Watts Aerco Benchmark 5000 Manuel utilisateur

Heating and Hot Water Solutions

AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913

USA: T: (845) 580-8000 • Toll Free: (800) 526-0288 • AERCO.com

Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST

Reference Manual

Benchmark®Boilers with

Edge [i] Controller

Natural Gas, Propane Gas and Dual Fuel

Modulating & Condensing Boilers

Models 750 through 6000

Other documents for this product include:

OMM-0144, GF-217 Installation and Startup Manual

OMM-0145, GF-218 Operation-Service Manual

TAG-0019, GF-2070 Boiler Application Guide

TAG-0022, GF-2050 Vent-Combustion Air Guide

TAG-0047, GF-2030 Benchmark Gas Guide

TAG-0048, GF-2060 Benchmark Power Guide

Applies to serial numbers:

G-20-0100 and above –BMK 750 –5000N

N-20-0050 and above –BMK 5000 & 6000

OMM-0146_A • GF-219 • 5/25/2020

Disclaimer

The information contained in this manual is subject to change without notice

from AERCO International, Inc. AERCO makes no warranty of any kind with

respect to this material, including, but not limited to, implied warranties of

merchantability and fitness for a particular application. AERCO International is

not liable for errors appearing in this manual, not for incidental or

consequential damages occurring in connection with the furnishing,

performance, or use of these materials.

Benchmark with Edge [I] Controller: Reference Manual

CONTENTS

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 2of 76

Table of Contents

TABLE OF CONTENTS...........................................................................................2

SECTION 1: SAFETY PRECAUTIONS ...................................................................3

1.1 WARNINGS & CAUTIONS .....................................................................................................................3

1.2 EMERGENCY SHUTDOWN...................................................................................................................4

1.3 PROLONGED SHUTDOWN...................................................................................................................4

SECTION 2: BENCHMARK 750 & 1000 PART LIST...............................................5

SECTION 3: BENCHMARK 1500 & 2000 PART LIST...........................................15

SECTION 4: BENCHMARK 2500 & 3000 PART LIST...........................................27

SECTION 5: BENCHMARK 4000 & 5000N PART LIST ........................................45

SECTION 6: BENCHMARK 5000 & 6000 PART LIST...........................................59

SECTION 7: SENSOR RESISTANCE CHART........................................................75

Benchmark with Edge [I] Controller: Reference Manual

SECTION 1: SAFETY PRECAUTIONS

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 3of 76

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 GasBurning 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.

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 onthe 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 (BMK750 –2000), 208 or 480 VAC (BMK2500 –

BMK3000), 480 VAC (BMK4000 & 5000N), or 208, 480 or 575 VAC (BMK5000 & 6000) and

24 volts AC may be used in this equipment. On international units, the voltage can be 220V

to 240V single phase. Therefore the cover on the unit’s power panel (located behind the unit’s

front panel) must be installed at all times, except during maintenance and servicing.

•A single-pole switch for single phase units, or three-pole switch for three phase units, must be

installed on the electrical supply line external to 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.

Benchmark with Edge [I] Controller: Reference Manual

SECTION 1: SAFETY PRECAUTIONS

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 4of 76

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 emergencyshutdown manual gas valve

to operating personnel.

Figure 1-1: Manual Gas Shutoff Valve

In addition, to ensure safety an emergency shutdown procedure that addresses the following

points should be designed and implement at the site:

•For automatically operated unattended boilers located in a boiler room, provide a manually

operated remote shutdown switch or circuit breaker located just inside or outside each boiler

room door. Design the system so activation of the emergency shutdown switch or circuit

breaker will immediately shut off the fuel supply to the unit(s).

•For automatically operated unattended boilers in a location other than a boiler room, provide a

manually operated remote shutdown switch or circuit breaker marked for easy identification at a

location readily accessible in the event of boiler mis-operation.

•Design the system so activation of the emergency shutdown switch or circuit breaker will

immediately shut off the fuel.

•For boilers monitored and/or operated from a continuously occupied control room, provide an

emergency shutdown switch in the control room that is hard-wired to immediately shut off the

fuel upon activation.

1.3 PROLONGED SHUTDOWN

If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the

manual gas valve located upstream from the unit. The installer must identify the emergency shut-

off device.

If the unit is being shut down for an extended period of time, such as a year or more, complete

the instructions in Section 8.12: Shutting Boiler Down For Extended Period in the Benchmark

750-6000 with Edge [i] Operation-Maintenance Manual (OMM-0145, GF-218).

When returning a unit to service after a prolonged shutdown, it is recommended that the

instructions in Section 4: Initial Startup Procedures and Section 5: Safety Device Testing of the

Benchmark 750-6000 with Edge [i] Operation-Maintenance Manual (OMM-0145, GF-218)

be performed to verify that all system-operating parameters are correct. (This page intentionally

blank)

VALVE

OPEN

VALVE

CLOSED

Benchmark with Edge [I] Controller: Reference Manual

SECTION 2: BENCHMARK 750 & 1000 PART LIST

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SECTION 2: BENCHMARK 750 & 1000 PART LIST

Item #

Qty

Part #

Description

EXHAUST MANIFOLD

92094

Boiler Drain Valve: 3/4 “

43086

Exhaust Manifold

84045

Exhaust Manifold Seal

9-22

Pipe Plug

HEAT EXCHANGER

58179-1

BMK 750 Heat Exchanger

58179-2

BMK 1000 Heat Exchanger

80080

Insulation: Shell

123692

Plug, 1-1/2” NPT

CONTROLS

123449

Temperature Sensor

93360

3/4“ Plug, NPT

61030

Temperature Sensor

58132 

Thermowell

69126 

Low Water Cutoff

Replacement Kit and/or Catalog number

UPPER LEFT-REAR VIEW

LOWER LEFT SIDE VIEW

AERCO International,

Inc. Blauvelt, NY

10913

Benchmark 750 & 1000 with Edge [i] Part List

Benchmark 750 –29502-TAB rev A 10/05/2019

Benchmark 1000 –29504-TAB rev A 10/24/2019

Sheet 1 of 5

LOWER RIGHT SIDE VIEW

Benchmark with Edge [I] Controller: Reference Manual

SECTION 2: BENCHMARK 750 & 1000 PART LIST

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 6of 76

Item #

Qty

Part #

Description

BURNER-BLOWER (See full diagram below)

24276-1

BMK 750 Burner-Blower Assy.

24276

BMK 1000 Burner-Blower Assy.

24276-2

BMK 750/1000 Propane Units

60011-4

Blower Proof Switch

81155

Pipe Flange gasket (gas train to A/F Valve)

61002-5

Blocked Inlet Switch, -4.5” W.C.

59139

Air Filter, 6” x 4.5” LG

65085

Ignition Transformer

97087-20

Flex Gas Tube 20" (50.8 cm)

GAS TRAIN ASSEMBLIES (See full diagrams below)

22140-1

BMK 750 & 1000 FM Gas Train

22140-2

BMK 750 & 1000 DBB Gas Train

22140-3-1

BMK 750 Propane Gas Train

22140-3-2

BMK 1000 Propane Gas Train

CONTROLS

24356-1 

Flame Rod

61026

O2Sensor

58023 

Ignitor-Injector

123863

Valve: Ball 1/8" NPT

59178

Vent: Air 1/8 NPT

58089 

Staged Ignition Assy.

58061 

Blower, 8.9” AMETEK

24367-1 

Air/Fuel Valve Assy., BMK 1000

24367-2 

Air/Fuel Valve Assy., BMK 750

24367-3 

Air/Fuel Valve Assy., BMK 750/1000 Propane

Replacement Kit and/or Catalog number

REAR VIEW

AERCO International,

Inc. Blauvelt, NY

10913

Benchmark 750 & 1000 with Edge [i] Part List

Benchmark 750 –29502-TAB rev A 10/05/2019

Benchmark 1000 –29504-TAB rev A 10/24/2019

Sheet 2 of 5

TOP-REAR VIEW

Benchmark with Edge [I] Controller: Reference Manual

SECTION 2: BENCHMARK 750 & 1000 PART LIST

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Enclosure Panels

Item #

Qty

Part #

Description

37154

Cover Assembly

25087

Front Frame Assembly

37155

Left -Rear Panel

37156

Right -Rear Panel

39217

Air Inlet Adapter 6”

59179

Handle, Concealed Pull

25085-3

Front Panel Assembly

59133

Latch, Compression

59174

Lifting Bar (removed after installation)

LEFT-REAR VIEW

FRONT-RIGHT VIEW

AERCO International,

Inc. Blauvelt, NY

10913

Benchmark 750 & 1000 with Edge [i] Part List

Benchmark 750 –29502-TAB rev A 10/05/2019

Benchmark 1000 –29504-TAB rev A 10/24/2019

Sheet 3 of 5

Benchmark with Edge [I] Controller: Reference Manual

SECTION 2: BENCHMARK 750 & 1000 PART LIST

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 8of 76

Power Panel

Item #

Qty

Part #

Description

24477

Power Panel

69141

DIN Rail End Stop

65109

12V POWER SUPPLY

65118

Fuse Terminal: DIN Mounted

65121

Terminal Block, White

60037

2 Pole Circuit Breaker, 20A

65122

Terminal Ground Block: DIN Mounted

65120

Terminal Block, Black

65156

Amplifier, Flame Rod Signal

65162

24V Power Supply (Sequencing Valve)

65011

Transformer, 115/24V 100VA

69102-2

Pump Relay

Front View (Front panel removed)

69344-3

Edge [i] Control Panel

69172

I/O Board

123966

Over Temp Switch

64088

Temp Limit Controller

AERCO International,

Inc. Blauvelt, NY

10913

Benchmark 750 & 1000 with Edge [i] Part List

Benchmark 750 –29502-TAB rev A 10/05/2019

Benchmark 1000 –29504-TAB rev A 10/24/2019

Sheet 4 of 5

Benchmark with Edge [I] Controller: Reference Manual

SECTION 2: BENCHMARK 750 & 1000 PART LIST

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 9of 76

Benchmark 750/1000 Spare Parts Kit P/N 58037-TAB

Part

Number

Description

58037-1

30 PSI

Apollo

58037-2

50 PSI

Conbraco

58037-3

75 PSI

Apollo

58037-4

100 PSI

Watts

58037-5

150 PSI

Watts

58037-6

60 PSI

Watts

58037-7

125 PSI

Watts

58037-8

160 PSI

Kunkle

24286

6” Exhaust Kit

24441

Condensate Trap Assy.

92006-5

1” Ball Valve

123675-5

Tridicator

123675-6

Tridicator

123675-7

Tridicator

92014

Pressure Relief Valve

92015-13

Pressure Relief Valve

92015-15

Pressure Relief Valve

92015-16

Pressure Relief Valve

92015-20

Pressure Relief Valve

92015-484

Pressure Relief Valve

92015-361

Pressure Relief Valve

123659

Pressure Relief Valve

9-234

3/4” Close Nipple

Wiring Harnesses (not shown in figures below)

Part #

Description

63038

HARNESS: BLOWER

63097

HARNESS: SENSOR/COMM

63147

HARNESS: WIRING: GAS TRAIN

63182

HARNESS: SHELL

63083

HARNESS: 02 SENSOR

65104

CABLE: H.V. IGNITION

124327

HARNESS: INTERLOCK

Additional Benchmark 750/1000 Kits Available

Part #

Description

27086-1 

Actuator: SSOV w/o P.O.C. Switch FRU Kit

64048 

SSOV With Pressure Regulator FRU Kit

24367-1 

A/F Valve Assy FRU Kit BMK 1000

24367-2 

A/F Valve Assy FRU Kit BMK 750

58061 

Blower FRU Kit: AMETEK 8.9"

24356-1 

Flame Rod

58023 

Ignitor-Injector

Replacement Kit and/or Catalog number

Other Accessories / Parts (Optional)

Part #

Description

92084-6

Motorized Sequencing Valve

AERCO International,

Inc. Blauvelt, NY

10913

Benchmark 750 & 1000 with Edge [i] Part List

Benchmark 750 –29502-TAB rev A 10/05/2019

Benchmark 1000 –29504-TAB rev A 10/24/2019

Sheet 5 of 5

Benchmark with Edge [I] Controller: Reference Manual

SECTION 2: BENCHMARK 750 & 1000 PART LIST

OMM-0146_A • GF-219 •5/25/2020 Technical Support •(800) 526-0288 •Mon-Fri, 8 am - 5 pm EST Page 10 of 76

Benchmark 750/1000 FM Gas Train

P/N 22140-1 rev J –10/31/2019

Item

Qty

Part #

Description

Item

Qty

Part #

Description

95026

Flange 1.25" NPT 125#: Threaded

92006-5

Ball Valve: 1" NPT

92036

Valve: SSOV 1" NPT

61002-12

High Gas Pressure Switch 4.7" W.C.

64048 

Actuator: SSOV w/ Regulator

92077

Ball Valve, 1/4" NPT MXF Brass

12951-2

Bushing: Control Box

99017

Snubber: Pressure: 1/4"

61002-1

Low Pressure Switch: 2.6" W.C. Fall N.O.

97087-20

Flexible Gas Tube: 20" LG

9-22

Pipe Plug: 1/4" NPT: Steel

99015

Damping Orifice: SSOV

Replacement Kit and/or Catalog number

Ce manuel convient aux modèles suivants

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