAULT
51
BST Deadband Hi
0
25
1
52
BST Deadband Lo
0
25
1
53
Deadband En Time
0
120 Sec
30 Sec
54
BST FR Up Rate
1
120
20
55
BST Bldg Ref Tmp
40°F (4.4°C)
230°F (110°C)
70°F (21.1°C)
56
BST Reset Ratio
0.1
9.9
1.2
57
System Start Tmp
30°F (-1.1°C)
120°F (48.9°C)
60°F (15.6°C)
58
*BST COMM MENU*
Disabled
Enabled
Disabled
59
Comm Address
0
127
0
60
BST Min Addr
1
128
1
61
BST Max Addr
1
128
8
62
SSD Address
0
250
247
63
SSD Poll Control
0
1000
0
64
Err Threshold
1
9
5
65
SSD Temp Format
Degrees
Points
Degrees
66
BST Upld Timer
0
9999 sec
0
* NOTE:
The 1 BST Units 8 menu item shows the current status for each unit controlled by BST, up to
a maximum of 8 units. The possible characters displayed are:
- = Off Line
* = Not Available (fault, etc.)
0 = Off
1 = On,
A = Lead On
a = Lead Off
B = Lag On
b = Lag Off
S = Setpoint Limit Active
The following example shows the status of 5 units being controlled by BST where:
Unit 1 & 3 are On
Unit 2 is Off
Unit 4 is Not Available
Unit 5 is Lead On
Unit 6 is Lag Off
1 BST Units 8
1
Page 28 of 164
11/29/2017
0
1
*
A
b
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMIT
Minimum
Maximum
DEFAULT
1
Stepper Fbk
Cal 0%, Verify 50%, Cal 100%
2
Purge Timer
5 sec.
60 sec
Depends on unit type/size
3
Post Purge Timer
0 sec.
60 sec.
0 sec.
4
IGN Position
5%
60%
Depends on unit type/size
5
Ign Pos Hold Tmr
0 sec.
60 sec.
0 sec.
6
FFWD Temp Disply
Enabled or Disabled
Disabled
7
Outlet Tmp Dsply
Enabled or Disabled
Disabled
8
Inlet Tmp Dsply
Enabled or Disabled
Disabled
9
Valv Pos Out Dsp
Enabled or Disabled
Enabled
10
Exhaust Tmp Dsp
Enabled or Disabled
Disabled
11
Exhaust Safety
Enabled or Disabled
Enabled
12
Flue Material
PVC,CPVC; PolyPro; Stainless
PVC,CPVC
13
Exhst Fault Temp
100 °F
500 °F
200 °F
14
Exhst Module Temp
100 °F
500 °F
190 °F
15
Exhst Warn Temp
100 °F
500 °F
180 °F
16
Exhst Tmp VP Adj
0
10
5
17
Exhst Adj Rate
1
600
30
18
VP Change Rate
5
600
25
19
VP Up Rate
0.5
60.0
Depends on unit type/size
20
VP Down Rate
0.5
60.0
Depends on unit type/size
21
Purge Blwr Offst
-1.0
8.0
Depends on unit type/size
22
4-20mA Purge Pct
60%
100%
70%
23
PWM In Adj
-5.0%
5.0%
0.0%
24
Analog In Adj
-5.0%
5.0%
0.0%
25
Flow In Adj
-5.0%
5.0%
0.0%
26
Supply Gas Pressure In Adj
-5.0%
5.0%
0.0%
27
Gas Plate dp In Adj
-5.0%
5.0%
0.0%
28
mA Out Adj
-1.0 mA
1.0 mA
0.0 mA
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Cal 0%
Page 29 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 2: OPERATION
TABLE 2-10: CALIBRATION Menu
MENU ITEM DISPLAY
AVAILABLE CHOICES OR LIMIT
Minimum
Maximum
1%
5%
DEFAULT
29
A/F Sensitivity
30
Power Reset
Automatic or Manual
Automatic
31
Water Temp Reset
Automatic or Manual
Automatic
32
Gas Press Reset
Automatic or Manual
Manual
33
Min Off Time
34
Heatr Tuning Dsp
Enabled or Disabled
Disabled
35
Heatr Bkpt Dsp
Enabled or Disabled
Disabled
36
Stop Level
0%
Start Level
16
37
Start Level
Stop Level
40%
22
38
Skip Range Cntr
10
95
40
39
Skip Range Span
0
3
0%
40
Skip Speed
0.5
2.0
0.5%
41
O2 Gain
0.500
1.500
1.000
42
O2 Offset
-24.0
+2.0
1.0
43
O2 Sensor
44
Cal Temp Sensors
45
FFWD Temp Offset
-20
+20
0
46
Exhst Tmp Offset
-20
+20
0
47
Outdr Air Offset
-20
+20
0
48
Inlet Air Offset
-20
+20
0
49
Inlet Wtr Offset
-20
+20
0
50
Outlet Wtr Offset
-20
+20
0
51
24 hr Max Cycles
0
9999
0
52
24 hr Max Ovrtemp
0
9999
0
53
0-10v Out Test
0.0
10.0
0.00
54
Spark Monitor
55
Min Spark Amps
0.0 Amps
2.5 Amps
0.10 Amps
56
Max Spark Amps
0.0 Amps
2.5 Amps
0.40 Amps
Page 30 of 164
11/29/2017
0 Min
15 Min
2%
1 Min
Enabled or Disabled
Depends on unit type/size
Off or Start
Off
Enabled or Disabled
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Depends on unit type/size
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. All temperature related parameters
are at their factory default values, which work well in most applications. However, it may be
necessary to change certain parameters to customize the unit to the system environment. After
reading this section, parameters can be customized to suit the needs of the specific application.
A complete listing and descriptions of the temperature related parameters are included in
Appendix A, while factory defaults are listed in Sections 2.4 – 2.10, above.
3.2 INDOOR/OUTDOOR RESET MODE
This mode of operation is based on outside air temperatures. As the outside air temperature
decreases, the supply header temperature will increase and vice versa. For this mode, it is
necessary to install an outside air sensor as well as select a building reference temperature and
a reset ratio.
3.2.1 Reset Ratio
Reset ratio is an adjustable number from 0.1 to 9.9. Once adjusted, the supply header
temperature will increase by that number for each degree that the outside air temperature
decreases. For instance, if a reset ratio of 1.6 is used, for each degree that outside air
temperature decreases the supply header temperature will increase by 1.6 degrees.
3.2.2 Building Reference Temperature
This is a temperature from 40°F to 230°F (4.4°C to 110°C). Once selected, it is the temperature
that the system references to begin increasing its temperature. For instance, if a reset ratio of
1.6 is used, and we select a building reference temperature of 70°F (21.1°C), then at an outside
temperature of 69°F (20.6°C), the supply header temperature will increase by 1.6° to 71.6°F
(0.9°C to 22°C).
3.2.3 Outdoor Air Temperature Sensor Installation
The outdoor air temperature sensor must be mounted on the North side of the building in an
area where the average outside air temperature is expected. The sensor must be shielded from
the sun's direct rays, as well as direct impingement by the elements. If a cover or shield is used,
it must allow free air circulation. The sensor may be mounted up to 200 feet (61m) from the
unit. Sensor connections are made at the Input/Output (I/O) Box on the front of the boiler.
Connections are made at the terminals labeled OUTDOOR AIR IN and AIR SENSOR COM
inside the I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is
provided on the cover of the I/O Box. Refer to Section 2.10: AC Electrical Power Wiring of the
Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) for additional
information on wiring.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 31 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
Indoor / Outdoor Setup Instructions
1. Refer to the Indoor/Outdoor reset ratio charts in Appendix E.
2. Choose the chart corresponding to the desired Building Reference Temperature.
3. Go down the left column of the chart to the coldest design outdoor air temperature
expected in your area.
4. Once the design outdoor air temperature is chosen, go across the chart to the desired
supply header temperature for the design temperature chosen in step 3.
5. Next, go up that column to the RESET RATIO row to find the corresponding reset ratio.
6. Access the Configuration menu and scroll through it until the display shows BLDG REF
TEMP (Building Reference Temperature). If necessary, refer to Section 2.3: C-More
Controller Menus, above, for detailed instructions on navigating the menus.
7. Press the CHANGE key. The display will begin to flash.
8. Use the ▲ and ▼ arrow keys to select the desired Building Reference Temperature.
9. Press ENTER to save any changes.
10. Next, scroll through the Configuration menu until the display shows RESET RATIO.
11. Press the CHANGE key. The display will begin to flash.
12. Use the ▲ and ▼ arrow keys to select the Reset Ratio determined in step 5.
13. Press ENTER to save the change.
3.3 CONSTANT SETPOINT MODE
The CONSTANT SETPOINT mode is used when a fixed header temperature is desired.
Common uses of this mode of operation include water source heat pump loops, and indirect
heat exchangers for potable hot water systems or processes.
No external sensors are required to operate in this mode. While it is necessary to set the
desired setpoint temperature, it is not necessary to change any other temperature-related
functions. The unit is factory preset with settings that work well in most applications. Prior to
changing any temperature-related parameters, other than the setpoint, it is suggested that an
AERCO representative be contacted. See Appendix A for descriptions of temperature-related
functions, and Sections 2.4 – 2.10 for their range of values and factory defaults.
Page 32 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
SETTING
Internal Setpt
Select desired setpoint using ▲ and ▼ arrow
keys (40°F to 240°F, 4.4°C to 115.6°C)
Boiler Mode
Constant Setpoint
See Section 2.3: C-More Controller Menus for detailed instructions on changing menu options.
3.4 REMOTE SETPOINT MODES
The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or
Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage
signal within the following ranges:
•
4-20 mA/1-5 VDC
•
0-20 mA/0-5 VDC
The factory default setting for the REMOTE SETPOINT mode is 4 - 20 mA/1 - 5 VDC. With this
setting, a 4 to 20 mA/1 to 5 VDC signal, sent by an EMS or BAS, is used to change the unit's
setpoint. The 4 mA/1V signal is equal to a 40°F (4.4°C) setpoint while a 20 mA /5V signal is
equal to a 240°F (115.6°C) setpoint. When a 0 to 20 mA/0 to 5 VDC signal is used, 0 mA is
equal to a 40°F (4.4°C) setpoint.
In addition to the current and voltage signals described above, the REMOTE SETPOINT mode
can also driven by a RS-485 Modbus Network signal from an EMS or BAS.
The REMOTE SETPOINT modes of operation can be used to drive single as well as multiple
units.
NOTE:
If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch
adjustment must be made on the PMC Board located in the C-More Controller. Contact your
local AERCO representative for details.
In order to enable the REMOTE SETPOINT mode, you must set menu items Boiler Mode and
Remote Signal in the Configuration menu as follows:
TABLE 3-2: Remote Setpoint Mode Settings
MENU OPTION
SETTING
Boiler Mode
Remote Setpoint
Remote Signal
4-20mA/1-5V, 0-20mA/0-5V, or Network
Refer to section 2.3: C-More Controller Menus for detailed instructions on changing menu
options.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 33 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
While it is possible to change the settings of temperature related functions, the unit is factory
preset with settings that work well in most applications. It is suggested that an AERCO
representative be contacted, prior to changing any temperature related function settings. See
Appendix A for descriptions of temperature-related functions, and Sections 2.4 – 2.10 for their
range of options and factory defaults.
3.4.1 Remote Setpoint Field Wiring
The only wiring connections necessary for the REMOTE SETPOINT mode are connection of the
remote signal leads from the source to the unit’s I/O Box. The I/O Box is located on the front
panel of the boiler. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are
made at the ANALOG IN terminals in the I/O Box. For a Network setting, the connections are
made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded)
at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity
must be observed. The source end of the shield must be connected at the source. When driving
multiple units, each unit’s wiring must conform to the above.
3.4.2 Remote Setpoint Startup
Since this mode of operation is factory preset and the setpoint is being externally controlled, no
startup instructions are necessary. In this mode, the REMOTE LED will light when the external
signal is present.
To operate the unit in the MANUAL mode, press the AUTO/MAN switch. The REMOTE LED
will go off and the MANUAL LED will light.
To change back to the REMOTE SETPOINT mode, simply press the AUTO/MAN switch. The
REMOTE LED will again light and the MANUAL LED will go off.
3.5 DIRECT DRIVE MODES
The unit’s air/fuel valve position (% open) can be changed by a remote signal which is typically
sent from an Energy Management System (EMS) or from a Building Automation System (BAS).
The Direct Drive mode can be driven by a current or voltage signal within the following ranges:
•
4-20 mA/1-5 VDC
•
0-20 mA/0-5 VDC
The factory default setting for the DIRECT DRIVE mode is 4-20 mA/1-5 VDC. With this setting,
a 4 to 20 mA signal, sent by an EMS or BAS is used to change the unit’s valve position from 0%
to 100%. A 4 mA/1V signal is equal to a 0% valve position, while a 20 mA /5V signal is equal to
a 100% valve position. When a 0-20 mA/0-5 VDC signal is used, zero is equal to a 0% valve
position.
In addition to the current and voltage signals described above, the DIRECT DRIVE mode can
also driven by a RS-485 Modbus Network signal from an EMS or BAS.
When in a DIRECT DRIVE mode, the unit is a slave to the EMS or BAS and does not have a
role in temperature control. DIRECT DRIVE can be used to drive single, or multiple units.
Page 34 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
To enable the DIRECT DRIVE mode, you must set menu items Boiler Mode and Remote
Signal in the Configuration menu as follows:
TABLE 3-3: Direct Drive Mode Settings
MENU OPTION
SETTING
Boiler Mode
Direct Drive
Remote Signal
4-20mA/1-5V, 0-20mA/0-5V, or Network
Refer to section 2.3: C-More Controller Menus for instructions on changing menu options.
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.
3.5.1 Direct Drive Field Wiring
The only wiring connections necessary for DIRECT DRIVE mode are connection of the remote
signal leads from the source to the unit’s I/O Box. For either a 4-20mA/0-5V or a 0-20mA/0-5V
setting, the connections are made at the ANALOG IN terminals in the I/O Box. For a Network
setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal
must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded
pair from 18 to 22 AWG. Polarity must be observed. The source end of the shield must be
connected at the source. When driving multiple units, each unit’s wiring must conform to the
above.
3.5.2 Direct Drive Startup
Since this mode of operation is factory preset and the valve position is being externally
controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when
the signal is present.
To operate the unit in MANUAL mode, press the AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light.
To change back to the Direct Drive mode, simply press the AUTO/MAN switch. The REMOTE
LED will again light and the MANUAL LED will go off.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 35 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).
The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS
mode is used when it is desired to operate multiple units in the most efficient manner possible.
For this mode of operation, an ACS Header Sensor must be installed between 2 and 10 feet
(0.61 and 3m) downstream of the LAST boiler in the boiler plant's supply water header. The
ACS can control up to 40 boilers; Up to 32 via Modbus (RS-485) network communication. For
ACS programming, operation, and Header Sensor installation details, see ACS Operations
Guide, GF-131. For operation via an RS-485 Modbus network, refer to Modbus Communication
Manual GF-114. To enable the ACS mode, you must set menu items Boiler Mode and Remote
Signal in the Configuration menu as follows:
TABLE 3-4: ACS Mode Settings
MENU OPTION
SETTING
Boiler Mode
Direct Drive
Remote Signal
Network (RS485)
Refer to section 2.3: C-More Controller Menus for instructions on changing menu options.
3.6.1 ACS External Field Wiring
Wiring connections for RS-485 Modbus control are made between the 485 A- and 485 B+
terminals on the ACS (boilers 9 through 40) and the RS-485 COMM terminals in the I/O Box on
the front of the boilers.
Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the proper
polarity for the ACS RS-485 COMM wiring connections. Shields should be terminated only at
the ACS and the boiler end must be left floating. Each unit’s wiring must conform to the above.
3.6.2 ACS Setup and Startup
This mode of operation is factory preset and the ACS controls the firing rate (air/fuel valve %
open position). There are no setup instructions for each individual unit.
To operate the unit in MANUAL mode, press the AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light
To change back to the ACS mode, simply press the AUTO/MAN switch. The REMOTE LED will
again light and the MANUAL LED will go off.
Page 36 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 spaceheating and domestic hot water needs. The theory behind this type of system is that the
maximum space-heating load and the maximum domestic hot water load do not occur
simultaneously. Therefore, boilers used for domestic hot water are capable of switching
between constant setpoint and ACS control.
For a typical CCS, an adequate number of boilers are installed to cover the space-heating load
on the design-day. However, one or more units are used for the domestic hot water load as well.
These boilers are the combination units and are referred to as the combo boilers. The combo
boilers heat water to a constant setpoint temperature. That water is then circulated through a
heat exchanger in a domestic hot water storage tank.
Only the AERCO Control System (ACS) is necessary to configure this system if only a single
valve is used to switch from space heating to domestic hot water. However, the ACS Relay
Panel is required in combination with the ACS when there are up to two isolation valves, boiler
interlocks, and/or a Domestic Hot Water (DHW) pump in a Combination heating plant where
AERCO boilers are being used for both Building Heat and Domestic Hot Water heating.
The following two options are available for using a combination system; one that uses only the
ACS, and one that requires the optional ACS Relay Box:
•
OPTION 1 - This option is selected when the ACS controls a boiler plant containing up to
eight combination boilers that are Domestic Hot Water Priority (DHW PRIORITY) boilers,
along with building heat (BLDG HEAT) boilers, and one hydronic isolation valve in the main
header between the BLDG HEAT boilers and the DHW PRIORITY boilers.
•
OPTION 2 – When this option is selected, the ACS Relay Panel must be used in conjunction
with the ACS. For this option, the ACS controls a boiler plant containing up to eight
combination boilers that are divided up into Building Priority (BLDG PRIORITY) boilers and
Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building heat (BLDG
HEAT) boilers, and using two hydronic isolation valves in the main header, one between the
BLDG HEAT and BLDG PRIORITY boilers, and the other between the BLDG PRIORITY
and the DHW PRIORITY boilers.
In Option 2, when the space-heating load is such that when all the space-heating boilers are at
the 100% valve position, the ACS will then ask the ACS Relay Box for the domestic boilers to
become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot
water) boilers will then become space-heating boilers. If the domestic hot water load is not
satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch
over to space heating, but there is a call for domestic hot water, the ACS Relay Box switches
the combo units back to the domestic load. The ACS in combination with the ACS Relay Box
will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW
PRIORITY boilers are not able to satisfy the domestic hot water demand.
When the combo units are satisfying the domestic load, they are in the CONSTANT SETPOINT
mode of operation. When the combo units switch over to space heating, their mode of operation
changes to follow the ACS command. For more information concerning the operation of the
ACS, consult the ACS Operations Guide, GF-131. For more information on the ACS Relay Box,
see section 2.14 in the same manual.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 37 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
3.7.2 Combination Control System Setup and Startup
Setup for the COMBINATION mode requires entries to be made in the Configuration menu for
boiler mode, remote signal type and setpoint (see Section 2.6: Configuration Menu for details).
The setpoint is adjustable from 40°F to 190°F (4.4°C to 87.8°C).
To enable the COMBINATION mode, you must set menu items Boiler Mode, Remote Signal
and Internal Setpt in the Configuration menu as follows:
TABLE 3-5: Combination Mode Settings
MENU OPTION
SETTING
Boiler Mode
Combination
Remote Signal
Network
Internal Setpt
40°F to 190°F (4.4°C to 87.8°C)
Refer to section 2.3: C-More Controller Menus for instructions on changing menu options.
While it is possible to change other temperature-related functions for COMBINATION mode,
these functions are preset to their factory default values. These default settings work well in
most applications. It is suggested that AERCO be contacted prior to changing settings other
than the unit’s setpoint. For a complete listing of temperature related function defaults, see
Sections 2.4 – 2.10.
To set the unit to the MANUAL mode, press the AUTO/MAN switch. The MANUAL LED will
light.
To set the unit back to the AUTO mode, press the AUTO/MAN switch. The MANUAL LED will
go off and the REMOTE LED will light.
When the boiler is switched to ACS control, the ACS controls the valve position. There are no
setup requirements to the boiler(s) in this mode.
Page 38 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. For a complete inspection check list see
ASME CSD-1 chart.
The following maintenance kits are available through your local AERCO Sales Representative:
Model
Kit P/N
Type
Components Serviced
750-3000
58025-01
58025-08
58025-17
58025-13
58025-19
58025-10
58025-18
12 Month
Ignitor, Flame Rod & Condensate trap
58025-01 plus: Burner, LWCO, Air Filter replacement
Same as 58025-08 except clean Air Filter
58025-01 plus: Burner, LWCO, Air Filter replacement
Same as 58025-13 except clean Air Filter
58025-01 plus: Burner, LWCO, Air Filter replacement
Same as 58025-10 except clean Air Filter
750-1000
1500-2000
2500-3000
24-Month
Water/Fireside
24-Month
Water/Fireside
24-Month
Water/Fireside
WARNING!
Prior to servicing, ensure that the following guidelines are strictly observed:
• Disconnect the AC power supply by turning off the service switch and AC supply circuit
breaker.
• Shut off the gas supply at the manual shut-off valve provided with the unit
• Allow the unit to cool to a safe water temperature to prevent burning or scalding
TABLE 4-1: Maintenance Schedule
ITEM
SEC
4.2
4.3
4.4
**
6 MOS.
Igniter-Injector Kit (P/N
58023)
Flame Detector Kit
(P/N 24356-1)
Lean O2 Sensor
(P/N 61026)
Combustion Calibration
4.5
Testing of Safety Devices
4.6
Burner
*Inspect
*Inspect
12 MOS.
Inspect, replace
if necessary
Inspect, replace
if necessary
24 MOS.
LABOR
TIME
Replace
15 mins.
Replace
15 mins.
*Inspect
Inspect
15 mins.
*Check
Check
See ASME
CSD-1 Chart
1 hr.
45 mins.
Inspect
Inspect, Clean
& Replace
Gaskets
Replace
Inspect, Clean &
Replace
Gaskets
4.8 Air Filter
Clean
* Only performed after initial 6 month period after initial startup.
** Combustion Calibration instructions are in Section 4.4 of OMM-0121 (GF-205)
4.7
Condensate Drain Trap
OMM-0122_0C
GF-206
*Inspect
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
2 hrs.
30 mins.
15 mins.
Page 39 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Figure 4-1a
through Figure 4-1c shows the complete burner assembly removed from the boiler and indicates
the location of the igniter-injector flame detector and other related components.
BLOWER PROOF SWITCH
BLOCKED INLET SWITCH
BLOWER
AIR/FUEL VALVE
GAS FLEX HOSE
STAGED IGNITION
SOLENOID
BURNER PLATE
FLAME DETECTOR
O2 SENSOR
BURNER
IGNITER-INJECTOR
Figure 4-1a: BMK 750/1000 Burner Assembly (Removed from Boiler)
Page 40 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
BLOWER
A/F VALVE
PLENUM
BLOWER
PLENUM
IGNITERINJECTOR
ASSEMBLY
BLOCKED
INLET
SWITCH
LEAN O2 SENSOR
PLENUM FLANGE/
BURNER TOP PLATE
BURNER
FLAME
DETECTOR
AIR/FUEL
VALVE
FLAME
OBSERVATION
PORT
Figure 4-1b: BMK 1500/2000 Burner Assembly (Removed from Boiler)
BLOWER
A/F VALVE
PLENUM
BLOWER
PLENUM
LEAN O2 SENSOR
BURNER
PLATE FLANGE
IGNITOR-INJECTOR
ASSEMBLY
BLOCKED
INLET
SWITCH
AIR/FUEL
VALVE
BURNER
FLAME
DETECTOR
FLAME OBSERVATION PORT
Figure 4-1c: BMK 2500/3000 Burner Assembly (Removed from Boiler)
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 41 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Set the ON/OFF switch on the C-More Controller to the OFF position. Disconnect AC
power from the unit
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This
will disengage the shroud from the four (4) pins in the side panels.
3. Disconnect the cable from the igniter-injector (see Figure 4-1a – Figure 4-1c, above).
4. Referring to Figure 4-2a – Figure 4-2c, below, use a 7/16” open-end wrench to disconnect
the compression nut securing the gas injector tube of the igniter-injector to the elbow of the
staged ignition assembly. Disconnect the staged ignition assembly from the igniter-injector.
FLAME
DETECTOR
& GASKET
STAGED
IGNITION
SOLENOID
IGNITER-INJECTOR
BURNER
PLATE
INDEXING
(CLOCKING)
WASHERS
(0-3 as required)
LEAN O2 SENSOR
& WASHER
Figure 4-2a: BMK 750/1000 Igniter-Injector & Flame Detector Mounting Details
COMPRESSION
FITTING & ELBOW
STAGED
IGNITION
SOLENOID
BLOWER
PLENUM
INJECTOR-IGNITER
ASSY WITH INDEXING
(CLOCKING) WASHERS
(0-3 as needed)
FLAME
OBSERVATION
PORT
LEAN O2 SENSOR
& WASHER
FLAME
DETECTOR &
GASKET
BURNER PLATE
FLANGE
Figure 4-2b: BMK 1500/2000 Igniter-Injector & Flame Detector Mounting Details
Page 42 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
Igniter-Injector Maintenance Procedure Instructions
COMPRESSION
FITTING &
ELBOW
STAGED IGNITION
SOLENOID
FLAME
DETECTOR &
GASKET
BLOWER
PLENUM
O2 SENSOR
& WASHER
FLEX GAS
HOSE NIPPLE
INJECTOR-IGNITOR
ASSY WITH INDEXING
(CLOCKING) WASHERS
(0-3 as needed)
FLAME
OBSERVATION
PORT
BURNER PLATE
FLANGE
Figure 4-2c: BMK 2500/3000 Igniter-Injector & Flame Detector Mounting Details
5. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end
wrench.
6. Check the igniter-injector for evidence of erosion or carbon build-up. If there is evidence of
substantial erosion or carbon build-up, the igniter-injector should be replaced. If carbon
build-up is present, clean the component using fine emery cloth. Repeated carbon build-up
is an indication that the combustion settings of the unit should be checked. To review
combustion calibration procedures, refer to Section 4.4 of the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121 (GF-205).
7. Prior to reinstalling the igniter-injector, apply a high temperature, conductive, anti-seize
compound to the threads.
8. Reinstall the igniter-injector in the burner plate using 1 to 3 indexing washers, as needed,
so that when the igniter-injector is tightened, its injector tube will be positioned within the
approximately 120° arc shown in Figure 4-3a through 4-3c, below. Note, the recommended
injection tube positioning differs for the positioning recommended in the past.
9. Torque the igniter-injector to 170 - 180 in-lbs (19.2 – 20.3 Nm). DO NOT over tighten.
NOTE:
If replacement igniter-injector (Kit P/N 58023) is being installed, a compression nut
containing a built-in ferrule and 3 indexing washers are included with the kit.
10. Connect the staged ignition assembly to the gas injector tube of the igniter-injector by
securing the compression nut to the elbow of the staged ignition assembly.
11. Reconnect the igniter-injector cable.
12. Reinstall the shroud on the unit.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 43 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
Igniter-Injector Maintenance Procedure Instructions
BLOWER
POSITION
INJECTOR TUBE
INSIDE THIS ARC
BURNER PLATE
INJECTOR TUBE
IGNITER-INJECTOR
Figure 4-3a: BMK 750/1000 Igniter-Injector Orientation
POSITION
INJECTOR TUBE
INSIDE THIS ARC
INJECTOR TUBE
IGNITER-INJECTOR
FLAME
DETECTOR
FLAME
OBSERVATION
PORT
O2 SENSOR
Figure 4-3b: BMK 1500/2000 Igniter-Injector Orientation
POSITION
INJECTOR TUBE
INSIDE THIS ARC
O2 SENSOR
INJECTOR TUBE
FLAME
OBSERVATION
PORT
IGNITER-INJECTOR
Figure 4-3c. BMK 2500/3000 Igniter-Injector Orientation
Page 44 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Inspect or replace the flame
detector as follows:
Flame Detector Maintenance Instructions
1. Set the C-More Controller’s ON/OFF switch to the OFF position. Disconnect AC power
from the unit.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This
will disengage the shroud from the four (4) pins in the side panels.
3. Disconnect the flame detector lead wire.
4. Remove the two (2) screws securing the flame detector to the plate (Figure 4-2a – 4-2c).
5. Remove the flame detector and gasket from the burner plate.
6. Thoroughly inspect the flame detector. If eroded, the detector should be replaced.
Otherwise clean the detector with a fine emery cloth.
7. Reinstall the flame detector and flame detector gasket.
8. Reconnect the flame detector lead wire.
9. Reinstall the shroud on the unit.
4.4 O2 SENSOR
The Lean Oxygen Sensor (P/N 61026) is located on the burner plate at the top of the unit (see
Figure 4-1a through 4-1c and Figure 4-2a through 4-2c). The sensor may be hot. Allow the unit
to cool sufficiently before removing or replacing the O2 sensor.
O2 Sensor Maintenance Instructions
1. Set the ON/OFF switch on the C-More Controller to the OFF position. Disconnect AC
power from the unit.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This
will disengage the shroud from the four (4) pins in the side panels.
3. Disconnect the O2 sensor lead wire by pushing in on the release tab and pulling apart the
connector.
4. Next, loosen and remove the O2 sensor and crush washer from the burner plate using a
15/16" open-end wrench.
5. Thoroughly inspect the O2 sensor. If eroded, the sensor should be replaced. Otherwise
clean the sensor with a fine emery cloth.
6. Reinstall the O2 sensor and crush washer on the burner plate.
7. Reconnect the sensor lead wire.
8. Reinstall the shroud on the unit.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 45 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Test schedules must conform to
local jurisdictions. The results of the tests should be recorded in a log book.
See The Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) for a
description and instructions for performing these tests.
4.6 BURNER INSPECTION
The burner assembly is located at the top of the unit's heat exchanger. The burner assembly
may be hot. Therefore, allow the unit to cool sufficiently before removing the burner assembly.
The following parts will be required for reassembly after burner inspection:
BMK 750/1000 Burner Inspection Parts
Part No.
Description
81143
Burner Gasket
81048
Flame Detector Gasket
81064
Blower Gasket
BMK 1500/2000 Burner Inspection Parts
Part No.
Description
81166
Burner Gasket (1 each)
88183
Burner Release Gasket (1 each)
81186
Burner Lower Release Gasket (1 each)
81048
Flame Detector Gasket (1 each)
BMK 2500/3000 Burner Inspection Parts
Part No.
Description
88173
Burner Upper Release Gasket
81180
Burner Gasket (Middle)
81185
Burner Lower Release Gasket
81048
Flame Detector Gasket (1 each)
NOTE:
Illustrations for the burner inspection procedure for all BMK models are presented first, starting
on the next page, followed by the written instructions.
Page 46 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
4.6.1 BMK 750/1000 BURNER INSPECTION
BMK 750/1000 Burner Inspection Instructions
REAR
FRONT
BLOWER
BURNER PLATE
3/16”–16 HEX NUTS (8)
BLOWER PROOF
SWITCH
IGNITER-INJECTOR
BLOCKED INLET
SWITCH
STAGED IGNITION
ASSEMBLY
1/2" BOLTS & NUTS (4)
(GAS TRAIN-to-A/F
VALVE)
AIR FILTER
Figure 4-4a: BMK 750/1000 Burner Assembly Mounting Details (Overhead View)
BLOWER PROOF SWITCH
BLOCKED INLET
SWITCH
AIR/FUEL VALVE
BLOWER
O2 SENSOR
FLAME DETECTOR
BURNER GASKET
STAGED IGNITION
BURNER PLATE
IGNITER/INJECTOR
BURNER
Figure 4-4b: BMK 750/1000 Burner Assembly (Exploded View)
1. Set the ON/OFF switch on the C-More Controller to the OFF position. Disconnect AC
power from the unit and turn off the gas supply.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This
will disengage the shroud from the four (4) pins in the side panels.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 47 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
BMK 750/1000 Burner Inspection Instructions
3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure
4-4b.
4. Remove the two (2) screws securing the flame detector to the plate. The flame detector is
secured to the burner plate with one (1) #10-32 screw and one (1) #8-32 screw.
5. Remove the flame detector and gasket from the burner plate.
6. Disconnect the cable from the igniter-injector.
7. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector
tube of the igniter-injector to the elbow of the staged ignition assembly (see Figure 4-1a).
Disconnect the staged ignition assembly from the igniter-injector.
8. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end
wrench.
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).
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. Remove the four 5/16-18 hex head screws securing the blower to the burner plate (Figure
4-4b).
14. Remove the blower and air/fuel valve from the burner plate by lifting straight up. Also,
remove the blower gasket.
15. Remove the eight (8) 3/8-16 nuts from the burner flange (Figure 4-4a) using a 9/16”
wrench.
NOTE:
The burner assembly weighs approximately 25 pounds (11.3 kg).
16. Remove the burner assembly from burner flange by pulling straight up.
17. Remove and replace the burner gasket.
NOTE:
During reassembly, apply a light coating of high-temperature, anti-seize lubricant to the
threads of the igniter-injector and grounding screw. Also, ensure that the igniter-injector is
properly positioned as indicated in Figure 4-3a. Torque the igniter-injector to 14 - 15 ft-lbs.
(19.0 - 20.3 Nm).
18. Beginning with the burner assembly removed in step 16, reinstall all the components in the
reverse order that they were removed. When reinstalling the burner flange (removed in
step 15), tighten the 3/8-16 nuts using a typical torque pattern. For example, loosely tighten
one nut, then loosely tighten a second nut on the opposite side, a third at 90 degrees to the
first two, and a fourth opposite the third, and then repeat this pattern with the remaining
four nuts. Repeat the entire pattern a second time to partially tighten all eight nuts, and
then repeat a third time until all eight nuts are fully torqued to 30 ft. lbs. (40.7 Nm).
19. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly
aligned with the heat exchanger top flange.
This completes the Benchmark 750/1000 burner inspection.
Page 48 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
4.6.2 BMK 1500 – 3000 BURNER INSPECTION
BMK 1500-3000 Burner Inspection Instructions
IGNITERINJECTOR
ASSEMBLY
BLOWER
PLENUM
5/16” x 1-3/4” BOLTS,
5/16” WASHERS &
NYLOCK NUTS (4 each)
3/8”-16
HEX NUTS
(8 each)
BLOWER
BURNER PLATE
A/F VALVE
PLENUM
1/2” NUTS
& BOLTS (4 ea.)
AIR
FILTER
Figure 4-5a: BMK 1500/2000 Burner Assembly Mounting Details
5/16” x 1-3/4” BOLTS, 5/16”
WASHERS & NYLOCK
NUTS (4 each)
BLOWER
PLENUM
BLOWER
3/8”-16
HEX NUTS
(8 each)
A/F VALVE PLENUM
BLOWER PROOF
SWITCH
GAS INLET PIPE
AIR/FUEL VALVE
MANUAL SHUTOFF VALVE
BLOCKED INLET
SWITCH
AIR
FILTER
GAS
TRAIN
Figure 4-5b: BMK 1500/2000 Burner Assembly Mounting Details
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 49 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
BMK 1500-3000 Burner Inspection Instructions
5/16” x 1-3/4” BOLTS,
5/16” WASHERS &
NYLOCK NUTS (4 each)
BLOWER PLENUM
IGNITERINJECTOR
ASSEMBLY
BLOWER
A/F VALVE
PLENUM
BURNER
PLATE
AIR/FUEL
VALVE FILTER
1/2” NUTS
& BOLTS (4 each)
3/8”-16
HEX NUTS
(8 each)
AIR FILTER
GAS TRAIN
Figure 4-5c: BMK 2500/3000 Burner Assembly Mounting Details
BLOWER
PLENUM
5/16” x 1-3/4” BOLTS,
5/16” WASHERS &
NYLOCK NUTS
(4 each)
3/8”-16
HEX NUTS
(8 each)
BLOWER
A/F VALVE
PLENUM
GAS INLET
PIPE
BLOWER
PROOF
SWITCH
MANUAL
SHUT-OFF
VALVE
AIR/FUEL
VALVE
BLOCKED INLET
SWITCH
AIR
FILTER
GAS
TRAIN
Figure 4-5d: BMK 2500/3000 Burner Assembly Mounting Details
Page 50 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
BMK 1500-3000 Burner Inspection Instructions
1. Set the ON/OFF switch on the C-More Controller to the OFF position. Disconnect AC
power from the unit and turn off the gas supply.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This
will disengage the shroud from the four (4) pins in the side panels.
3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure
4-2b (BMK 1500/2000) or Figure 4-2c (BMK 2500/3000).
4. Remove the two (2) screws securing the flame detector to the plate. The flame detector is
secured to the burner plate with one (1) #10-32 screw and one (1) #8-32 screw.
5. Remove the flame detector and gasket from the burner plate.
6. Disconnect the cable from the igniter-injector.
7. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector
tube of the igniter-injector to the elbow of the staged ignition assembly (see Figure 4-2b
(BMK 1500/2000) or Figure 4-2c (BMK 2500/3000). Disconnect the staged ignition
assembly from the igniter-injector.
8. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end
wrench.
9. Loosen and remove the four 5/16 x 1-3/4” bolts, washers, and nuts from the blower plenum
where it attaches to the blower. See Figure 4-5a & 4-5b (BMK 1500/2000) or Figure 4-5c &
4-5d (BMK 2500/3000).
10. You must either rig a support for the blower to hold it in place or remove the blower from
the unit and set it aside for later reassembly.
11. Remove the eight (8) 3/8-16 nuts, using a 9/16” wrench, attaching the blower plenum to the
burner. See Figure 4-5a & 4-5b (BMK 1500/2000) or Figure 4-5c & 4-5d (BMK 2500/3000).
12. Remove the blower plenum from between the blower and the burner and set it aside for
later reassembly. The O2 sensor and flame observation port remain assembled to the
plenum flange.
13. Remove the burner by pulling straight up.
NOTE:
The burner assembly weighs approximately 65 lbs. (29.5 kg).
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. Note that the
LOWER RELEASE GASKET has tabs, which the others do not.
NOTE:
During reassembly, apply a light coating of high-temperature, anti-seize lubricant to the
threads of the igniter-injector and grounding screw. Also, ensure that the igniter-injector is
properly positioned as indicated in Figure 4-3b or Figure 4-3c. Torque the igniter-injector to
14 - 15 ft-lbs. (19.0 - 20.3 Nm).
(Continued)
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 51 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 4 – MAINTENANCE
BMK 1500-3000 Burner Inspection Instructions
IMPORTANT!
NOTE:
The LOWER RELEASE GASKET (P/N 81186)
features four tabs around its periphery.
Use ALL THREE gaskets provided, even if there
is only one existing gasket being replaced.
81183 – UPPER RELEASE GASKET
81166 – MIDDLE BURNER GASKET
81186 – LOWER RELEASE GASKET
BARE
BURNER
INSTALLED IN
HEAT
EXCHANGER
ASSY.
Figure 4-6: Bare Burner and Replacement Gaskets Location
15. Beginning with the burner assembly, reinstall all the components in the reverse order that
they were removed. When reinstalling the blower plenum (removed in step 11), tighten the
3/8-16 nuts using a typical torque pattern (for example, loosely tighten one nut, then
loosely tighten a second nut on the opposite side, a third at 90 degrees to the first two, and
a fourth opposite the third, and then repeat this pattern with the remaining four nuts.
Repeat the entire pattern a second time to partially tighten all eight nuts, and then repeat a
third time until all eight nuts are fully torqued to 35 ft. lbs. (47.5 Nm).
16. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly
aligned with the heat exchanger top flange.
This completes the Benchmark 1500/3000 burner inspection.
Page 52 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 – 3000 Installation and Startup Guide, OMM-0121
(GF-205)). This trap should be inspected and cleaned in accordance with the maintenance
schedule shown in Table 4-1, above, to ensure proper operation.
To inspect and clean the trap, proceed as follows:
Condensate Drain Trap Maintenance Instructions
1. Disconnect the external condensate trap by loosening and then removing connections on
the inlet and outlet sides of the condensate trap (see Figure 4-7).
2. Loosen the four (4) thumbscrews securing the trap’s cover and then remove the cover and
the O-ring from under the cover.
3. Remove the float and then thoroughly clean the trap and float. Also inspect the drain piping
for blockage. If the trap cannot be thoroughly cleaned, replace the entire trap (P/N 24441).
4. Replace the float, install the O-ring (P/N 84017), and then replace the trap cover.
5. Reassemble all piping and hose connections to the condensate trap inlet and outlet.
THUMB SCREWS (4)
COVER
3/4" NPT Port
Thumb
Screw
CONDENSATE
TRAP O-RING
(P/N 84017)
FLOAT
INLET
OUTLET
O-Rings
(2)
CROSS-SECTION
3/4" NPT Port
EXPLODED
VIEW
Figure 4-7: External Condensate Trap – Cross-Section & Exploded View
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 53 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
TABLE 4-2: Available Air Filters
Benchmark Model
Part Number
750, 1000
59139
1500, 2000
59138
2500, 3000
88014
To inspect/replace the air filter, proceed as follows:
Air Filter Cleaning and Replacement Instructions
1. Set the ON/OFF switch on the C-More Controller to the OFF position. Disconnect AC
power from the unit.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This
will disengage the shroud from the four (4) pins in the side panels.
3. Refer to Figure 4-8 and locate the air filter attached to the air/fuel valve inlet.
AIR/FUEL VALVE
AIR FILTER
HOSE CLAMP
MANUAL SHUTOFF VALVE
AIR FILTER
GAS TRAIN
Figure 4-8: Air Filter Location (BMK 1500/2000 Shown)
4. Using a flat-tip screwdriver or 5/16” nut driver, loosen the clamp securing the filter to the
inlet flange of the air/fuel valve. Remove the filter and clamp.
Page 54 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Do NOT use WD-40.
6. Each replacement air filter is equipped with its own clamp. Therefore, simply install the
replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat-tip
screwdriver or 5/16” nut driver.
7. Replace the top shroud on the unit and return boiler to service use.
4.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST
The LWCO capacitor should be tested for electrical shorts every 12 months and replaced,
then tested, every 24 months. The LWCO capacitor integrity test consists of two parts as
described in the next two sections. The first procedure explains how to test for electrical
shorting of the LWCO probe capacitor, while the second procedure instructs how to perform
the standard Low Water Cutoff test using the C-More Controller.
Refer to Figure 4-9 for an illustration of the LWCO probe assembly and its typical installation.
Rear
Panel
LWCO Probe
Plastic Acorn Nut
Capacitor Assembly
(Covered By Large
Shrink Tubing)
Hot Water
Outlet Pipe
Connector
(to Shell Harness)
LWCO Probe
Terminal
Figure 4-9: LWCO Probe Location (BMK1500 Shown)
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 55 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 – Capacitor Electrical Short Test Instructions
1. Turn the AC power to the unit to OFF.
WARNING!
High voltages are used to power these units and so it is required that power applied to
these units is removed first before performing the procedure described in this instruction.
Serious personal injury or death may occur if this warning is not observed.
2. Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on
the rear panel of the C-More Controller (see Figure 4-10).
UNPLUG SHELL HARNESS CABLE
FROM P5 CONNECTOR
Figure 4-10: Removing Shell Harness Cable from P5 Conn. on C-More Rear Panel
3. Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on
the unit shell as shown on left in Figure 4-11.
4. Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed
from the C-More Controller) as shown on right in Figure 4-11.
OHMMETER
ST
CONNECT 1 LEAD
TO LWCO TERMINAL
ND
CONNECT 2 LEAD
TO PIN #6
19-PIN SHELL HARNESS
CABLE CONNECTOR
LWCO PROBE
ASSEMBLY CONNECTOR
Figure 4-11: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable
Page 56 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. Turn the AC power to the unit to the ON position.
2. Press the TEST switch on the C-More Controller and confirm that the blinking LOW
WATER LEVEL message appears on the C-More display within 4 seconds.
3. Press the RESET key, followed by the Clear button, and confirm that the LOW WATER
LEVEL message is cleared.
4.10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD
If the boiler is to be taken out of service for an extended period of time (one year or more), the
following instructions must be followed.
Shutting Boiler Down For An Extended Period Instructions
1. Set ON/OFF switch on the C-More Controller to the OFF position to shut down the boiler’s
operating controls.
2. Disconnect AC power from the unit.
3. Close the water supply and return valves to isolate boiler.
4. Close external gas supply valve.
5. Open relief valve to vent water pressure.
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. Review installation requirements included in Section 2 of the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121 (GF-205).
2. Inspect all piping and connections to the unit.
3. Inspect exhaust vent and air inlet duct work (if applicable).
4. Perform initial startup per Section 4 of the Benchmark 750 – 3000 Installation and Startup
Guide, OMM-0121 (GF-205).
5. Perform safety device testing and scheduled maintenance procedures per Sections 4 and
5 of this manual.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 57 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 412), passes through the monitor’s orifice. If an adequate AC current is not detected in the wire
during ignition, the unit automatically shuts down. The monitor’s wires are connected to the I/O
board’s Spark Signal terminals (see section 2.11.4 in the Benchmark 750 – 3000 Installation
and Startup Guide, OMM-0121 (GF-205) for details).
Spark
Monitor
Wire 140
Ignition
Transformer
Wire 140
To I/O
Board
Tab
Figure 4-12: Spark Detector Sensor (AC Current Transducer) P/N 61034
If the spark monitor needs to be replaced, open the monitor’s orifice by pulling on the tab at
the side, remove Wire# 140, disconnect the monitor’s wires are from the I/O board, r e m o v e
the old monitor from its position, i n s t a l l a new monitor in its place, r o u t e wire# 140
through the new sensor orifice, and connect the wires to the I/O board’s Spark Signal
terminals, red wire to the positive (+) terminal and black to negative (-).
Page 58 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. These tables are comprised of three columns labeled:
Fault Indication, Probable Cause and Corrective Action. The numbered items in the Probable Cause and
Corrective Action columns correspond to each other. For example, Probable Cause No. 1 corresponds to
Corrective Action No. 1, etc.
When a fault occurs in the unit, proceed as follows to isolate and correct the fault:
Fault Correction Instructions
1. Observe the fault messages displayed in the C-More Controller display.
2. Refer to the Fault Indication column in Troubleshooting Table 5-1 which follows and locate the Fault
that best describes the existing conditions.
3. Proceed to the Probable Cause column and start with the first item (1) listed for the Fault Indication.
4. Perform the checks and procedures listed in the Corrective Action column for the first Probable
Cause candidate.
5. Continue checking each additional Probable Cause for the existing fault until the fault is corrected.
6. Section 5-2 contains additional troubleshooting information which may apply when a no fault
message is displayed.
If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your
local AERCO Representative.
NOTE:
The front panel of the C-More Controller contains an RS232 port. This port is used only by factory-trained
personnel to monitor onAER communications via a portable computer.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 59 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
(This page intentionally blank)
Page 60 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. Blower stopped running due to thermal or
1. Check combustion blower for signs of excessive heat or high current
current overload.
2. Blocked Blower inlet or inlet air filter.
drain that may trip thermal or current overload devices.
2. Inspect the inlet to the combustion blower including the air filter at
the air/fuel valve for signs of blockage.
3. Remove the Blower Proof switch and inspect for signs of blockage,
clean or replace as necessary.
4. Remove the Blocked Inlet switch and inspect for signs of blockage,
clean or replace as necessary.
5. Check the continuity of the Blower Proof switch with the combustion
blower running. If there is an erratic resistance reading or the
resistance reading is greater than zero ohms, replace the switch.
6. Turn off unit and check the continuity of the Blocked Inlet switch. If
there is an erratic resistance reading or the resistance reading is
greater than zero ohms, replace the switch.
7. Check the actual inlet air temperature and measure voltage at AUX
input in the I/O Box. Verify that the voltage conforms to the values
shown in Appendix C.
8. Refer to CORRECTIVE ACTION 7 and verify that the voltage
conforms to the values shown in Appendix C.
9. Check wire connection from I/O Box 0-10V signal to the Blower
Motor.
10. Measure voltage at the I/O box 0-10V output. A voltage of 10V
equates to a 100% open valve position.
11. Check the Analog Out option on the C-More Configuration menu.
Valve Position 0-10V should be selected.
12. Check Air/Fuel Valve position at 0%, 50% and 100% open
positions. The positions on the VALVE POSITION bargraph
should match the readings on the Air/Fuel Valve dial.
13. Check igniter-injector for soot or erosion of electrode. Check
injector solenoid valve to insure proper open/close operation.
3. Blockage in Blower Proof switch.
4. Blockage in Blocked Inlet switch.
5. Defective Blower Proof switch.
6. Defective Blocked Inlet switch.
AIRFLOW
FAULT
DURING
IGNITION
7. Loose temperature to AUX connection in I/O
Box.
8.
Defective temperature sensor.
Loose wire connection between the 0-10V
signal from I/O box to the Blower input.
10. Defective I/O Box.
9.
11. Wrong 0-10V output selection on the C-More
Controller.
12. Defective Air-Fuel Valve potentiometer.
13. Hard light.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 61 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. Blower not running or running too slow.
1. Start the unit. If the blower does not run check the blower solid state
2. Defective Blocked Inlet switch.
AIRFLOW
FAULT
DURING
PURGE
3. Blockage in air filter or Blocked Inlet switch.
4. Blocked blower inlet or inlet ductwork.
5. No voltage to Blocked Inlet switch from C-More
Controller.
6. PROBABLE CAUSES from 3 to 12 for
AIRFLOW FAULT DURING IGNITION apply for
this fault.
1. Blower stopped running due to thermal or
current overload.
2. Blocked Blower inlet or inlet ductwork.
AIRFLOW
FAULT
DURING RUN
3. Blockage in air filter or Blocked Inlet switch.
4. Defective Blocked Inlet switch.
5. Combustion oscillations.
6. Probable causes from 3 to 16 for AIRFLOW
FAULT DURING IGNITION applies for this fault.
Page 62 of 164
11/29/2017
relay for input and output voltage. If the relay is OK, check the
blower.
2. Start the unit. If the blower runs, turn off unit and check the Blocked
Inlet switch for continuity. Replace the switch if continuity does not
exist.
3. Remove the air filter and Blocked Inlet switch and inspect for signs
of blockage. Clean or replace as necessary.
4. Inspect the inlet to the combustion blower including any ductwork
leading up to the combustion blower for signs of blockage.
5. During the start sequence, verify that 24 VAC is present between
each side of the switch and ground. If 24 VAC is not present, refer
fault to qualified service personnel.
6. See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT
DURING IGNITION.
1. Check combustion blower for signs of excessive heat or high
current draw that may trip thermal or current overload devices.
2. Inspect the inlet to the combustion blower, including any ductwork
leading up to the combustion blower, for signs of blockage.
3. Remove the air filter and Blocked Inlet switch and inspect for signs
of blockage, clean or replace as necessary.
4. Verify that 24 VAC is present between each side of the switch and
ground. If 24 VAC is not present at both sides, replace switch.
5. Run unit to full fire. If the unit rumbles or runs rough, perform
combustion calibration.
6. See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT
DURING IGNITION.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
DELAYED
INTERLOCK
OPEN
Probable Causes
Corrective Action
1. Delayed Interlock Jumper not properly installed
1. Check to insure jumper is properly installed across the delayed
or missing.
2. Device proving switch hooked to interlocks is
not closed.
interlock terminals in the I/O Box.
2. If there are 2 external wires on these terminals, check to see if an
end switch for a proving device (such as a pump, louver, etc.) is tied
these interlocks. Ensure that the device and/or its end switch is
functional. A jumper may be temporarily installed to test the
interlock.
1. Check I/O Box to ensure signal is hooked up.
--Hook up if not installed.
--If installed, check polarity.
--Measure signal level.
--Check wiring continuity between source and unit.
2. Check signal at source to ensure it is isolated.
3. Check DIP switch on PMC board to ensure it is set correctly for the
type of signal being sent. Check control signal type set in
Configuration menu.
1. Remove and inspect the Flame Detector for signs of wear. Replace
if necessary.
2. Close the internal gas valve in the unit. Install and arc a spark igniter
outside the unit.
3. If there is no spark, check for 120VAC at the primary side to the
ignition transformer during the ignition cycle.
4. If 120VAC is not present, the IGST Board in the C-More Controller
may be defective. Refer fault to qualified service personnel.
5. While externally arcing the spark igniter, observe the open/close
indicator in the Safety Shut-Off Valve to ensure it is opening. If the
valve does not open, check for 120VAC at the valve input terminals.
If 120VAC is not present, the IGST board in the C-More Controller
may be defective. Refer fault to qualified service personnel.
1. Direct drive signal is not present:
DIRECT DRIVE
SIGNAL FAULT
--Not yet installed.
--Wrong polarity.
--Signal defective at source.
--Broken or loose wiring.
2. Signal is not isolated (floating).
3. C-More Controller signal type selection switches
not set for correct signal type (voltage or
current).
1. Worn Flame Detector.
2. No spark from Spark Igniter.
3. Defective Ignition Transformer.
FLAME LOSS
DURING IGN
4. Defective Ignition/Stepper (IGST) Board.
5. Defective SSOV.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 63 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. Worn Flame Detector or cracked ceramic.
1. Remove and inspect the Flame Detector for signs of wear or
2. Defective Regulator.
FLAME LOSS
DURING RUN
3. Poor combustion calibration.
4. Debris on burner.
5. Blocked condensate drain.
1. The Heat Demand Relays on the
HEAT DEMAND
FAILURE
HIGH EXHAUST
TEMPERATURE
Ignition/Stepper (IGST) board failed to activate
when commanded.
2. Relay is activated when not in Demand.
1. Poor combustion calibration.
2. Carboned heat exchanger due to incorrect
combustion calibration.
1. Incorrect supply gas pressure.
cracked ceramic. Replace if necessary.
2. Check gas pressure readings using a gauge or manometer into and
out of the Air/Fuel Valve to ensure that the gas pressure into and
out of the valve is correct.
3. Check combustion calibration using the procedures in Section 4.4 of
the Benchmark 750 – 3000 Installation and Startup Guide, OMM0121 (GF-205).
4. Remove the burner and inspect for any carbon build-up or debris.
Clean and reinstall.
5. Remove blockage in condensate drain.
1. Press CLEAR button and restart the unit. If the fault persists,
replace Ignition/Stepper (IGST) Board.
2. Defective relay. Replace IGST Board.
1. Check combustion calibration using procedures in Section 4.4 of the
Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121
(GF-205).
o
o
2. If exhaust temperature is greater than 200 F (93.3 C), check
combustion calibration. Calibrate or repair as necessary.
1. Check to ensure gas pressure at inlet of SSOV does not exceed
14” W.C. (3.49 kPa).
2. Defective SSOV Actuator.
2. If gas supply pressure downstream of SSOV Actuator cannot be
HIGH GAS
PRESSURE
3. Defective High Gas Pressure switch.
Page 64 of 164
11/29/2017
lowered to the range specified in Table 4-1 (Natural Gas) or Table
4-4 (Propane) in Section 4.4 of the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121 (GF-205), the SSOV
Actuator may be defective.
3. Remove the leads from the High Gas Pressure switch. Measure
continuity across the common (C) and normally closed (NC)
terminals with the unit not firing. Replace the switch if continuity
does not exist.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. Faulty Water temperature switch.
1. Test the temperature switch to insure it trips at its actual water
2. Incorrect PID settings.
2. Check PID settings (see Section 2-7: Tuning Menu, items 1 -3, for
temperature setting.
HIGH WATER
TEMP
SWITCH OPEN
3. Faulty shell temperature sensor.
4. Unit in MANUAL mode.
5. Unit setpoint is greater than Over Temperature
switch setpoint.
6. System flow rate changes are occurring faster
than units can respond.
HIGH WATER
TEMPERATURE
IGN BOARD
COMM FAULT
1. See HIGH WATER TEMPERATURE SWITCH
OPEN.
2. Temp HI Limit setting is too low.
1. Communication fault has occurred between the
PMC board and Ignition/Stepper (IGST) board.
OMM-0122_0C
GF-206
details). If the settings have been changed, record the current
readings then reset them to the default values.
3. Using the resistance charts in Appendix C, measure the resistance
of Shell sensor and BTU sensor at a known water temperature.
4. If unit is in MANUAL mode, switch to AUTO mode.
5. Check setpoint of unit and setpoint of Temperature switch; Ensure
that the temperature switch is set higher than the unit’s setpoint.
6. If the system is a variable flow system, monitor system flow changes
to ensure that the rate of flow change is not faster than what the
units can respond to.
1. See HIGH WATER TEMPERATURE SWITCH OPEN.
2. Check Temp HI Limit setting.
1. Press CLEAR button and restart unit. If fault persists, contact
qualified Service Personnel.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 65 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. Air/Fuel Valve not rotating.
1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)
2. Defective or shorted switch.
IGN SWTCH
CLOSED
DURING
PURGE
3. Switch wired incorrectly.
4. Defective Power Supply Board or fuse.
5. Defective IGST Board.
1. Air/Fuel Valve not rotating to ignition position.
IGN SWTCH
OPEN
DURING
IGNITION
2. Defective Ignition switch.
3. Defective Power Supply Board or fuse.
4. Defective IGST Board.
Page 66 of 164
11/29/2017
position. If the valve does not rotate at all or does not rotate fully
open, check the Air/Fuel Valve calibration. If calibration is okay, the
problem may be in the Air-Fuel Valve or the C-More Controller.
Refer to qualified service personnel.
2. If the Air/Fuel Valve does rotate to purge, check the ignition switch
for continuity between the N.O. and COM terminals. If the switch
shows continuity when not in contact with the cam replace the
switch.
3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals). If the switch is wired
correctly, replace the switch.
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)
position, then back to ignition position (towards closed) during the
ignition cycle. If the valve does not rotate back to the ignition
position, check the Air/Fuel Valve calibration. If calibration is okay,
the problem may be in the Air/Fuel Valve or the C-More Controller.
Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check the
ignition position switch for continuity between the N.O. and COM
terminals when in contact with the cam.
3. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. Interlock jumper not installed or removed.
1. Check for a jumper properly installed across the interlock terminals
2. Energy Management System does not have unit
INTERLOCK
OPEN
enabled.
3. Device proving switch hooked to interlocks is
LINE VOLTAGE
OUT OF
PHASE
not closed.
1. Line and Neutral switched in AC Power Box.
2. Incorrect power supply transformer wiring.
1. Incorrect supply gas pressure.
LOW GAS
PRESSURE
2. Defective Low Gas Pressure switch.
1. Insufficient water level in system.
2. Defective water level circuitry.
LOW WATER
LEVEL
3. Defective water level probe.
MODBUS
COMMFAULT
Unit not seeing information from Modbus network.
OMM-0122_0C
GF-206
in the I/O box.
2. If there are two external wires on these terminals check any Energy
Management system to see if they have the units disabled (a jumper
may be temporarily installed to see if the interlock circuit is
functioning).
3. Check that proving switch for any device hooked to the interlock
circuit is closing and that the device is operational.
1. Check hot and neutral in AC Power Box to ensure they are not
reversed.
2. Check transformer wiring, in AC Power Box, against the power box
transformer wiring diagram to ensure it is wired correctly.
1. Measure gas pressure upstream of the SSOV Actuator(s) with the
unit firing. Ensure it is above the values in Table 5-1 (BMK 7502500) or above the value calculated in step 4 in section 5.2.2 (BMK
3000)of the Benchmark 750 – 3000 Installation and Startup Guide,
OMM-0121 (GF-205).
2. Measure gas pressure at the Low Gas Pressure switch. If it is
greater than 1 inch above the Low Gas Pressure switch setting
(see Table 5-1 (BMK 750-2500) or above the value calculated in
step 4 in section 5.2.2 (BMK 3000) in section 5.2 of the Benchmark
750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205))
measure continuity across the switch and replace if necessary.
1. Check system for sufficient water level.
2. Test water level circuitry using the C-More Controller front panel
LOW WATER TEST and RESET buttons. Replace water level
circuitry if it does not respond.
3. Check continuity of probe end to the shell, change probe if there is
no continuity.
Check network connections. If fault persists, contact qualified
Service Personnel.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 67 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
PRG SWTCH
CLOSED
DURING
IGNITION
Probable Causes
Corrective Action
1. A/F Valve rotated open to purge and did not
1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)
rotate to ignition position.
2. Defective or shorted switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or fuse.
5. Defective IGST Board.
1. Defective Purge switch.
PRG SWTCH
OPEN
DURING
PURGE
2. No voltage present at switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or fuse
5. Defective IGST Board.
OUTDOOR
TEMP
SENSOR
FAULT
1. Loose or broken wiring.
2. Defective Sensor.
3. Incorrect Sensor.
Page 68 of 164
11/29/2017
position, then back to ignition position (towards closed) during the
ignition cycle. If the valve does not rotate back to the ignition
position, check the Air/Fuel Valve calibration. If calibration is okay,
the problem may be in the Air/Fuel Valve or the C-More Controller.
Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check the
purge switch for continuity between the N.O. and COM terminals. If
the switch shows continuity when not in contact with the cam, check
to ensure that the switch is wired correctly (correct wire numbers on
the normally open terminals).
3. If the switch is wired correctly, replace the switch.
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. If the air-fuel valve does rotate, check Purge switch for continuity
when closing. Replace switch if continuity does not exist.
2. Measure for 24 VAC from each side of the switch to ground. If
24VAC is not present, refer fault to qualified service personnel.
3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. Inspect Outdoor Temperature sensor for loose or broken wiring.
2. Check resistance of sensor to determine if it is within specification.
3. Ensure that the correct sensor is installed.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
O2 % OUT OF
RANGE
RECIRC PUMP
FAILURE
REMOTE
SETPT
SIGNAL FAULT
Probable Causes
Corrective Action
1. Combustion Calibration incorrect.
1. Check Combustion Analyzer and recalibrate the boiler.
2. Blocked inlet air duct or louver.
2. Unblock air inlet and measure open area for combustion air to the
1. Internal recirculation pump failed.
room.
1. Replace recirculation pump.
1. Remote setpoint signal not present:
1. Check I/O Box to ensure signal is hooked up.
Not yet installed.
Wrong polarity.
Signal defective at source.
Broken or loose wiring.
2. Signal is not isolated (floating) if 4 to 20 mA.
3. C-More Controller signal type selection switches
not set for correct signal type (voltage or current).
Hook up if not installed.
If installed, check polarity.
Measure signal level.
Check continuity of wiring between source and unit.
2. Check signal at source to ensure it is isolated.
3. Check DIP switch on PMC board to ensure it is set correctly for the
type of signal being sent. Check control signal type set in item 6 of the
Configuration menu (see Section 2.6: Configuration Menu).
1. Replace Flame Detector.
2. Check open/close indicator window of Safety Shut-Off Valve (SSOV)
and ensure that the SSOV is fully closed. If not fully closed, replace the
valve and or actuator.
Close the Gas Shut-Off Valve downstream of SSOV (see Section 1,
Figure 1-1). Install a manometer or gauge at the leak detection port
between the SSOV and Gas Shut Off Valve. If a gas pressure reading
is observed replace the SSOV Valve and/or Actuator.
1. Defective Flame Detector.
2. SSOV not fully closed.
RESIDUAL
FLAME
SSOV FAULT
DURING
PURGE
SSOV FAULT
DURING RUN
See SSOV SWITCH OPEN
SSOV switch closed for 15 seconds during run.
1. Replace or adjust micro-switch in SSOV actuator. If fault persists,
replace actuator.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 69 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
SECTION 5 – TROUBLESHOOTING GUIDE
TABLE 5-1: Boiler Troubleshooting Procedures
Fault
Indication
Probable Causes
Corrective Action
1. SSOV relay failed on IGST board.
1. Press CLEAR button and restart unit. If fault persists, replace
2. Floating Neutral.
2. The Neutral and Earth Ground are not connected at the source and
3. Hot and Neutral reversed at SSOV.
therefore there is a voltage measured between the two. Normally this
measurement should be near zero or no more than a few millivolts.
3. Check SSOV power wiring.
1. Actuator not allowing for full closure of gas
1. Observe operation of the Safety Shut-Off Valve (SSOV) through
Ignition/Stepper (IGST) Board.
SSOV RELAY
FAILURE
valve.
2. SSOV powered when it should not be
SSOV
SWITCH OPEN
3. Defective switch or Actuator.
4. Incorrectly wired switch.
1. Air/Fuel Valve out of calibration.
2. Air/Fuel Valve unplugged.
STEPPER
MOTOR
FAILURE
3. Loose wiring connection to the stepper motor.
4. Defective Air/Fuel Valve stepper motor.
5. Defective Power Supply Board or fuse.
6. Defective IGST Board.
Page 70 of 164
11/29/2017
indicator on the Valve actuator and ensure that the valve is fully and
not partially closing.
2. If the SSOV never closes, it may be powered continuously. Close
the gas supply and remove power from the unit. Refer fault to
qualified service personnel.
3. Remove the electrical cover from the SSOV and check switch
continuity. If the switch does not show continuity with the gas valve
closed, either adjust or replace the switch or actuator.
4. Ensure that the SSOV Proof of Closure switch is correctly wired.
1. Refer to the C-More User Manual OMM-0032 (GF-112) and perform
the Stepper Feedback Calibration procedure in Section 6, section
6.2.1.
2. Check that the Air/Fuel Valve is connected to the C-More Controller.
3. Inspect for loose connections between the Air/Fuel Valve motor and
the wiring harness.
4. Replace stepper motor.
5. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
Hard Light-Off
Fluctuating Gas Pressure
Air/Fuel Valve “hunting” at
the 70% Valve Position
Probable Causes
Corrective Action
1. Clogged/damaged Gas Injector
1. Disconnect the Staged Ignition Assembly solenoid from the Gas
on Igniter-Injector (Figure 4-1a
through Figure 4-1c).
2. Defective Staged Ignition
Solenoid (Figure 4-1a through
Figure 4-1c).
injector Tube of the Igniter-Injector (Figure 4-1a through Figure 4-1c)
and inspect Gas Injector to ensure it is not clogged or damaged.
2. Close the Manual Shutoff Valve. Attempt to start the unit and listen for
a “clicking” sound that the Staged Ignition Solenoid makes during
Ignition Trial. If “clicking” sound is not heard after 2 or 3 attempts,
replace the Staged Ignition Solenoid.
1. Gas pressure going into unit is
1. Stabilize gas pressure going into unit. If necessary, troubleshoot
fluctuating.
2. Damping Orifice not installed.
Building Supply Regulator.
2. Check if the gas train is supposed to have a Damping Orifice, and if
so, ensure that it is installed in the SSOV Actuator shown in Figure 51, below. For DBB Gas Trains, the Damping Orifice is installed in the
downstream SSOV Actuator).
1. IGST and Power Supply Boards
1. Check to ensure that the IGST and Power Supply Boards are Rev. E
in C-More Controller are
outdated.
OMM-0122_0C
GF-206
or higher.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 71 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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)
Page 72 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
1
Active Setpoint
2
Outlet Temp
This is the setpoint temperature to which the control is set
when operating in the Constant Setpoint, Remote Setpoint or
Outdoor Reset Mode. When in the Constant Setpoint Mode,
this value is equal to the Internal Setpoint setting in the
Configuration Menu. When in the Remote Setpoint Mode, this
value is the setpoint equivalent to the remote analog signal
supplied to the unit. When in the Outdoor Reset Mode, this is
the derived value from the charts in Appendix E.
Displays the outlet water temperature.
3
Inlet Temp
Displays the inlet water temperature.
4
Air Temp
Air Temp is the air temperature at the input to the Air/Fuel
Valve. This reading is one of the parameters used to control
the Blower Motor speed.
5
Outdoor Temp
Outdoor temperature is displayed in ºF or ºC, only if outdoor
temperature sensor is installed and enabled.
6
Valve Position In
Desired input valve position. This would normally be the same
as the fire valve position shown on the bar graph (valve
position out) when the boiler is operating.
7
Valve Position Out
Displays actual real time Valve Position.
8
FFWD Temp
Displays BST header temperature
9
Exhaust Temp
Displays the exhaust temperature in °F (default) or ºC.
10
Flame Strength
Displays flame strength from 0% to 100%.
11
Min Flame Str
Not Used
12
O2 Monitor
Enables or disables the O2 Monitor.
13
Oxygen Level
Displays the real-time combustion oxygen (O2) level (%)
measured by the O2 sensor.
14
Ignition Time
Displays the elapsed time between confirmation of gas valve
opening (POC) until a stable flame is detected.
15
SSOV Time to OPN
Displays the elapsed time between 120VAC being applied to
the Gas Valve and confirmation of gas valve opening (POC).
16
Spark Current
Displays the current going to the ignition transformer.
17
Run Cycles
Displays the total number of run cycles.
18
Run Hours
Displays total run time of unit in hours.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 73 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-1: OPERATING Menu Item Descriptions
MENU OPTIONS
19
Fault Log
DESCRIPTION
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 74 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
1
Password
Allows Level 1 or Level 2 password to be entered.
Entering the Level 1 Password (159) allows options in the Setup,
Configuration and Tuning menus to be modified.
Entering the Level 2 Password (6817) allows options in the
Calibration and Diagnostics Menus to be changed or activated, in
addition to all Level 1 Menu options.
2
Language
Permits selection of the language of displayed messages. English is
the only option at this time.
3
Time
Allows user to set the time, from 12:00 am to 11:59 pm.
4
Date
Allows user to set the date, from 01/01/00 to 12/31/99
5
Unit of Temp
Permits selection of temperature displays in degrees Fahrenheit (°F)
or degrees Celsius (°C).
6
Comm Address
For RS-485 communications. RS232 should have its own
(programmable) password.
7
Baud Rate
Allows communications Baud Rate to be set (2400 to 19.2K).
Default is 9600.
8
onAER Mode
Allows selection of either Ethernet or SD Card.
9
Min Upload Timer
Mandatory for AERCO onAER Remote Data Collection (ORDC).
This parameter enables ORDC and defines the minimum amount of
time between heartbeat data uploads in seconds. The COMM LED
will light during the upload.
10
Unit Alpha
Mandatory for AERCO onAER Remote Data Collection. This value
must match the first alpha digit on the Code Plate, e.g., G-12-1234.
11
Unit Year
Mandatory for AERCO onAER Remote Data Collection. This value
must match the 2-digit year on the Code Plate, e.g., G-12-1234.
12
Unit Serial #
Mandatory for AERCO onAER. Remote Data Collection. This value
must match the 4-digit serial # on the Code Plate, e.g., G-12-1234.
13
Software Version
Identifies the current software version of the C-More Controller.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 75 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. No changes will be required under normal operating conditions.
TABLE A-3: CONFIGURATION Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
1
Internal Setpoint
Allows internal setpoint to be set from Lo Temp Limit of 40°F to
Hi Temp Limit of 240°F (4.4°C to 115.6°C).
2
Unit Type
Can be one of the following: BMK Blr Std, BMK Blr Std Dual,
BMK Blr LN, BMK Blr LN Dual.
3
Unit Size
Sets unit size, depending on the Unit Type:
750 MBH (220 kW), 1000 MBH (293 kW), 1500 MBH (439.6
kW), 2000 MBH (586.1 kW), 2500 MBH (732.6 kW), 3000 MBH
(879.2 kW)
4
Fuel Type
Allows selection of Natural Gas or Propane.
5
Boiler Mode
Only available if Unit Type = Boiler. Allows selection of:
Constant Setpoint, Remote Setpoint, Direct Drive,
Combination, or Outdoor Reset Mode.
6
Remote Signal
Only available if Mode = Remote Setpoint, Direct Drive or
Combination. Used to set the type of external signal which will
be used when operating in the Remote Setpoint, Direct Drive
or Combination Mode.
7
Outdoor Sensor
Allows outdoor sensor function to be set to Enabled or
Disabled.
Bldg Ref Temp
Only available if Boiler Mode = Outdoor Reset. Allows the
building reference temperature to be set when operating a
boiler in the Outdoor Reset Mode.
9
Reset Ratio
Only available if Boiler Mode = Outdoor Reset. Permits setting
of Reset Ratio when operating boiler in the Outdoor Reset
Mode.
10
System Start Tmp
Only if Outdoor Sensor = Enabled. This menu item allows the
system start temperature to be set.
11
Setpt Lo Limit
Used to set the minimum allowable setpoint, from 40°F (4.4°C)
up to the Setpt Hi Limit.
12
Setpt Hi Limit
Used to set the maximum allowable setpoint, from the Setpt Lo
Limit up to 210°F (98.9°C).
13
Temp Hi Limit
This is the maximum allowable outlet temperature, up to 210°F
(98.9°C). Any temperature above this setting will turn off the
unit. The temperature must then drop 5°F (2.75°C) below this
setting to allow the unit to run.
14
Max Valve Position
Sets the maximum allowable valve position for the unit.
15
Pump Delay Timer
Specifies the amount of time, up to 30 minutes, to keep the
pump running after the unit turns off.
8
Page 76 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-3: CONFIGURATION Menu Item Descriptions
MENU OPTIONS
DESCRIPTION
16
Aux Start On Dly
Specifies the amount of time to wait, up to 120 seconds,
between activating the Aux Relay (due to a demand) and
checking the pre-purge string to start the boiler.
17
Failsafe Mode
Allows the Failsafe mode to be set to either Constant Setpoint
or Shutdown.
18
Analog Output
Must be set to Valve Pos 0-10V for all Benchmark models. DO
NOT CHANGE from its default value.
19
Lo Fire Timer
Specifies how long, from 2 to 600 seconds, to remain in the low
fire position after ignition, before going to the desired output.
20
Setpt Limiting
Setpoint Limiting can be Enabled or Disabled.
21
Setpt Limit Band
22
Network Timeout
Specifies the timeout value in seconds before a Modbus fault is
declared, up to 999 seconds.
Shutoff Dly Temp
This feature delays the shutdown of a boiler in order to reduce
excessive cycling. This specifies the temperature value the
Outlet Temperature is permitted to rise above setpoint before
being shut down.
Demand Offset
This entry will reduce excessive ON/OFF cycling in AUTO
mode. When this entry is a non-zero value, the unit will not turn
on again until Valve Position In (Operating menu item 7)
reaches the Start Level value AND the Outlet Temperature
goes below the Active Setpoint – Demand Offset. In addition,
the boiler will fire at the 29% Valve Position level or below for a
period of one minute.
When this entry is set to zero, the unit will turn on again as
soon as the Valve Position In reaches the Start Level value
(Calibration menu item 37). There will not be a one minute
delay when firing at the 29% Valve Position level.
23
24
OMM-0122_0C
GF-206
The Setpoint Limit Band can be set from 0°F to 10°F (0°C to
5.5°C).
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 77 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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.
The Deadband ZONE is defined as operating with an Outlet
Temperature between Active Setpoint + Deadband High and
Active Setpoint – Deadband Low.
When the Outlet Temperature reaches Active Setpoint and
remains there for a period of 15 seconds, the unit will go into a
DEADBAND MODE at which point no Valve Position
corrections will be attempted while the Outlet Temperature
remains anywhere within the Deadband ZONE. When the unit
is in the DEADBAND MODE, the °F or °C LED will flash on and
off. When the Outlet Temperature drifts out of the Deadband
ZONE, the DEADBAND MODE will be terminated and the PID
LOOP will again attempt Valve Position corrections.
Setting range is 0°F (0°C) to 25°F (13.75°C). Default is 5°F
(2.75°C) for both Deadband High and Deadband Low).
25
Deadband High
26
Deadband Low
27
IGST Version
Displays the version of the IGST Board installed.
28
IGN Time Setting
Displays the MAX Ignition time of 4 Seconds or 7 Seconds as
set in the Safety String Harness.
29
Slow Shutdown
Set the Slow Shutdown feature to Enabled or Disabled.
30
Slow Sht Duration
If Slow Shutdown = Enabled, sets the time a boiler will
continue to run at the Stop Level after running above the Slow
Sht Threshold level, up to 9,999 seconds.
31
Slow Sht Threshold
Sets the Fire Rate above which a boiler will trigger the Slow
Shutdown feature.
32
O2 Warnings
Enables or disables AERtrim warning messages.
33
O2 Trim ID
Displays 4 digit AERtrim ID number. Pre-populated on all units.
Changes each time the unit is powered up.
34
Fixed ID
Displays the unit’s fixed 4 digit ID number. Pre-populated on all
units. Does not change.
35
O2 Trim Key
Displays the value of the AERtrim 4 digit license key. Prepopulated on all units.
36
O2 Trim Menu
When set to Enabled, the AERtrim menu options appears.
37
BST Menu
When set to Enabled, the BST menu options appears.
Page 78 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
1
2
3
DESCRIPTION
Prop Band
Generates a fire rate based on the error that exists between
the setpoint temperature and the actual outlet temperature.
If the actual error is less than the proportional band setting
(1°F to 120°F, 0.55°C to 66°C), the fire rate will be less than
100%. If the error is equal to or greater than the
proportional band setting, the fire rate will be 100%.
Integral Gain
This sets the fraction of the output, due to setpoint error, to
add or subtract from the output each minute to move
towards the setpoint. Gain is adjustable from 0.00 to 1.00
(Default is 1.0).
Derivative Time
This value (0.0 to 2.0 min.) responds to the rate of change
of the setpoint error. This is the time that this action
advances the output.
Warmup – The feature embodied in menu items 4, 5 and 6 eliminates Temperature
Overshoots during the “Warmup” period of a cold ignition cycle on all boilers by
temporarily modifying the PID Gain parameter during warmup and for a period defined
in the Tuning menu.
4
Warmup Prop
Band
Range = 1 – 120°F (0.55°C to
66°C)
Default = 95 (52°C)
5
Warmup Int Gain
Range = 0.00 – 2.00
Default = .50
6
Warmup PID
Timer
Range = 0 - 240 seconds
Default = 20 seconds
7
Reset Defaults?
OMM-0122_0C
GF-206
Allows Tuning menu options to be reset to their Factory
Default values.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 79 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).
TABLE A-5: COMBUSTION CAL Menu Item Descriptions
MENU OPTION
1
CAL Voltage:
BMK 750 = 18%
BMK 1000 = 18%
BMK 1500 = 16%
BMK 2000 = 18%
BMK 2500 = 16%
BMK 3000 = 14%
DESCRIPTION
Displays the default DC drive voltage provided to the blower
at each Air/Fuel Valve position (Items 1 – 6). This drive
voltage adjusts the rotational speed of the blower to maximize
combustion efficiency.
2
CAL Voltage 30%
3
CAL Voltage 40%
4
CAL Voltage 50%
5
CAL Voltage 70%
6
CAL Voltage 100%
7
Set Valve Position
Permits selection of the Air/Fuel Valve position (% open) to be
set from 0 to 100%.
8
Blower Output
Permits the DC drive voltage to the blower to be monitored.
9
Set Stby V out
Permits the Standby Voltage to be set from 0 to 4.00 Volts.
10
Oxygen Level
Permits the combustion oxygen level to be displayed (0% to
25%)
Page 80 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
1
MENU OPTION
DESCRIPTION
Stepper Fbk
Allows the Air/Fuel Valve stepper motor feedback current to be calibrated at
the 0% (fully closed) and 100% (fully open) positions. Verification can also
be accomplished at the 50% position.
2
Purge Timer
Allows adjustment of the pre-ignition purge time.
3
Post Purge Timer
Allows adjustment of the purge time when a unit shuts down.
4
IGN Position
Allows adjustment of the valve position (Fire Rate) during the ignition
sequence.
5
Ign Pos Hold Tmr
6
FFWD Temp Disply
Enabled or Disabled.
7
Outlet Tmp Dsply
Enabled or Disabled.
8
Inlet Tmp Dsply
Enabled or Disabled.
9
Valv Pos Out Dsp
Enabled or Disabled.
10
Exhaust Tmp Dsp
Enabled or Disabled.
11
Exhaust Safety
Enabled or Disabled.
12
Flue Material
Select flue material: PVC, Polypropylene, or stainless
13
Exhst Fault Temp
Fault threshold temperature
14
Exhst Module Temp
Decreases Valve Position to lower exhaust temperature.
15
Exhst Warn Temp
Flue temperature high warning
16
Exhst Tmp VP Adj
VP adjust value
17
Exhst Adj Rate
VP adjust rate
18
VP Change Rate
19
VP Up Rate
Allows adjustment of the Valve Position (Fire Rate) increase rate when
raising the Valve Position. VP Up Rate is defined as Seconds per Step.
20
VP Down Rate
Allows adjustment of the Valve Position (Fire Rate) decrease rate when
lowering the Valve Position. VP Down Rate is defined as Seconds per Step.
21
Purge Blwr Offst
Allows adjustment of the blower speed (Blower Output Voltage) during the
Purge cycle.
22
4-20mA Purge Pct
Allows adjustment of the blower speed (Blower Output Voltage) during the
Purge cycle when using an Emerson VFD Drive to control the Blower Motor.
23
PWM In Adj
Allows the Pulse Width Modulation (PWM) duty cycle to be adjusted from 5.0% to +5.0% in 0.1% increments.
24
Analog In Adj
Allows adjustment of the analog input from -5.0% to +5.0%.
25
Flow In Adj
Allows adjustment of the water Flow Rate Input from
-5.0% to +5.0%.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 81 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-6: CALIBRATION Menu Item Descriptions
MENU OPTION
DESCRIPTION
26
Supply Gas Pressure
In Adj
Allows adjustment of the Supply Gas Pressure level from
-5.0% to +5.0% in 0.1 % increments.
27
Gas Plate dp In Adj
Allows adjustment of the Gas Plate dp level from -5.0% to +5.0% in 0.1%
increments.
28
mA Out Adj
Allows adjustment of the milliamp output from -5.0 mA to +5.0 mA.
29
A/F Sensitivity
Allows adjustment of the Air/Fuel (A/F) Valve stepper motor sensitivity to be
adjusted from 1% to 5% in 1% increments.
30
Power Reset
Allows the Power Reset Option to be set to AUTO or MANUAL.
31
Water Temp Reset
Allows the Water Temperature Reset function to be set to AUTO or
MANUAL.
32
Gas Press Reset
Allows the Gas Pressure Reset function to be set to AUTO or MANUAL.
33
Min Off Time
Allows the minimum Off time to be set from 0 to 10 minutes.
34
Heatr Tuning Dsp
Allows Heater Tuning Display to be Enabled or Disabled.
35
Heatr Bkpt Dsp
Allows Heater Breakpoint Display to be Enabled or Disabled. When Enabled,
Breakpoints can be viewed and/or changed.
36
Stop Level
Allows the Stop Level to be set to a valve position ranging from 0% to the
presently set Start Level.
37
Start Level
Allows the Start Level to be set to a valve position ranging from the presently
set Stop Level to a maximum of 40%.
SKIP FEATURE:
Items 38 – 40 embody a feature that allows the user to define a Fire Zone the C-More will avoid. In the rare
instance when a unit emits an objectionable noise at a certain Fire Rate and no other remedy solves the
problem, a Fire Rate skip zone may be defined to command the C-More to Skip-Over the defined Fire Rate.
38
– Skip Range CNTR
Defines the Center (Fire Rate) of the skip band.
39
– Skip Range Span
Defines the + and – band of the Skip Zone Size.
40
– Skip Speed
Defines the speed (Seconds/Fire Rate) at which the band will be skipped.
O2 Settings:
Items 41 – 43 allow calibration of oxygen readings.
41
– O2 Gain
Range = 0.5 to 1.5. (Unity Gain, No Mods)
42
– O2 Offset
Range = -3.0 to +3.0.
43
– O2 Sensor
Enables the O2 Sensor
44
Cal Temp Sensors
Allows calibration of the temperature sensor
Temperature Channel Offset:
Items 45 – 50 embody the feature, which allow the user to field calibrate all six temperature channels by
entering an offset corresponding to the desired temperature channel.
45
– FFWD Temp Offset
Page 82 of 164
11/29/2017
Range: -20 to + 20 (either ºF or °C)
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX A: BOILER MENU DESCRIPTIONS
TABLE A-6: CALIBRATION Menu Item Descriptions
MENU OPTION
DESCRIPTION
46
– Exhst Tmp Ofset
Range: -20 to + 20 (either ºF or °C)
47
– Outdr Air Offset
Range: -20 to + 20 (either ºF or °C)
48
– Inlet Air Offset
Range: -20 to + 20 (either ºF or °C)
49
– Inlet Wtr Offset
Range: -20 to + 20 (either ºF or °C)
50
– Outlet Wtr Offset
Range: -20 to + 20 (either ºF or °C)
51
24 hr Max Cycles
Maximum cycles in 24 hour period.
52
24 hr Max Ovrtemp
Maximum over-temp in 24 hour period.
53
0-10v Out Test
Set the blower voltage at 0-10v for testing.
54
Spark Monitor
Enables or disables the Spark Monitor function, which displays the AC
current on the input of the Ignition Transformer.
56
Min Spark Amps
Allows the adjustment of the minimum spark current required at the spark
transformer input.
56
Max Spark Amps
Allows the adjustment of the maximum spark current required at the spark
transformer input.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 83 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX A: BOILER MENU DESCRIPTIONS
(This page intentionally blank)
Page 84 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
XX sec
Displayed if Demand Delay is active.
DISABLED
HH:MM pm, pm
MM/DD/YY
Displayed if ON/OFF switch is set to OFF. The display also shows
the time (am or pm) and date that the unit was disabled.
FLAME PROVEN
Displayed after flame has been detected for a period of 2 seconds.
Initially, the flame strength is shown in %. After 5 seconds has
elapsed, the time and date are shown in place of flame strength.
IGNITION TRIAL
XX sec
Displayed during ignition trial of startup sequence. The duration of
cycle counts up in seconds.
PURGING
XX sec
Displayed during the purge cycle during startup. The duration of
the purge cycle counts up in seconds.
STANDBY
Displayed when ON/OFF switch is in the ON position, but there is
no demand for heat. The time and date are also displayed.
WAIT
Prompts the operator to wait.
WARMUP
XX sec
Displayed for 2 minutes during the initial warm-up only.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 85 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES
TABLE B-2: FAULT MESSAGES
TABLE B-2: Fault Messages
FAULT MESSAGE
FAULT DESCRIPTION
AIRFLOW FAULT
DURING PURGE
The Blower Proof switch opened during purge,
or air inlet is blocked.
AIRFLOW FAULT
DURING IGN
The Blower Proof switch opened during ignition.
AIRFLOW FAULT
DURING RUN
The Blower Proof switch opened during run.
DELAYED
INTERLOCK OPEN
The Delayed Interlock is open.
DIRECT DRIVE
SIGNAL FAULT
The direct drive signal is not present or is out of range.
FFWD TEMP
SENSOR FAULT
The temperature measured by the Feed Forward (FFWD) Sensor
is out of range.
FLAME LOSS
DURING IGN
The Flame signal was not seen during ignition or lost within 5
seconds after ignition.
FLAME LOSS
DURING RUN
The Flame signal was lost during run.
HEAT DEMAND
FAILURE
The Heat Demand Relays on the Ignition board failed to activate
when commanded.
HIGH EXHAUST
TEMPERATURE
The Exhaust Temperature has exceeded 200°F (93.3°C).
GAS PRESSURE
FAULT
The High Gas Pressure Limit switch is open or the Low Gas
Pressure Limit switch is open.
HIGH WATER
TEMPERATURE
The temperature measured by the Outlet Sensor exceeded the
Temp Hi Limit setting.
HIGH WATER TEMP
SWITCH OPEN
The High Water Temperature Limit switch is open.
IGN BOARD
COMM FAULT
A communication fault has occurred between the PMC board and
Ignition board.
IGN SWTCH CLOSED
DURING PURGE
The Ignition Position Limit switch on the Air/Fuel Valve closed
during purge.
IGN SWTCH OPEN
DURING IGNITION
The Ignition Position Limit switch on the Air/Fuel Valve opened
during ignition.
INTERLOCK
OPEN
The Remote Interlock is open.
LINE VOLTAGE
OUT OF PHASE
The Line (Hot) and Neutral wires are reversed.
Page 86 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES
TABLE B-2: Fault Messages
FAULT MESSAGE
FAULT DESCRIPTION
LOW WATER
LEVEL
The Low Water Cutoff board is indicating low water level.
NETWORK COMM
FAULT
The RS-485 network information is not present or is corrupted.
O2 % OUT OF RANGE
The O2 % has gone below 3% or above 8%.
OUTDOOR TEMP
SENSOR FAULT
The temperature measured by the Outdoor Air Sensor is out of
range.
The temperature measured by the Outlet Sensor is out of range:
OUTLET TEMP
SENSOR FAULT
•
OUTLET TEMPERATURE display = SHt
sensor is shorted
•
OUTLET TEMPERATURE display = Opn indicates
sensor is open-circuited
Indicates
PRG SWTCH CLOSED
DURING IGNITION
The Purge Position Limit switch on the Air/Fuel Valve closed
during ignition.
PRG SWTCH OPEN
DURING PURGE
The Purge Position Limit switch on the Air/Fuel Valve opened
during purge.
REMOTE SETPT
SIGNAL FAULT
The Remote Setpoint signal is not present or is out of range.
RESIDUAL
FLAME
The Flame signal was seen for more than 60 seconds during
standby.
SSOV
SWITCH OPEN
The SSOV switch opened during standby.
SSOV FAULT
DURING PURGE
The SSOV switch opened dug purge.
SSOV FAULT
DURING IGN
The SSOV switch closed or failed to open during ignition.
SSOV FAULT
DURING RUN
The SSOV switch closed for more than 15 seconds during run.
SSOV RELAY
FAILURE
A failure has been detected in one of the relays that control the
SSOV.
STEPPER MOTOR
FAILURE
The Stepper Motor failed to move the Air/Fuel Valve to the desired
position.
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 87 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES
(This page intentionally blank)
Page 88 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART
Appendix C: SENSOR RESISTANCE/VOLTAGE CHART
Temperature Sensor Resistance Voltage Chart (BALCO)
TEMPERATURE
°F
°C
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
-40
-34.4
-28.9
-23.3
-17.2
-12.2
-6.7
-1.1
4.4
10
15.5
21.1
26.7
32.2
37.8
43.3
48.9
54.4
60
65.6
71.1
76.7
82.2
87.8
93.3
98.9
104.4
110
115.6
121.1
OMM-0122_0C
GF-206
RES (OHMS)
VOLTS*
779.0
797.5
816.3
835.4
854.8
874.6
894.7
915.1
935.9
956.9
978.3
1000.0
1022.0
1044.4
1067.0
1090.0
1113.3
1137.0
1160.9
1185.2
1209.5
1234.7
1260.0
1285.6
1311.4
1337.7
1364.2
1391.0
1418.2
1445.7
1.93
1.96
1.99
2.02
2.05
2.07
2.10
2.12
2.15
2.17
2.20
2.23
2.25
2.27
2.30
2.32
2.34
2.36
2.39
2.41
2.43
2.45
2.47
2.50
2.52
2.54
2.56
2.58
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 89 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART
(This page intentionally blank)
Page 90 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. The owner or user of an automatic boiler system
should set up a formal system of periodic preventive maintenance and testing. Tests should be
conducted on a regular basis and the results recorded in a log-book.
Recommended Periodic Testing
ITEM
FREQUENCY
ACTION BY
REMARKS
NOTE: Refer to indicated sections of this manual and the Benchmark 750 – 3000 Installation and
Startup Guide OMM-0121 (GF-205) for detailed procedures.
Gauges, monitors
and indicators
Daily
Operator
Visual inspection and record readings in
operator log
Daily
Operator
Visual check against factory recommended
specifications
Weekly
Operator
Verify factory settings
Semi-Annually
Service Technician
Verify factory settings
Annually
Service Technician
Check with combustion calibration test
equipment (see Section 4.4 of the Benchmark
750 – 3000 Installation and Startup Guide,
OMM-0121 (GF-205)), and the O2 sensor in
Section 4.4 of this guide.
Flue, vent, stack or
intake air duct
Monthly
Operator
Visually inspection condition and check for
obstructions
Spark Igniter-Injector
Weekly
Operator
See Section 4.2.
Air/Fuel Valve
position
Weekly
Operator
Check position indicator dial. See Section 3.2
in the Benchmark 750 – 3000 Installation and
Startup Guide, OMM-0121 (GF-205).
SSOV Leakage test
Annually
Service Technician
Check for leakage in accordance with the
SSOV manufacturer’s (Siemens)
recommendations.
Instrument and
equipment settings
Firing Rate Control
Flame failure
Weekly
Operator
Close manual gas shutoff valve and check
safety shutdown. See Section 5.7 in the
Benchmark 750 – 3000 Installation and
Startup Guide, OMM-0121 (GF-205).
Flame signal strength
Weekly
Operator
Check flame strength using the C-More
Controller’s Operating menu (see section 2.4).
Low water level cut
off and alarm
Weekly
Operator
See section 5.4 in the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121
(GF-205).
Semi-Annually
Operator
Perform a slow drain test in accordance with
ASME Boiler and Pressure Vessel Code,
Section IV.
Annually
Service Technician
Slow drain test
High water temp.
safety control test
OMM-0122_0C
GF-206
See section 5.5 in the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121
(GF-205).
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 91 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX D – RECOMMENDED PERIODIC TESTING
Recommended Periodic Testing
ITEM
FREQUENCY
ACTION BY
Operating controls
Annually
Operator
See section 2.2.
Low air flow
Monthly
Operator
See section 5.8 in the Benchmark 750 – 3000
Installation and Startup Guide, OMM-0121
(GF-205).
High and low gas
pressure interlocks
Monthly
Operator
See sections 5.2 and 5.3 in the Benchmark
750 – 3000 Installation and Startup Guide,
OMM-0121 (GF-205).
Air/Fuel Valve purge
position switch
Annually
Service Technician
See section 5.10 in the Benchmark 750 –
3000 Installation and Startup Guide, OMM0121 (GF-205).
Air/Fuel Valve
ignition position
switch
Annually
Service Technician
See section 5.11 in the Benchmark 750 –
3000 Installation and Startup Guide, OMM0121 (GF-205).
Safety valves
As required
Operator
Inspect burner
components
Semi-Annually
Service Technician
Condensate Trap
SemiAnnually
Operator
See section 4.7.
Oxygen (O2) Level
Monthly
Operator
Verify oxygen level is between 3% and 8%
during boiler operation.
Page 92 of 164
11/29/2017
REMARKS
Check per A.S.M.E. Boiler and Pressure
Vessel Code, Section IV.
See section 4.6.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
50
53
56
59
62
65
68
71
74
77
80
83
86
89
92
50
54
58
62
66
70
74
78
82
86
90
94
98
102
106
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
50
56
62
68
74
80
86
92
98
104
110
116
122
128
134
50
57
64
71
78
85
92
99
106
113
120
127
134
141
148
50
58
66
74
82
90
98
106
114
122
130
138
146
154
162
50
59
68
77
86
95
104
113
122
131
140
149
158
167
176
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
50
60
72
83
94
105
116
127
138
149
160
171
182
193
204
50
62
74
86
98
110
122
134
146
158
170
182
194
206
218
Header Temperature for a Building Reference Temperature = 60°F (15.6°C)
AIR TEMP
°F
°C
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
OMM-0122_0C
GF-206
RESET RATIO
0.6
60
63
66
69
72
75
78
81
84
87
90
93
96
99
102
105
108
0.8
60
64
68
72
76
80
84
88
92
96
100
104
108
112
116
120
124
1.0
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
1.2
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
150
156
1.4
60
67
74
81
88
95
102
109
116
123
130
137
144
151
158
165
172
1.6
60
68
76
84
92
100
108
116
124
132
140
148
156
164
172
180
188
1.8
60
69
78
87
96
105
114
123
132
141
150
159
168
177
186
195
204
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
2.0
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
2.2
60
71
82
93
104
115
126
137
148
159
170
181
192
203
214
2.4
60
72
84
96
108
120
132
144
156
168
180
192
204
216
Page 93 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
65
68
71
74
77
80
83
86
89
92
95
98
101
104
107
110
113
116
65
69
73
77
81
85
89
93
97
101
105
109
113
117
121
125
129
133
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
65
71
77
83
89
95
101
107
113
119
125
131
137
143
149
155
161
167
65
72
79
86
93
100
107
114
121
128
135
142
149
156
163
170
177
201
65
73
81
89
97
105
113
121
129
137
145
153
161
169
177
185
193
218
65
74
83
92
101
110
119
128
137
146
155
164
173
182
191
200
209
65
75
85
95
105
115
125
135
145
155
165
175
185
195
205
215
65
76
87
98
109
120
131
142
153
164
175
186
197
208
219
65
77
89
101
113
125
137
149
161
173
185
197
209
Header Temperature for a Building Reference Temperature = 70°F (21.1°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
-28.9
70
73
76
79
82
85
88
91
94
97
100
103
106
109
112
115
118
121
124
70
74
78
82
86
90
94
98
102
106
110
114
118
122
126
130
134
138
142
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
70
76
82
88
94
100
106
112
118
124
130
136
142
148
154
160
166
172
178
70
77
84
91
98
105
112
119
126
133
140
147
154
161
168
175
182
189
196
70
78
86
94
102
110
118
126
134
142
150
158
166
174
182
190
198
206
214
70
79
88
97
106
115
124
133
142
151
160
169
178
187
196
205
214
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
70
81
92
103
114
125
136
147
158
169
180
191
202
213
70
82
94
106
118
130
142
154
166
178
190
202
214
Page 94 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
23.9
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
-26.1
75
78
81
84
87
90
93
96
99
102
105
108
111
114
117
120
123
126
129
75
79
83
87
91
95
99
103
107
111
115
119
123
127
131
135
139
143
147
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
75
81
87
93
99
105
111
117
123
129
135
141
147
153
159
165
171
177
183
75
82
89
96
103
110
117
124
131
138
145
152
159
166
173
180
187
194
201
75
83
91
99
107
115
123
131
139
147
155
163
171
179
187
195
203
211
219
75
84
93
102
111
120
129
138
147
156
165
174
183
192
201
210
219
75
85
95
105
115
125
135
145
155
165
175
185
195
205
215
75
86
97
108
119
130
141
152
163
174
185
196
207
218
75
87
99
111
123
135
17
159
171
183
195
207
219
Header Temperature for a Building Reference Temperature = 80°F (26.7°C)
AIR TEMP
RESET RATIO
°F
°C
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
26.7
23.9
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
-20.6
-23.3
80
83
86
89
92
95
98
101
104
107
110
113
116
119
122
125
128
131
134
80
84
88
92
96
100
104
108
112
116
120
124
128
132
136
140
144
148
152
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
80
86
92
98
104
110
116
122
128
134
140
146
152
158
164
170
176
182
188
80
87
94
101
108
115
122
129
136
143
150
157
164
171
178
185
192
199
206
80
88
96
104
112
120
128
136
144
152
160
168
176
184
192
200
208
216
80
89
98
107
116
125
134
143
152
161
170
174
188
197
206
215
80
90
100
110
120
130
140
150
160
170
180
190
200
210
80
91
102
113
124
135
146
157
168
179
190
201
212
80
92
104
116
128
140
152
164
176
188
200
212
OMM-0122_0C
GF-206
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 95 of 164
11/29/2017
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
32.2
29.4
26.7
23.9
21.1
18.3
15.6
12.8
10.0
7.2
4.4
1.7
-1.1
-3.9
-6.7
-9.4
-12.2
-15.0
-17.8
90
93
96
99
102
105
108
111
114
117
120
123
126
129
132
135
138
141
144
90
94
98
102
106
110
114
118
122
126
130
134
138
142
146
150
154
158
162
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
90
96
102
108
114
120
126
132
138
144
150
156
162
168
174
180
186
192
198
90
97
104
111
118
125
132
139
146
153
160
167
174
181
188
195
202
209
216
90
98
106
114
122
130
138
146
154
162
170
178
186
194
202
210
218
90
99
108
117
126
135
144
153
162
171
180
189
198
207
216
90
100
110
120
130
140
150
160
170
180
190
200
210
90
101
112
123
134
145
156
167
178
189
200
90
102
114
126
138
150
162
174
186
198
210
Page 96 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
40
EXHAUST MANIFOLD
1
2
1
1
43086
84045
MANIFOLD: EXHAUST
SEAL: EXHAUST MANIFOLD
GAS TRAIN ASSEMBLY
4
1
5
1
22140-1
22140-2
22140-3
81155
STD FM GAS TRAIN ASSY
DBB GAS TRAIN ASSY
PROPANE GAS TRAIN ASSY
GASKET: 1 1/4" PIPE FLANGE
BURNER, AIR/FUEL VALVE, HEAT EXCHANGER
8
10
1
1
12
1
13
14
1
1
17
1
24276-TAB
46026
24367-1
24367-2
24277
81143
28576
28586
BURNER A/F ASSEMBLY
BURNER
BMK 1000 A/F Valve Replacement Kit
BMK 750 A/F Valve Replacement Kit
STAGED IGNITION ASSY
GASKET: BURNER
BMK 750 HEAT EXCHANGER
(Single Inlet)
BMK 1000 HEAT EXCHANGER
(Single Inlet)
HOSES & INSULATION
18
19
BLOWER
20
24
25
26
27
1
1
97087-20
80080
TUBE: FLEXIBLE GAS 20" (50.8 cm)
INSULATION: SHELL
1
1
1
1
1
58061
24356-1
61026
58023
59139
BLOWER BMK 750/100 Replacement Kit
FLAME DETECTOR Replacement Kit
LEAN OXYGEN SENSOR
IGNITER-INJECTOR Replacement Kit
AIR FILTER: 6" X 4.5 (11.4 cm) LG
123966
123552
60011-4
61002-5
65085
61034
60026
64081
65011
65109
65120
SWITCH: OVER TEMP-AUTO RESET
SWITCH: OVER TEMP-MANUAL RESET
BLOWER PROOF SWITCH ASSY:
BLOCKED INLET SWITCH -4.5 W.C.
IGNITION TRANSFORMER
SPARK MONITOR (AC Transducer)
CIRCUIT BREAKER 2 POLE 20A
ECU
TRANSFORMER 115V/24V 100VA
12V POWER SUPPLY
TERMINAL BLOCK: DIN MOUNTED: BLK
CONTROLS
28
29
30
31
32
33
34
35
36
37
39
1
1
1
1
1
1
1
1
1
1
2
AERCO International,
Inc. Blauvelt, NY
10913
Page 97 of 164
10/25/2017
41
2
42
43
45
46
47
48
49
51
52
60
61
62
3
2
1
1
1
2
2
1
1
1
1
1
1
69
1
65121
65122
65118
64088
24327
69102-2
124512
123449
58132
69186-4
69172
65156
61030
61024
65162
TERMINAL BLOCK: DIN MOUNTED:
WHT
TERMINAL GROUND BLOCK: DIN
MOUNTED
FUSE TERMINAL: DIN MOUNTED
LIMIT CONTROL TEMPERATURE
ASSEMBLY: POWER SUPPLY COVER
BENCHMARK PUMP RELAY
FUSE: 4 AMP
SENSOR: TEMPERATURE
THERMOWELL Replacement Kit
C-MORE CONTROLLER
I/O (PCB) ASSEMBLY
FLAME ROD SIGNAL AMPLIFIER
OUTLET TEMP SENSOR
AIR INLET TEMPERATURE SENSOR
24V POWER SUPPLY (SEQUENCING
VALVE)
SHEET METAL/PANEL ASSEMBLY
70
71
72
73
74
76
77
78
79
82
1
1
1
1
1
2
4
1
1
1
37155
37156
37154
25087
25085-3
59179
59133
50010
50011
39217
PANEL: LEFT (Black)
PANEL: RIGHT (Black)
TOP COVER ASSY (Black)
FRONT FRAME ASSY. (Black)
FRONT PANEL
HANDLE, CONCEALED PULL
LATCH: COMPRESSION
LATCH: DRAW
KEEPER: DRAW LATCH
AIR INLET ADAPTER: 6" PVC (Black)
OTHER ACCESSORIES / PARTS
89
90
91
94
1
1
1
1
122843
123863
92094
59178
LOW WATER CUTOFF
VALVE: BALL 1/8" NPT
BOILER DRAIN VALVE: 3/4 MNPT x GHT
VENT: AIR 1/8 NPT
 Not shown on drawing
Benchmark 750/1000 Part List
09/28/2017
BMK 750 28321-TAB rev F
BMK 1000 28253-TAB rev F
Sheet 1 of 6
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
Benchmark 750/1000 Spare Parts Kit P/N 58037-TAB
Part
Number
Description
24286
24441
92006-5
123675-2
123675-3
123675-4
92014
92015-13
92015-15
92015-16
92015-20
92015-484
92015-361
123659
9-234
6” Exhaust Kit
Condensate Trap Assy.
1” Ball Valve
Tridicator
Tridicator
Tridicator
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
¾” Close Nipple
58037-1 58037-2 58037-3 58037-4 58037-5 58037-6 58037-7 58037-8
30 PSI
50 PSI
75 PSI 100 PSI 150 PSI 60 PSI 125 PSI 160 PSI
Apollo Conbraco Apollo
Watts
Watts
Watts
Watts Kunkle
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Wiring Harnesses (not shown in figures below)
Part #
Description
63182
63083
63085
HARNESS: SHELL
HARNESS: O2 SENSOR
HARNESS: CONTROL
63090
HARNESS: TEMPERATURE LIMIT CONTROL
63097
63147
63150
65104
124327
HARNESS: I/O SENSOR/COMM
HARNESS: WIRING: GAS TRAIN
HARNESS: FLAME ROD
CABLE: H.V. IGNITION
HARNESS: INTERLOCK
Additional Benchmark 750/1000 Kits Available
Part #
Description
27086-1
64048
ACTUATOR: SSOV w/o P.O.C. SWITCH Replacement Kit
SSOV WITH PRESSURE REGULATOR Replacement Kit
Other Accessories / Parts (Optional)
Part #
Description
92084-6
MOTORIZED SEQUENCING VALVE
AERCO International,
Inc. Blauvelt, NY
10913
Page 98 of 164
11/29/2017
Benchmark 750/1000 Part List
09/28/2017
BMK 750 28321-TAB rev F
BMK 1000 28253-TAB rev F
Sheet 2 of 6
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
Benchmark 750/1000
Gas Trains
4
FM Gas Train 22140-1
Propane Gas Train 22140-3
LEFT-REAR VIEW
FRONT VIEW
AERCO International,
Inc. Blauvelt, NY
10913
Page 99 of 164
10/25/2017
DBB Gas Train 22140-2
RIGHT-REAR VIEW
Benchmark 750/1000 Part List
09/28/2017
BMK 750 28321-TAB rev F
BMK 1000 28253-TAB rev F
Sheet 3 of 6
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
8
Benchmark 750/1000
Burner – Air/Fuel Valve Assembly
P/N 24276-TAB
Full Diagram Below
AERCO International,
Inc. Blauvelt, NY
10913
Page 100 of 164
11/29/2017
Benchmark 750/1000 Part List
09/28/2017
BMK 750 28321-TAB rev F
BMK 1000 28253-TAB rev F
Sheet 4 of 6
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
AERCO International,
Inc. Blauvelt, NY
10913
Page 101 of 164
10/25/2017
Benchmark 750/1000 Part List
09/28/2017
BMK 750 28321-TAB rev F
BMK 1000 28253-TAB rev F
Sheet 5 of 6
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
TOP VIEW
REAR VIEW
LEFT SIDE VIEW
AERCO International,
Inc. Blauvelt, NY
10913
Page 102 of 164
11/29/2017
FRONT VIEW
RIGHT SIDE VIEW
Benchmark 750/1000 Part List
09/28/2017
BMK 750 28321-TAB rev F
BMK 1000 28253-TAB rev F
Sheet 6 of 6
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
Benchmark 750/1000 FM Gas Train – P/N 22140-1
Item Qty
1
3
4
6
7
13
1
1
1
2
1
2
Part #
Description
95026
92036
64048
12951-2
61002-1
9-22
1.25"NPT 125#: THREADED FLANGE
VALVE: SSOV 1" NPT
ACTUATOR: SSOV W/ REGULATOR
BUSHING: CONTROL BOX
LOW PRESSURE SWITCH: 2.6" W.C. FALL N.O.
PIPE PLUG: 1/4" NPT: STEEL
AERCO International,
Inc. Blauvelt, NY
10913
Page 103 of 164
10/25/2017
Item
Qty
16
23
25
27
29
30
1
1
3
1
1
1
Part #
Description
92006-5
61002-12
92077
99017
97087-20
99015
VALVE: BALL 1" NPT
HIGH GAS PRESSURE SWITCH 4.7" W.C.
1/4" NPT MXF BRASS BALL VALVE
SNUBBER: PRESSURE: 1/4"
TUBE: FLEXIBLE GAS 20" (50.8 cm) LG
DAMPING ORIFICE: SSOV
Benchmark 750-1000 FM Gas Train
04/11/2017
22140-1 rev G
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
Benchmark 750/1000 DBB Gas Train – P/N 22140-2
Item Qty
Part #
Description
1
2
1
4
1
1
2
95026
92036
64048
12951-2
61002-1
99015
9-22
1.25" NPT 125#: THREADED FLANGE
VALVE: SSOV 1" NPT
ACTUATOR: SSOV W/ REGULATOR
BUSHING: CONTROL BOX
LOW PRESSURE SWITCH: 2.6" W.C. FALL N.O.
DAMPING ORIFICE: SSOV
PIPE PLUG: 1/4" NPT: STEEL
1
3
4
6
7
8
13
AERCO International,
Inc. Blauvelt, NY
10913
Page 104 of 164
11/29/2017
Item
Qty
16
18
19
21
23
33
36
1
1
1
1
1
3
1
Part #
Description
92006-5
27086-1
61002-12
122774
99017
92077
97087-20
VALVE: BALL 1" NPT
ACTUATOR: SSOV w/o P.O.C. SWITCH
HIGH GAS PRESSURE SWITCH 4.7" W.C.
VALVE: VENT 3/4" NPT
SNUBBER: PRESSURE: 1/4"
1/4" NPT MXF BRASS BALL VALVE
TUBE: FLEXIBLE GAS 20" " (50.8 cm) LG
Benchmark 750/1000 DBB Gas Train
10/15/2015
22140-2 rev E
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
BMK 750/1000 PROPANE Gas Train – P/N 22140-3
Item Qty Part #
1
2
3
11
12
23
1
1
1
1
2
2
95026
92103
64048
93420
9-22
12951-2
Description
THREADED FLANGE: 1.25" NPT 125#
VALVE: SSOV 1/2" NPT
ACTUATOR: SSOV W/ REGULATOR
UNION ½" NPT FEMALE BLACK MI
PIPE PLUG: 1/4" NPT: STEEL
BUSHING: CONTROL BOX
AERCO
International, Inc.
Blauvelt, NY 10913
Page 105 of 164
10/25/2017
Item Qty
24
25
29
31
32
33
1
3
1
1
1
1
Part #
Description
92006-3
92077
93474
99017
97087-20
99015
VALVE: FULL PORT BALL 1/2" NPT BRASS
1/4" NPT MXF BRASS BALL VALVE
REDUCING COUPLING 1 X 1/2"
SNUBBER: PRESSURE: 1/4"
TUBE, FLEXIBLE GAS 20"
DAMPING ORIFICE: SSOV
Benchmark 750/1000 Gas Train – Propane
04/11/2017
22140-3 rev H
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX F – BENCHMARK 750/1000 PART LIST
Benchmark 750/1000 Burner, Blower, Air/Fuel Valve Assy. – P/N 24276-TAB
Item Qty
1
2
3
4
5
6
7
8
9
11
Part #
24276
24276-1
24276-2
1
1
1
1
1
1
1
1
1
1
Part #
Description
42140
81143
81064
24111
59104
24277
66034
88004
81048
60011-4
PLATE: BURNER
GASKET: BURNER
GASKET: BLOWER
BLOWER: AMETEK 8.9"
OBSERVATION PORT
STAGED IGNITION ASSY
FLAME ROD
O-RING #2-244 BUNA-N
GASKET: FLAME ROD LOW NOx
SWITCH ASSY: BLOWER PROOF
Item
Qty
12
13
15
17
18
19
20
24
25
3
1
1
1
1
1
1
1
1
Qty
Item 15
Description
1
24298
24298-1
24298-2
A/F VALVE ASSY BMK 1000
A/F VALVE ASSY BMK 750
A/F VALVE ASSY BMK 750/1000 PROPANE
AERCO International,
Inc. Blauvelt, NY
10913
Page 106 of 164
11/29/2017
Part #
Description
53033
46026
See Table
61002-5
59171
61026
61024
66026
9-21
WASHER: CLOCKING
BURNER: BMK 1.0
A/F VALVE ASSY
BLOCKED INLET SWITCH -4.5" W.C.
REFLECTOR: SIGHT GLASS
LEAN OXYGEN SENSOR
AIR INLET TEMPERATURE SENSOR
IGNITOR-INJECTOR
PLUG: HEX HD 1/8 NPT
Benchmark 750/1000 Burner Assembly
08/15/2017
24276-TAB Rev K
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
40
EXHAUST MANIFOLD
1
2
3
1
1
1
39187
81165
9-22
GAS TRAIN ASSEMBLY
4
1
22188
22199
22198
22201
EXHAUST MANIFOLD
EXHAUST MANIFOLD SEAL
PIPE PLUG - EXHAUST MANIFOLD
BMK 1500 STANDARD GAS TRAIN
BMK 1500-2000 DBB GAS TRAIN
BMK 1500/2000 GAS TRAIN Dual Fuel
BMK 1500/2000 GAS TRAIN Dual Fuel DBB
HOSES & INSULATION
16
1 97087-72
17
1 80089
FLEX GAS TUBE 72"
SHELL INSULATION
BLOWER
18
21
22
24
25
26
58038
24356-1
61026
58023
59138
43095
BLOWER Replacement Kit
FLAME DETECTOR KIT Replacement Kit
LEAN OXYGEN SENSOR
IGNITER-INJECTOR - Replacement Kit
AIR FILTER, 6”
BLOWER PLENUM, BMK 1500‐2000
123966
123552
60011-4
60011-2
61002-5
69186-4
65085
93230
64081
65011
65109
69141
65120
SWITCH: OVER TEMP-AUTO RESET
SWITCH: OVER TEMP-MANUAL RESET
BMK 1500 BLOWER PROOF SWITCH
BMK 2000 BLOWER PROOF SWITCH
BLOCKED INLET SWITCH -4.5" W.C.
C-MORE CONTROLLER
IGNITION TRANSFORMER
SNUBBER - AIR/FUEL VALVE
ECU, O2 SENSOR
TRANSFORMER 115V/24V 100VA
12V POWER SUPPLY
DIN RAIL MOUNT END STOP
TERMINAL BLOCK: DIN MOUNTED: BLK
CONTROLS
27
1
28
1
29
1
30
31
32
34
35
36
37
38
39
1
1
1
1
1
1
1
3
2
AERCO
International, Inc.
Blauvelt, NY 10913
Page 107 of 164
10/25/2017
65121
3
2
65118
1
1
1
1
2
2
1
64088
60026
65156
65162
124512
123449
58132
54
55
59
60
61
62
67
1
1
1
1
1
1
1
1
63035-1
33170
124324
61024
69102-3
61030
69172
61034
68
1
65147
41
42
43
BURNER, AIR/FUEL VALVE, HEAT EXCHANGER
24378
BMK 1500 BURNER ASSY
8
1 24378-1
BMK 2000 BURNER ASSY
24378-2
BMK 2000 BURNER ASSY Dual Fuel
46042
BURNER, BMK 1500
10
1 46044
BURNER, BMK 2000
11
1 24277
STAGED IGNITION ASSY
14
1 43090
AIR FUEL VALVE PLENUM
AIR/FUEL VALVE ASSY, BMK 1500
24311-3
Replacement Kit
15
1
AIR/FUEL VALVE ASSY, BMK 2000
24311-10
Replacement Kit
1
1
1
1
1
1
2
44
45
46
47 
48
49
51
65122
TERMINAL BLOCK: DIN MOUNTED: WHT
TERMINAL GROUND BLOCK: DIN
MOUNTED
FUSE TERMINAL: DIN MOUNTED
LIMIT CONTROL TEMPERATURE, DIGITAL
CONTROLLER
CIRCUIT BREAKER
FLAME DETECTOR SIGNAL AMPLIFIER
24V POWER SUPPLY (Sequencing Valve)
FUSE: 4 AMP
SENSOR: TEMPERATURE
THERMOWELL Replacement Kit
FUEL SELECTOR SWITCH & HARNESS
Dual Fuel Only
MOUNTING PANEL
GROUND BAR
AIR INLET TEMPERATURE SENSOR
PUMP RELAY
SENSOR: OUTLET TEMPERATURE
INPUT/OUTPUT (PCB) ASSY
SPARK MONITOR (Current Transducer)
EBM 12VDC AXIAL VENT FAN
Dual Fuel Only
SHEET METAL/PANEL ASSEMBLY
70
1 38035
I/O PANEL COVER
71
1 38036
POWER PANEL COVER
72
1 37157
BACK PANEL: RIGHT (Black)
73
1 37158
BACK PANEL: LEFT (Black)
74
2 35029
TOP RAIL (Black)
75
1 25087
FRONT FRAME ASSEMBLY (Black)
76
1 25085-3 FRONT PANEL ASSEMBLY
78
2 59179
HANDLE, CONCEALED PULL
79
4 59133
LATCH, COMPRESSION
80
1 37159
TOP PANEL: FRONT (Black)
81
1 37160
TOP PANEL: BACK (Black)
82
2 30155
SIDE PANEL (Black)
8" AIR INLET ADAPTER, BMK 2000 (Black)
39215
84
6" AIR INLET ADAPTER, BMK 1500 (Black)
1 39218
OTHER ACCESSORIES & PARTS
90
1 69126
LOW WATER CUTOFF/CAPACITOR ASSY
91
1 123863
1/8" NTP BALL VALVE
92
1 92094
3/4" DRAIN VALVE
95
1 59178
1/8" AIR VENT
 Not shown on drawing
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 1 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Spare Parts Kits: BMK 1500 P/N 58088-TAB, BMK 2000 P/N 58087-TAB
Part #
Description
123540
24441
See Table Below
See Table Below
External 2” Ball Valve
Condensate Trap
Pressure Relief Valve
Pressure/Temp Gauge
Benchmark 1500 Spare Parts Kits P/N 58088-TAB
Benchmark 2000 Spare Parts Kits P/N 58087-TAB
Kit Number *
Description
Pressure
Relief
Valve
58088-C30
58088-C50
58088-C60
58088-C75
58088-C100
58088-C125
58088-C150
58088-W30
58088-W50
58088-W60
30 PSI (207 kPa) KIT (CONBRACO)
50 PSI (345 kPa) KIT (CONBRACO)
60 PSI (414 kPa) KIT (CONBRACO)
75 PSI (517 kPa) KIT (CONBRACO)
100 PSI (689 kPa) KIT (CONBRACO)
125 PSI (862 kPa) KIT (CONBRACO)
150 PSI (1034 kPa) KIT (CONBRACO)
30 PSI (207 kPa) KIT (WATTS)
50 PSI (345 kPa) KIT (WATTS)
60 PSI (414 kPa) KIT (WATTS)
92023-1
92023-2
92023-3
92023-4
92023-5
92023-6
92023-7
92023-8
92023-9
92023-10
Pressure/
Temp
Gauge
123675-5
123675-5
123675-6
123675-6
123675-6
123675-6
123675-7
123675-5
123675-5
123675-6
58088-W75
75 PSI (517 kPa) KIT (WATTS)
92023-11
123675-6
58088-W100
100 PSI (689 kPa) KIT (WATTS)
92023-12
123675-6
58088-W125
125 PSI (862 kPa) KIT (WATTS)
92023-13
123675-6
58088-W150
150 PSI (1034 kPa) KIT (WATTS)
92023-14
123675-7
58088-K160
160 PSI (1103 kPa) KIT (KUNKLE)
92023-15
123675-7
Kit Number *
Description
Pressure
Relief Valve
58087-1
58087-2
58087-3
58087-4
58087-5
58087-6
58087-7
58087-8
58087-9
30 PSI (207 kPa)
50 PSI (345 kPa)
75 PSI (517 kPa)
100 PSI (689 kPa)
150 PSI (1034 kPa)
60 PSI (414 kPa)
125 PSI (862 kPa)
160 PSI (1103 kPa)
40 PSI (276 kPa)
123620-W30
123620-W50
123620-W75
123620-W100
123620-W150
123620-W60
123620-W125
123620-K160
92015-45
Pressure/
Temp
Gauge
123675-5
123675-5
123675-6
123675-6
123675-7
123675-6
123675-6
123675-7
123675-5
* For Dual Fuel units add “DF” to the part number (i.e., 58088-C30-DF)
Wiring Harnesses (not shown in figures below)
Part #
Description
63057
63058
63083
63090
63103
63104
63105
63111
63134
63150
63156
65104
HARNESS: BLOWER POWER
HARNESS: BLOWER SIGNAL
HARNESS: O2 SENSOR
HARNESS, TEMP LIMIT CONTROL
HARNESS: SHELL
HARNESS: I/O INTERLOCK
HARNESS: I/O SENSOR/COMM
HARNESS: CONTROL
VENT FAN POWER WIRE – DUAL FUEL ONLY
HARNESS: FLAME DETECTOR
POWER CABLE, 24V SEQUENCE VALVE
CABLE, H.V. IGNITION
Additional Benchmark 1500/2000 Kits Available
Part #
Description
27086-1
64048
ACTUATOR: SSOV w/o P.O.C. SWITCH Replacement Kit
SSOV WITH PRESSURE REGULATOR Replacement Kit
Other Accessories / Parts (Optional)
Part #
Description
92084-6
MOTORIZED SEQUENCING VALVE
AERCO
International, Inc.
Blauvelt, NY 10913
Page 108 of 164
11/29/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 2 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
AERCO
International, Inc.
Blauvelt, NY 10913
Page 109 of 164
10/25/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 3 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
8
Benchmark 1500/2000
Burner-Air/Fuel Valve Assembly
P/N 24378, 24378-1 & 24378-2
Full part lists below
AERCO
International, Inc.
Blauvelt, NY 10913
Page 110 of 164
11/29/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 4 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
4
4
Benchmark 1500/2000
Standard FM Gas Train
P/N 22188
Benchmark 1500/2000
Double Block & Bleed Gas Train
P/N 22199
See full part lists below
See full part lists below
AERCO
International, Inc.
Blauvelt, NY 10913
Page 111 of 164
10/25/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 5 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
4
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
PROPANE
Gas Train
P/N 22197
AERCO
International, Inc.
Blauvelt, NY 10913
Page 112 of 164
11/29/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 6 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
4
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
PROPANE
Gas Train
P/N 22200
AERCO
International, Inc.
Blauvelt, NY 10913
Page 113 of 164
10/25/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 7 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
REAR VIEW
TOP VIEW
LEFT SIDE VIEW
AERCO
International, Inc.
Blauvelt, NY 10913
Page 114 of 164
11/29/2017
FRONT VIEW
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 8 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
PARTIAL FRONT VIEW
AERCO
International, Inc.
Blauvelt, NY 10913
Page 115 of 164
10/25/2017
Benchmark 1500/1500DF, 2000/2000DF Part List
10/02/2017
Benchmark 1500 29313-TAB rev G
Benchmark 2000 29337-TAB rev G
Sheet 9 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500-2000 Natural Gas Standard Gas Train – P/N 22188
Item Qty Part #
1
1 123542
4
1 64048
5
2 12951-2
6
3 92077
7
4 9-22
8
1 99017
9
1 61002-12
AERCO
International, Inc.
Blauvelt, NY 10913
Page 116 of 164
11/29/2017
Description
FLANGE 2" 125# 2"NPT
ACTUATOR, SSOV W/ REGULATOR
BUSHING, CONTROL BOX
1/4" NPT MXF BRASS BALL VALVE
PIPE PLUG, 1/4" NPT, STEEL
SNUBBER, PRESSURE, 1/4"
HIGH GAS PRESSURE SWITCH 4.7" W.C.
Item Qty Part #
11
1 97087-20
14
1 61002-11
23
1 124150
26
1 93382
28
1 92006-7
29
1 9-294
Description
FLEX HOSE, 20"
LOW GAS PRESSURE SWITCH 3.6" W.C.
VALVE, SSOV 1-1/2" NPT
2'' NPT CAP
VALVE, BALL BRASS 1-1/2" NPT
UNION, 2" NPT 300#
Benchmark 1500-2000 Gas Train
05/28/2015
22188 rev E
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500-2000 Natural Gas DBB Gas Train – P/N 22199
Item Qty Part No
1
4
5
6
19
20
21
22
23
1
1
4
1
1
1
1
1
1
123542
64048
12951-2
97087-20
93382
92006-7
9-294
124142
27086-1
AERCO
International, Inc.
Blauvelt, NY 10913
Page 117 of 164
10/25/2017
Description
FLANGE 2" 125# 2" NPT
ACTUATOR, SSOV W/ REGULATOR
BUSHING, CONTROL BOX
TUBING, FLEXIBLE 20"
2'' NPT CAP
VALVE, BALL BRASS 1-1/2" NPT
UNION, 2" NPT 300#
VALVE, SSOV, DOUBLE BODY, 2" NPT
ACTUATOR, SSOV W/O P.O.C. SWITCH
Item Qty Part No
27
29
33
34
36
37
39
42
1
1
2
1
1
3
1
3
124094
122774
95029
99017
61002-12
92077
61002-11
9-22
Description
UNION, 3/4" NPT #150
VALVE, VENT 3/4" NPT
FLANGE, SSOV 1 1/2" NPT
SNUBBER, PRESSURE, 1/4"
HIGH GAS PRESSURE SWITCH 4.7" W.C.
1/4" NPT MXF BRASS BALL VALVE
LOW GAS PRESSURE SWITCH 3. 6" W.C.
PIPE PLUG, 1/4" NPT, STEEL
Benchmark 1500-2000 DBB Gas Train
11/10/2015
22199 rev F
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500DF – 2000DF NATURAL GAS Gas Train – P/N 22188-1
Item
1
7
8
9
10
11
18
Qty.
1
1
2
3
3
1
1
Part No.
123542
64048
12951-2
92077
9-22
99017
124150
Description
FLANGE 2" 125# 2" NPT
ACTUATOR, SSOV W/ REGULATOR
BUSHING, CONTROL BOX
1/4" NPT MXF BRASS BALL VALVE
PIPE PLUG, 1/4" NPT, STEEL
SNUBBER, PRESSURE, 1/4"
VALVE, SSOV 1-1/2" NPT
AERCO
International, Inc.
Blauvelt, NY 10913
Page 118 of 164
11/29/2017
Item
20
21
22
24
29
31
Qty.
1
1
1
1
2
1
Part No.
93382
92006-7
9-294
9-291
60020
97087-20
Description
2'' NPT CAP
VALVE, BALL BRASS 1-1/2" NPT
UNION, 2" NPT 300#
UNION, 1" NPT 300# BI
GAS PRESSURE SWITCH, 2-20" W.C.
FLEX HOSE, 20"
Benchmark 1500DF-2000DF Gas Train
NATURAL GAS
05/05/2015
22188-1 rev C, component of 22198
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500DF – 2000DF PROPANE Gas Train – P/N 22197
Item
1
2
3
4
8
Qty.
1
1
2
1
1
Part No.
92036
64048
12951-2
9-22
92077
AERCO
International, Inc.
Blauvelt, NY 10913
Page 119 of 164
10/25/2017
Description
VALVE, SSOV 1" NPT
ACTUATOR, SSOV W/ REGULATOR
BUSHING, CONTROL BOX
PIPE PLUG, 1/4" NPT, STEEL
1/4" NPT MXF BRASS BALL VALVE
Item
11
15
19
21
Qty.
1
1
1
2
Part No.
99017
9-291
93466
60020
Description
SNUBBER, PRESSURE, 1/4"
UNION, 1" NPT 300# BI
CAP, 1" NPT M/I
GAS PRESSURE SWITCH, 2-20” W.C.
Benchmark 1500DF-2000DF
PROPANE Gas Train
09/17/2015
22197 rev D, component of 22198
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500DF – 2000DF DBB NATURAL GAS Train – P/N 22199-1
Item Qty
1
1
7
1
8
2
9
4
10
3
11
1
19
1
20
1
21
1
Part No. Description
123542 FLANGE 2" 125# 2" NPT
64048
ACTUATOR, SSOV W/ REGULATOR
12951-2 BUSHING, CONTROL BOX
92077
1/4" NPT MXF BRASS BALL VALVE
9-22
PIPE PLUG, 1/4" NPT, STEEL
99017
SNUBBER, PRESSURE, 1/4"
93382
2'' NPT CAP
92006-7 VALVE, BALL BRASS 1-1/2" NPT
9-294
UNION, 2" NPT 300#
AERCO
International, Inc.
Blauvelt, NY 10913
Page 120 of 164
11/29/2017
Item
24
25
26
27
33
41
44
49
Qty
1
1
1
2
1
1
2
1
Part No.
9-291
124142
27086-1
95029
124094
122774
60020
97087-20
Description
UNION, 1" NPT 300# BI
VALVE, SSOV, DOUBLE BODY, 2" NPT
ACTUATOR, SSOV W/O P.O.C. SWITCH
FLANGE, SSOV 1 1/2" NPT
UNION, 3/4" NPT #150
VALVE, VENT 3/4" NPT
GAS PRESSURE SWITCH, 2-20" W.C.
TUBING, FLEXIBLE 20"
Benchmark 1500DF-2000DF
DBB NATURAL GAS Gas Train
09/17/2015
22199-1 rev D, component of 22201
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500DF – 2000DF DBB PROPANE Gas Train – P/N 22200
Item Qty
1
2
5
8
14
16
1
2
2
2
1
1
Part #
Description
64048
ACTUATOR, SSOV W/ REGULATOR
BUSHING, CONTROL BOX
PIPE PLUG, 1/4" NPT, STEEL
1/4" NPT MXF BRASS BALL VALVE
SNUBBER, PRESSURE, 1/4"
UNION, 1" NPT 300# BI
12951-2
9-22
92077
99017
9-291
AERCO
International, Inc.
Blauvelt, NY 10913
Page 121 of 164
10/25/2017
Item
17
20
27
28
29
31
Qty Part #
Description
2
1
1
1
1
2
VALVE, SSOV 1" NPT1
ACTUATOR, SSOV W/O P.O.C. SWITCH
UNION, 3/4" NPT #150
CAP, 1" NPT M/I
VALVE, VENT 3/4" NPT
GAS PRESSURE SWITCH, 2-20" W.C.
92036
27086-1
124094
93466
122774
60020
Benchmark 1500DF-2000DF
DBB PROPANE Gas Train
10/16/2015
22200 rev E, component of 22201
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX G – BENCHMARK 1500/2000 PART LIST
Benchmark 1500/2000 Burner Assembly – P/N 24378-TAB
Item
Qty
1
2
3
4
5
6
8
9
12
15
16
17
1
1
1
1
1
1
1
5
1
1
1
1
Part #
Description
69078
43090
See Table
See Table
81057
43095
59138
9-21
See Table
See Table
61002-5
81100
BLOWER: AMETEK 12.3"
AIR FUEL VALVE PLENUM
AIR/FUEL VALVE ASSEMBLY
BURNER
GASKET: BLOWER
BLOWER PLENUM
FILTER: AIR 6"
PLUG: HEX HD 1/8 NPT
AIR INLET TEMPERATURE SENSOR
BLOWER PROOF SWITCH ASSEMBLY
BLOCKED INLET SWITCH -4.5" W.C.
GASKET: BLOWER 12.3"
Item
Qty
Part #
Description
19
20
21
22
23
24
25
26
27
32
35
1
1
1
1
1
1
1
1
1
1
1
81166
66026
61026
81048
66034
59104
81183
24277
81184
81186
53033
BURNER GASKET
IGNITOR-INJECTOR
LEAN OXYGEN SENSOR
GASKET: FLAME ROD LOW NOx
FLAME ROD
OBSERVATION PORT
BURNER GASKET: UPPER RELEASE
STAGED IGNITION ASSY
GASKET: BLOWER
BURNER GASKET: LOWER RELEASE
WASHER: CLOCKING
Burner Assembly Parts
Part #
24378
24378-1
24378-2
Description
BMK 1500
BMK 2000
BMK 2000 DF
AERCO
International, Inc.
Blauvelt, NY 10913
Page 122 of 164
11/29/2017
Item 3
24220-3
24220-10
24220-3
Item 4
46042
46044
46044
Item 12
61024
61024
61024
Item 15
60011-4
60011-2
60011-2
Benchmark 1500/2000 Burner Assembly
08/09/2017
24378-TAB rev G
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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 #
EXHAUST MANIFOLD
1
2
3
1
1
6
39156
84040
9-22
Description
MANIFOLD: EXHAUST
SEAL: MANIFOLD
PIPE PLUG: 1/4" NPT: STEEL
GAS TRAIN ASSEMBLY
4
1
22190
22211
22210
22209
22171
22173
22174
22183
BMK 2500 FM GAS TRAIN ASSY
BMK 2500 GAS TRAIN: DBB
BMK 2500 GAS TRAIN: Dual Fuel
BMK 2500 GAS TRAIN: Dual Fuel DBB
BMK 3000 FM GAS TRAIN
BMK 3000 GAS TRAIN: DBB
BMK 3000 GAS TRAIN: Dual Fuel
BMK 3000 GAS TRAIN: Dual Fuel DBB
BURNER, AIR/FUEL VALVE AND HEAT EXCHANGER
8
1
10
1
11
14
1
1
26015-1
26015-2
26014-1
26014-2
46039
46038
24277
43090
24311-1
24311-7
15
1
24311-8
24311-9
BMK 2500 BURNER ASSY 460 VAC
BMK 2500 BURNER ASSY 208 VAC
BMK 3000 BURNER ASSY 460 VAC
BMK 3000 BURNER ASSY 208 VAC
BMK 2500 BURNER
BMK 3000 BURNER
STAGED IGNITION ASSY.
AIR/FUEL VALVE PLENUM
AIR/FUEL VALVE, BMK 3000
Replacement Kit
AIR/FUEL VALVE, BMK 3000 DF
Replacement Kit
AIR/FUEL VALVE, BMK 2500
Replacement Kit
AIR/FUEL VALVE, BMK 2500 DF
Replacement Kit
HOSES & INSULATION
16
17
1
1
97087-72
80081
FLEX TUBE 72" LG
SHELL INSULATION
58063-1 
58063-2
61026
24356-1
58023
88014
43091
123966
123552
60011-2
60011-5
61002-5
69186-4
65085
BLOWER 460V Replacement Kit
BLOWER 208V Replacement Kit
LEAN OXYGEN SENSOR
FLAME DETECTOR Replacement Kit
IGNITOR-INJECTOR Replacement Kit
AIR FILTER
BLOWER PLENUM
ADJUSTABLE TEMP LIMIT SWITCH
OVER TEMP-MANUAL RESET SWITCH
BMK 3000 BLOWER PROOF SWITCH
BMK 2500 BLOWER PROOF SWITCH
BLOCKED INLET SWITCH -4.5" W.C.
C-MORE CONTROLLER
IGNITION TRANSFORMER
BLOWER
18
1
22
21
24
25
26
27
28
1
1
1
1
1
1
1
29
1
30
31
32
1
1
1
AERCO International,
Inc. Blauvelt, NY
10913
Page 123 of 164
11/29/2017
34
35
36
37
38
39
40
41
42
1
1
1
1
3
2
2
3
2
93230
64081
65011
65109
69141
65120
65121
65122
65118
43
1
64088
44
46
47
48
49
1
1
2
2
1
65128
65162
124512
123449
58132
51
1
63035-1
53
54
55
60
61
62
67
1
1
1
1
1
1
1
124310
33170
124324
69102-3
61030
69172
61034
68
1
65147
SNUBBER - AIR/FUEL VALVE
ECU, O2 SENSOR
TRANSFORMER 115V/24V 100VA
12V POWER SUPPLY
DIN RAIL MOUNT END STOP
TERMINAL BLOCK: DIN MOUNTED: BLK
TERMINAL BLOCK: DIN MOUNTED: WHT
TERMINAL GROUND BLOCK: DIN MOUNTED
FUSE TERMINAL: DIN MOUNTED
LIMIT CONTROL TEMPERATURE, DIGITAL
CONTROLLER
3 POLE 20A BREAKER
24V POWER SUPPLY (Sequencing Valve)
FUSE: 4 AMP
SENSOR: TEMPERATURE
THERMOWELL Replacement Kit
FUEL SELECTOR SWITCH & HARNESS
Dual Fuel Only
TRANSFORMER – 460V ONLY
MOUNTING PANEL
GROUND BAR
PUMP RELAY
SENSOR: OUTLET TEMPERATURE
INPUT/OUTPUT (PCB) ASSY
SPARK MONITOR (Current Transducer)
EBM 12VDC AXIAL VENT FAN
Dual Fuel Only
SHEET METAL/PANEL ASSEMBLY
69
70
71
72
73
74
75
76
79
80
81
82
84
85
1
1
2
1
1
2
1
1
4
1
1
2
1
2
38035
38036
59179
37148
37149
35046
25087
25085-3
59133
30156
30157
30155
39215
38044
I/O PANEL COVER
POWER PANEL COVER
HANDLE, CONCEALED PULL
BACK PANEL RIGHT (Black)
BACK PANEL: LEFT (Black)
TOP RAIL (Black)
FRONT FRAME ASSEMBLY (Black)
FRONT PANEL
LATCH, COMPRESSION
TOP PANEL, FRONT (Black)
TOP PANEL, BACK (Black)
SIDE PANEL (Black)
AIR INLET ADAPTER, 8” (Black)
AIR INLET COVER PANEL (Black)
OTHER ACCESSORIES & PARTS
90
1
69126
LOW WATER CUTOFF/CAPACITOR ASSY
91
1
123863
1/8" NTP BALL VALVE
92
1
92094
3/4" DRAIN VALVE
95
1
59178
1/8" AIR VENT
 Not shown on drawing
 Only used in 460 v units
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 1 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500/3000 Spare Parts Kit P/N 58048-TAB
Kit Number * Description
58048-C30
58048-C50
58048-C60
58048-C75
58048-C100
58048-C125
58048-C150
58048-W50
58048-W60
58048-W75
58048-W100
58048-W125
58048-W150
58048-K160
30 PSI (207 kPa) KIT (CONBRACO)
50 PSI (345 kPa) KIT (CONBRACO)
60 PSI (414 kPa) KIT (CONBRACO)
75 PSI (517 kPa) KIT (CONBRACO)
100 PSI (689 kPa) KIT (CONBRACO)
125 PSI (862 kPa) KIT (CONBRACO)
150 PSI (1034 kPa) KIT (CONBRACO)
50 PSI (345 kPa) KIT (WATTS)
60 PSI (414 kPa) KIT (WATTS)
75 PSI (517 kPa) KIT (WATTS)
100 PSI (689 kPa) KIT (WATTS)
125 PSI (862 kPa) KIT (WATTS)
150 PSI (1034 kPa) KIT (WATTS)
160 PSI (1103 kPa) KIT (KUNKLE)
Pressure Relief
Valve Kit
92016-1
92016-2
92016-3
92016-4
92016-5
92016-6
92016-7
92016-8
92016-9
92016-10
92016-11
92016-12
92016-13
92016-14
Pressure/Temp Condensate
Trap Assy.
Gauge
123675-5
123675-5
123675-6
123675-6
123675-6
123675-6
123675-7
24441
123675-5
123675-6
123675-6
123675-6
123675-6
123675-7
123675-7
2” Ball
Valve
123540
* For Dual Fuel units add “DF” to the part number (i.e., 58048-C30-DF)
Other Accessories / Parts (Optional)
Part #
Description
92084-6
MOTORIZED SEQUENCING VALVE
Wiring Harnesses (not shown in figures below)
Part #
Description
63004
63059
63083
63090
63103
63104
63105
63109
63111
63134
65104
HARNESS: 460V TRANSFORMER – 460 V only
HARNESS: DRIVE REACTOR BMK 3.0
HARNESS: O2 SENSOR
HARNESS: TEMPERATURE LIMIT CONTROL
HARNESS: SHELL
HARNESS: I/O INTERLOCK
HARNESS: I/O SENSOR/COMM
HARNESS: GAS TRAIN
HARNESS: CONTROL
VENT FAN POWER WIRE – DUAL FUEL ONLY
CABLE, H.V. IGNITION
Benchmark 2500/3000 Kits Available
Part #
Description
27086-1
64048
ACTUATOR: SSOV w/o P.O.C. SWITCH Replacement Kit
SSOV WITH PRESSURE REGULATOR Replacement Kit
AERCO International,
Inc. Blauvelt, NY
10913
Page 124 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 2 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
`
AERCO International,
Inc. Blauvelt, NY
10913
Page 125 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 3 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
8
Benchmark 2500/3000
Burner - Air/Fuel Valve Assembly
P/N 26015-TAB & 26014-TAB
Full part lists below
AERCO International,
Inc. Blauvelt, NY
10913
Page 126 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 4 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
4
4
Benchmark 3000
Standard FM Gas Train
P/N 22171
See full drawing below
Benchmark 3000
Double Block & Bleed Gas Train
P/N 22173
See full drawing below
4
4
Benchmark 2500
Standard FM Gas Train
P/N 22190
See full drawing below
Benchmark 2500
Double Block & Bleed Gas Train
P/N 22211
See full drawing below
AERCO International,
Inc. Blauvelt, NY
10913
Page 127 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 5 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
NATURAL
GAS
INLET
PROPANE
INLET
Natural Gas
P/N 22177
NATURAL
GAS
INLET
PROPANE
INLET
Natural Gas
P/N 22177-1
Propane
P/N 22178
Propane
P/N 22178-1
4
4
Benchmark 3000 Dual Fuel
FM Gas Train
P/N 22174
Benchmark 3000 Dual Fuel
Double Block & Bleed Gas Train
P/N 22183
See full diagram below
See full diagram below
AERCO International,
Inc. Blauvelt, NY
10913
Page 128 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 6 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
NATURAL
GAS
INLET
PROPANE
INLET
NATURAL
GAS
INLET
PROPANE
INLET
Natural Gas
P/N 22209-1
Natural Gas
P/N 22210-1
Propane
P/N 22209-2
Propane
P/N 22210-2
4
4
Benchmark 2500 Dual Fuel
FM Gas Train
P/N 22210
Benchmark 2500 Dual Fuel
Double Block & Bleed Gas Train
P/N 22209
See full diagram below
See full diagram below
AERCO International,
Inc. Blauvelt, NY
10913
Page 129 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 7 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
REAR VIEW
TOP VIEW
LEFT SIDE VIEW
AERCO International,
Inc. Blauvelt, NY
10913
Page 130 of 164
11/29/2017
FRONT VIEW
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 8 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
PARTIAL FRONT VIEW – FRONT PANEL REMOVED
AERCO International,
Inc. Blauvelt, NY
10913
Page 131 of 164
11/29/2017
Benchmark 2500/2500DF & 3000/3000DF Part List
10/09/2017
Benchmark 2500 28536-TAB rev E
Benchmark 3000 28382-TAB rev F
Sheet 9 of 9
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 3000 FM Gas Train – P/N 22171
Item
1
5
7
Qty.
1
1
1
9
1
10
12
18
2
1
1
P/N
123542
123540
99015
64048
12951-2
124136
97087-12
AERCO
International, Inc.
Blauvelt, NY 10913
Page 132 of 164
11/29/2017
Description
FLANGE 2" 125# 2" NPT
VALVE: BALL 2" FULL PORT
DAMPING ORIFICE: SSOV
ACTUATOR: SSOV W/
REGULATOR
BUSHING: CONTROL BOX
VALVE: SSOV 2" NPT
FLEX GAS TUBING 12"
Item
26
27
29
Qty.
1
2
1
31
1
32
33
2
1
P/N
60020
9-22
99017
Description
SWITCH: GAS PRESSURE 2-20" W.C.
PIPE PLUG: 1/4" NPT: STEEL
SNUBBER: PRESSURE: 1/4"
60032
92143
9-294
SWITCH: GAS PRESSURE 1-20" W.C.
1/4" BALL VALVE: WATTS
UNION: 2" NPT 300#
Benchmark 3000 FM Gas Train
01/17/2017
P/N 22171 rev J
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 3000 DBB Gas Train – NATURAL GAS – P/N 22173
Item
1
4
6
7
11
12
13
15
18
Qty
1
1
2
1
1
1
1
1
4
Part #
123542
123540
95030
124142
64048
27086-1
99015
123769
12951-2
AERCO
International, Inc.
Blauvelt, NY 10913
Page 133 of 164
11/29/2017
Description
FLANGE 2" 125# 2"NPT
VALVE: BALL 2" FULL PORT
FLANGE: SSOV 2" NPT
VALVE: SSOV: DOUBLE BODY: 2" NPT
ACTUATOR: SSOV W/ REGULATOR
ACTUATOR: SSOV W/O P.O.C. SWITCH
DAMPING ORIFICE: SSOV
VALVE: SOLENOID N.O. 1" NPT
BUSHING: CONTROL BOX
Item
23
27
28
31
35
36
37
38
39
Qty
1
1
2
1
2
1
1
1
1
Part #
93382
99017
9-22
97087-16
92143
9-294
60020
124094
60032
Description
2'' NPT CAP
SNUBBER: PRESSURE: 1/4"
PIPE PLUG: 1/4" NPT: STEEL
TUBING: FLEXIBLE GAS 12"
1/4" BALL VALVE: WATTS
UNION: 2" NPT 300#
SWITCH: GAS PRESSURE 2-20" W.C.
UNION: 3/4" NPT #150
SWITCH: GAS PRESSURE 2-20" W.C.
Benchmark 3000 DBB Gas Train – Natural
Gas
01/04/2017
22173 rev K
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500 FM Gas Train – P/N 22190
Item Qty
1
1
7
1
10
1
11
1
15
1
19
1
24
1
Part #
123542
92006-7
124150
64048
93382
97087-12
61002-11
AERCO
International, Inc.
Blauvelt, NY 10913
Page 134 of 164
11/29/2017
Description
FLANGE 2" 125# 2"NPT
VALVE: BALL BRASS 1-1/2" NPT
VALVE: SSOV 1-1/2" NPT
ACTUATOR: SSOV W/ REGULATOR
2'' NPT CAP
Flex Tubing 12"
LOW GAS PRESSURE SWITCH 3.6" W.C.
Item Qty
25
3
26
2
28
2
29
1
32
1
33
1
34
1
Part #
92077
9-22
12951-2
99017
99015
9-294
61002-22
Description
1/4" NPT MXF BRASS BALL VALVE
PIPE PLUG: 1/4" NPT: STEEL
BUSHING: CONTROL BOX
SNUBBER: PRESSURE: 1/4"
DAMPING ORIFICE: SSOV
UNION: 2" NPT 300#
HIGH GAS PRESSURE SWITCH 3.0" W.C.
Benchmark 2500 FM Gas Train
07/21/2016
22190 – rev D
Page 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500 Natural Gas DBB Gas Train – P/N 22211
Item Qty
1
1
7
1
9
1
13
1
17
1
21
1
22
3
23
2
25
4
Part #
123542
92006-7
64048
93382
97087-12
61002-11
92077
9-22
12951-2
Description
Item Qty
FLANGE 2" 125# 2"NPT
26
1
VALVE: BALL BRASS 1-1/2" NPT
29
1
ACTUATOR: SSOV W/ REGULATOR
30
1
2'' NPT CAP
31
2
Flex Gas Tubing 12"
32
1
LOW GAS PRESSURE SWITCH 3.6" W.C. 33
1
1/4" NPT MXF BRASS BALL VALVE
40
1
PIPE PLUG: 1/4" NPT: STEEL
41
1
BUSHING: CONTROL BOX
42
1
AERCO
International, Inc.
Blauvelt, NY 10913
Page 135 of 164
11/29/2017
Part #
99017
99015
124137
95029
27086-1
122774
124094
9-294
61002-22
Description
SNUBBER: PRESSURE: 1/4"
DAMPING ORIFICE: SSOV
VALVE: SSOV: DOUBLE BODY: 1-1/2" NPT
FLANGE: SSOV 1 1/2" NPT
ACTUATOR: SSOV W/O P.O.C. SWITCH
VALVE: VENT 3/4" NPT
UNION: 3/4" NPT #150
UNION: 2" NPT 300#
HIGH GAS PRESSURE SWITCH: 3.0" W.C.
Benchmark 2500 Natural Gas DBB Gas Train
07/22/2016
22211 rev E
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 3000 DF Gas Train – NATURAL GAS – P/N 22177
Item
1
6
7
8
9
Qty
1
1
1
4
1
Part #
124142
123542
64048
12951-2
99017
11
1
27086-1
12
14
2
1
9-22
93382
AERCO
International, Inc.
Blauvelt, NY 10913
Page 136 of 164
11/29/2017
Description
VALVE: SSOV: DOUBLE BODY: 2" NPT
FLANGE 2" 125# 2"NPT
ACTUATOR: SSOV W/ REGULATOR
BUSHING: CONTROL BOX
SNUBBER: PRESSURE: 1/4"
ACTUATOR: SSOV W/O P.O.C.
SWITCH
PIPE PLUG: 1/4" NPT: STEEL
2'' NPT CAP
Item
16
20
21
22
25
Qty
1
1
1
2
1
Part #
99015
123540
9-294
95030
60032
Description
DAMPING ORIFICE: SSOV
VALVE: BALL 2" FULL PORT
UNION: 2" NPT 300#
FLANGE: SSOV 2" NPT
SWITCH: GAS PRESSURE 2-20" W.C.
26
1
60020
SWITCH: GAS PRESSURE 2-20" W.C.
27
2
92143
1/4" BALL VALVE: WATTS
Benchmark 3000DF Gas Train – NATURAL GAS
01/03/2017
22177 rev F, component of 22174
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 3000 DF PROPANE Gas Train – P/N 22178
Item
Qty
Part #
1
1
124142
2
1
64048
3
1
27086-1
6
8
11
12
2
1
1
1
9-22
99017
93382
99015
Description
VALVE: SSOV: DOUBLE BODY: 2"
NPT
ACTUATOR: SSOV W/ REGULATOR
ACTUATOR: SSOV W/O P.O.C.
SWITCH
PIPE PLUG: 1/4" NPT: STEEL
SNUBBER: PRESSURE: 1/4"
2'' NPT CAP
DAMPING ORIFICE: SSOV
Item
Qty
Part #
Description
13
4
12951-2
BUSHING: CONTROL BOX
17
2
95030
FLANGE: SSOV 2" NPT
23
1
60032
SWITCH: GAS PRESSURE 2-20" W.C.
24
25
*
1
2
1
60020
SWITCH: GAS PRESSURE 2-20" W.C.
92143
1/4" BALL VALVE: WATTS
97087-12 FLEX HOSE 12”
*
AERCO
International, Inc.
Blauvelt, NY 10913
Page 137 of 164
11/29/2017
Benchmark 3000 DF Gas Train – PROPANE
01/03/2017
22178 rev F, component of 22174
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 3000 DF DBB NATURAL GAS Gas Train – P/N 22177-1
Item
1
4
7
8
9
11
12
14
Qty
1
1
1
4
1
1
2
1
Part #
124142
123540
123542
12951-2
99017
27086-1
9-22
93382
AERCO
International, Inc.
Blauvelt, NY 10913
Page 138 of 164
11/29/2017
Description
VALVE: SSOV: DOUBLE BODY: 2" NPT
VALVE: BALL 2" FULL PORT
FLANGE 2" 125# 2"NPT
BUSHING: CONTROL BOX
SNUBBER: PRESSURE: 1/4"
ACTUATOR: SSOV W/O P.O.C. SWITCH
PIPE PLUG: 1/4" NPT: STEEL
2'' NPT CAP
Item
15
19
23
25
29
32
33
34
Qty
1
1
1
1
2
1
1
2
Part #
99015
123769
64048
9-294
95030
60032
60020
92143
Description
DAMPING ORIFICE: SSOV
VALVE, SOLENOID N.O. 1" NPT
ACTUATOR: SSOV W/ REGULATOR
UNION: 2" NPT 300#
FLANGE: SSOV 2" NPT
SWITCH: GAS PRESSURE 2-20" W.C.
SWITCH: GAS PRESSURE 2-20" W.C.
1/4" BALL VALVE: WATTS
Benchmark 3000DF DBB Gas Train – NATURAL GAS
01/03/2017
22177-1 rev F, component of 22183
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 3000 DF DBB PROPANE Gas Train – P/N 22178-1
Item
1
2
3
6
8
11
12
13
Qty
1
1
1
2
1
1
1
4
Part #
124142
64048
27086-1
9-22
99017
93382
99015
12951-2
AERCO
International, Inc.
Blauvelt, NY 10913
Page 139 of 164
11/29/2017
Description
VALVE: SSOV: DOUBLE BODY: 2" NPT
ACTUATOR: SSOV W/ REGULATOR
ACTUATOR: SSOV W/O P.O.C. SWITCH
PIPE PLUG: 1/4" NPT: STEEL
SNUBBER: PRESSURE: 1/4"
2'' NPT CAP
DAMPING ORIFICE: SSOV
BUSHING: CONTROL BOX
Item
16
22
24
25
29
32
*
Qty
2
2
1
1
1
1
1
Part #
95030
92143
60032
60020
123769
123771
97005-5
Description
FLANGE: SSOV 2" NPT
1/4" BALL VALVE: WATTS
SWITCH: GAS PRESSURE 2-20" W.C.
SWITCH: GAS PRESSURE 2-20" W.C.
VALVE: SOLENOID N.O. 1" NPT
UNION: MA x FEM 1" NPT: 150# M.I.
FLEX HOSE, 18”
Benchmark 3000 DF DBB Gas Train – PROPANE
01/05/2017
22178-1 rev E, component of 22183
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500 Dual Fuel FM Gas Train, Natural Gas – P/N 22210-1
Item
1
7
9
10
14
17
22
23
Qty
1
1
1
1
1
1
1
3
Part #
123542
92006-7
124150
64048
93382
97087-12
61002-21
92077
Description
FLANGE 2" 125# 2" NPT
VALVE: BALL BRASS 1-1/2" NPT
VALVE: SSOV 1-1/2" NPT
ACTUATOR: SSOV W/ REGULATOR
2'' NPT CAP
TUBING: FLEXIBLE GAS 12"
LOW GAS PRESSURE SWITCH 7.5" W.C.
1/4" NPT MXF BRASS BALL VALVE
AERCO
International, Inc.
Blauvelt, NY 10913
Page 140 of 164
11/29/2017
Item
24
25
27
29
30
32
33
34
Qty
2
2
1
1
2
1
1
1
Part #
9-22
12951-2
99015
93310
99017
61002-15
9-294
61002-22
Description
PIPE PLUG: 1/4" NPT: STEEL
BUSHING: CONTROL BOX
DAMPING ORIFICE: SSOV
1-1/2" 150# BLACK IRON UNION
SNUBBER: PRESSURE: 1/4"
HIGH GAS PRESSURE SWITCH 7.0" W.C.
UNION: 2" NPT 300#
HIGH PRESSURE SWITCH 3.0
Benchmark 2500 DF FM Gas Train – Natural Gas
02/19/2016
22210-1 rev B, component of 22210
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500 Dual Fuel FM Gas Train – Propane – P/N 22210-2
Item
5
6
9
16
17
Qty
1
1
1
1
1
P/N
124150
64048
93382
61002-11
92077
AERCO
International, Inc.
Blauvelt, NY 10913
Page 141 of 164
11/29/2017
Description
VALVE: SSOV 1-1/2" NPT
ACTUATOR: SSOV W/ REGULATOR
2'' NPT CAP
LOW GAS PRESSURE SWITCH 3.6" W.C.
1/4" NPT MXF BRASS BALL VALVE
Item Qty P/N
18
1
9-22
19
2
12951-2
21
1
99015
23
1
9-294
Description
PIPE PLUG: 1/4" NPT: STEEL
BUSHING: CONTROL BOX
DAMPING ORIFICE: SSOV
UNION: 2" NPT 300#
Benchmark 2500 DF FM Gas Train – PROPANE
02/19/2016
22210-2 rev B, component of 22210
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500 DF DBB Gas Train – NATURAL GAS – P/N 22209-1
Item Qty
1
1
7
1
9
1
13
1
17
1
21
1
24
2
25
3
26
1
27
1
Part #
123542
92006-7
Description
Item Qty
FLANGE 2" 125# 2"NPT
28
2
VALVE: BALL BRASS 1-1/2" NPT
29
1
64048
ACTUATOR: SSOV W/ REGULATOR
30
1
93382
2'' NPT CAP
35
1
97087-12 TUBING, FLEXIBLE GAS 12"
36
1
61002-21 LOW GAS PRESSURE SWITCH 7.5" W.C.
39
1
9-22
PIPE PLUG: 1/4" NPT: STEEL
41
2
92077
1/4" NPT MXF BRASS BALL VALVE
42
1
99015
DAMPING ORIFICE: SSOV
43
1
124137
VALVE: SSOV: DOUBLE BODY: 1-1/2" NPT
AERCO
International, Inc.
Blauvelt, NY 10913
Page 142 of 164
11/29/2017
Part #
95029
27086-1
122774
124094
9-294
93310
99017
61002-15
61002-22
Description
FLANGE: SSOV 1 1/2" NPT
ACTUATOR: SSOV W/O P.O.C. SWITCH
VALVE: VENT 3/4" NPT
UNION: 3/4" NPT #150
UNION: 2" NPT 300#
1-1/2" 150# BLACK IRON UNION
SNUBBER: PRESSURE: 1/4"
HIGH GAS PRESSURE SWITCH 7.0" W.C.
SWITCH, HIGH 3.0
Benchmark 2500DF DBB Gas Train –
NATURAL GAS
22209-1 rev C, component of 22209
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
02/19/2016
Sheet 1 of 1
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Benchmark 2500 DF DBB Gas Train – PROPANE – P/N 22209-2
Item Qty
7
1
10
1
15
1
16
1
17
1
18
4
Part #
64048
93382
61002-11
92077
9-22
12951-2
AERCO
International, Inc.
Blauvelt, NY 10913
Page 143 of 164
11/29/2017
Description
ACTUATOR: SSOV W/ REGULATOR
2'' NPT CAP
LOW GAS PRESSURE SWITCH 3.6" W.C.
1/4" NPT MXF BRASS BALL VALVE
PIPE PLUG: 1/4" NPT: STEEL
BUSHING, CONTROL BOX
Item Qty
19
1
20
1
22
1
23
1
24
2
25
1
Part #
99015
9-294
124137
27086-1
95029
122774
Description
DAMPING ORIFICE: SSOV
UNION: 2" NPT 300#
VALVE: SSOV: DOUBLE BODY: 1-1/2" NPT
ACTUATOR: SSOV W/O P.O.C. SWITCH
FLANGE: SSOV 1 1/2" NPT
VALVE, VENT 3/4“ NPT
Benchmark 2500 DF DBB Gas Train
PROPANE
03/23/2016
22209-2 rev C, component of 22209
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX H – BENCHMARK 2500/3000 PART LIST
Burner Assembly: BMK 2500 P/N 26015-TAB, BMK 3000 P/N 26014-TAB
Item Qty
1
2
3
1
1
1
4
1
5
6
7
8
9
10
11
1
1
1
1
1
1
1
Part #
Description
43091
See Table
43090
46039
46039
See Table
59104
61026
66034
66026
81048
24277
BLOWER PLENUM (MACHINING)
3 PHASE BLOWER Replacement Kit
AIR FUEL VALVE PLENUM
BURNER: BMK 2500
BURNER: BMK 3000
A/F VALVE ASSY Replacement Kit
OBSERVATION PORT
LEAN OXYGEN SENSOR
FLAME ROD
IGNITOR-INJECTOR
GASKET: FLAME ROD LOW NOX
STAGED IGNITION ASSY
Description
Item 2
460VAC SINGLE FUEL
208VAC SINGLE FUEL
460VAC DUAL FUEL
208VAC DUAL FUEL
58063-1
58063-2
58063-1
58063-2
AERCO
International, Inc.
Blauvelt, NY 10913
Page 144 of 164
11/29/2017
Item Qty Part #
13
1
14
15
17
19
25
27
31
32
33
34
1
2
1
1
1
1
1
1
1
1
60011-5
60011-2
61002-5
9-22
81057
81157
61024
88015
93230
81180
81173
81185
Description
BLOWER PROOF SWITCH, BMK 2500
BLOWER PROOF SWITCH, BMK 3000
BLOCKED INLET SWITCH -4.5" W.C.
PIPE PLUG: 1/4" NPT: STEEL
GASKET: BLOWER
BLOWER GASKET
AIR INLET TEMPERATURE SENSOR
O RING, 3/16 x 7”
SNUBBER
GASKET: BURNER
RELEASE GASKET
RELEASE GASKET: LOWER
Item 5
BMK 2500
24311-8
24311-8
24311-9
24311-9
BMK 3000
24311-1
24311-1
24311-7
24311-7
Benchmark 2500 - 3000 Burner Assembly
08/10/2017
BMK 2500 – 26015-TAB rev E
BMK 3000 – 26014-TAB rev K
Sheet 1 of 1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Appendix I: WIRING DIAGRAMS
Benchmark 750/1000 – Drawing Number: 68038 rev G Sheet 1 of 2
Page 145 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 750/1000 – Drawing Number: 68038 rev G Sheet 2 of 2
Page 146 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 1500/2000 – Drawing Number 68050 rev C page 1 of 2
Page 147 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 1500/2000 – Drawing Number 68050 rev C page 2 of 2
Page 148 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 1500/2000 DBB – Drawing Number 68071 rev C page 1 of 2
Page 149 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 1500/2000 DBB – Drawing Number 68071 rev C page 2 of 2
Page 150 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 3000 208 VAC – Diagram 68040 rev F, Sheet 1 of 2
Page 151 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 3000 208 VAC – Drawing Number: 68040 rev F, Sheet 2 of 2
Page 152 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 3000 460 VAC – Drawing Number: 68041 rev F Sheet 1 of 2
Page 153 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 3000 460 VAC – Drawing Number: 68041 rev E Sheet 2 of 2
Page 154 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 2500 208 VAC – Drawing Number: 68060 rev C Sheet 1 of 2
Page 155 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 2500 208 VAC – Drawing Number: 68060 rev C Sheet 2 of 2
Page 156 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 2500/3000 208 VAC DBB – Drawing Number: 68062 rev C Sheet 1 of 2
Page 157 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 2500/3000 208 VAC DBB – Drawing Number: 68062 rev C Sheet 2 of 2
Page 158 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 2500/3000 460 VAC DBB – Drawing Number: 68063 rev B Sheet 1 of 2
Page 159 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
APPENDIX I – WIRING DIAGRAMS
Benchmark 2500/3000 460 VAC DBB – Drawing Number: 68063 rev B Sheet 2 of 2
Page 160 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
ROCKER
SWITCH
P/N 124947
ENCLOSURE
P/N 124951
POWER SUPPLY BOARD
P/N 124362
V.F.D DISPLAY
MODULE
P/N 124527
IGNITION STEPPER BOARD
P/N 124361
FISH PAPER INSULATOR
P/N 124960
PUSH BUTTON
SWITCHES
P/N 124954
FRONT FACE PLATE, BENCHMARK
P/N 124949
VERTICAL OVERLAY, BENCHMARK
P/N 124718
Figure J-1 – C-More Controller - Exploded View
Page 161 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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. SENSOR/COMM HARNESS
CONNECTOR (24 PIN)
TO INPUT/OUTPUT (I/O) BOX
SENSOR HARNESS CONNECTOR
(7 PIN)
Figure J-2: C-More Controller Rear View
Page 162 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
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
120 VAC Blower Replacement Kit
BMK 750/1000
BMK 1500/2000
BMK 2500/3000
58061
58038
58063-1 – 460V
58063-2 – 208V
64048
64048
64048
27086-1
27086-1
27086-1
123552
123552
123552
SSOV Actuator/Regulator Combo - Used
on:
• ALL FM gas trains
• Downstream SSOV on DBB gas
trains
SSOV Actuator Without Proof of Closure
Switch - Used on:
• Upstream SSOV on DBB gas trains
Temperature Switch - Manual Reset
TABLE K-2: Recommended Spare Parts For Maintenance
DESCRIPTION
PART NUMBER
Annual Maintenance Kit
BMK 750 – 3000: 58025-01
BMK 750/1000:
24-month Waterside/Fireside Inspection Kit
58025-08
BMK 1500/2000: 58025-13
BMK 2500/3000: 58025-10
TABLE K-3: Optional Spare Parts
DESCRIPTION
PART NUMBER
C-More Controller
69186-4
Burner
BMK 750/1000
46026
BMK 1500
46042
BMK 2000
46044
BMK 2500
46039
BMK 3000
46038
Lean Oxygen Sensor
Page 163 of 164
11/29/2017
61026
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide
Change log:
Date
Description
Rev B:
07/17/2017 DIR 17-050: Corrected part and kit numbers and figure numbers in
Section 4: Maintenance
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.
(Reference 17-076)
DIR 17-080: Verified and corrected part numbers in Appendix F
through G.
Changed By
Chris Blair
Chris Blair
© AERCO International, Inc., 2017
Page 164 of 164
11/29/2017
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
OMM-0122_0C
GF-206
Download PDF
Similar pages