TECHNICAL INSTRUCTIONS

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1 TECHNICAL INSTRUCTIONS Annual Maintenance Kit For Benchmark Boilers Maintenance Flame Detector P/N Ignitor- Injector P/N Gasket P/N Condensate Trap O-Ring P/N Condensate Trap Orifice Gasket P/N Created 04/03/2014 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. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 1 of 6

2 1. INTRODUCTION This Technical Instruction Document (TID) provides instructions for performing recommended annual maintenance of Benchmark 750 and Benchmark 1000 Boilers. 2. LIST OF TOOLS The following tools are required to perform the instructions in this bulletin. Flat-head screwdriver or 5/16 nut driver Phillips head screwdriver #2 Torque wrench The following wrenches (open-end, box or socket) are used: o 7/16 o 3/4" o 1 3. MAINTENANCE KIT CONTENTS Table 1: Benchmark 750/1000 Annual Maintenance Contents Item Part No. Quantity Description IGNITOR-INJECTOR FLAME DETECTOR FLAME DETECTOR GASKET CONDENSATE TRAP ORIFICE GASKET CONDENSATE TRAP O-RING 4. INSTALLATION INSTRUCTIONS WARNING Remove electrical power before working on the unit. Adhere to all local codes regarding lock-out, tag-out procedures. WARNING The ignitor-injector and flame detector may be hot, therefore, care must be exercised to avoid burns. It is easier to remove these parts from the unit after the unit has cooled to room temperature. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 2 of 6

4.1 Replacing the Ignitor-Injector The instructions below replace the ignitor-injector (p/n 58023). 1. Set the ON/OFF switch on the control panel, to the OFF position.

Disconnect the electrical cable from the ignitor-injector. Blower O 2 Sensor Staged Ignition Solenoid Elbow Compression Nut Ignitor-Injector Gasket Burner Plate Figure 1.

3 4.1 Replacing the Ignitor-Injector The instructions below replace the ignitor-injector (p/n 58023). 1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power from the unit by turning off power at the breaker. 2. Remove the panels from the top and sides of the unit, exposing the intake manifold and air filters. 3. Disconnect the electrical cable from the ignitor-injector. Blower O 2 Sensor Staged Ignition Solenoid Elbow Compression Nut Ignitor-Injector Gasket Burner Plate Figure 1. Ignitor-Injector & Locations 4. Use a 7/16 wrench to disconnect the compression nut securing the igniter-injector s gas injector tube to the elbow of the staged ignition assembly and then disconnect the staged ignition solenoid from the igniter-injector. Elbow Compression Nut O 2 Sensor Ignitor-Injector Figure 2. Ignitor-Injector Disassembly 5. Use a 1" wrench to remove the ignitor-injector from the burner plate and discard it. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 3 of 6

Torque the ignitor-injector to approximately 170-180 in-lbs. DO NOT over tighten. O 2 Sensor Gas Injector Tube Ignitor-Injector 120 Figure 3.

4 6. Install the new ignitor-injector, included with the kit, onto the burner plate. Use zero to three indexing washers, as needed, so that the igniter-injector s gas injector tube is positioned within the 120 angle range shown below. Torque the ignitor-injector to approximately in-lbs. DO NOT over tighten. O 2 Sensor Gas Injector Tube Ignitor-Injector 120 Figure 3. Ignitor-Injector Orientation (viewed from above looking down) 7. Connect the igniter-injector s gas injector tube to the elbow of the staged ignition solenoid with the new compression nut, included with the kit. 8. Reconnect the igniter-injector cable. 4.2 Replacing the and Gasket The instructions below replace the flame detector (p/n 66034) and flame detector gasket (p/n 81048). 1. Disconnect the flame detector lead wire. 2. Disconnect the flame detector lead wire and then remove the two (2) #10-32 Phillips head screws securing the flame detector to the burner plate. Gasket Figure 4. Replacement 3. Remove the flame detector and gasket from the burner plate and discard them. 4. Install the new flame detector and flame detector gasket, included with the kit, fastening them with the #10-32 Phillips head screws removed in step Reconnect the flame detector lead wire. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 4 of 6

5 4.3 Replacing the Condensate Trap O-Ring New Style Trap There are two types of condensate traps in service, and older and a newer style. The instructions in this section apply ONLY to the NEWER style condensate trap. For the older-style trap, see section 4.4. These instructions replace the condensate trap O-ring (p/n 84017), located under the condensate trap s cover. The condensate trap is attached to the exhaust manifold s condensate drain pipe. Figure 5. Condensate Trap Location 1. Disconnect the external condensate trap from the exhaust manifold by loosening the thumb screw on the trap inlet. 2. Disconnect the condensate trap outlet from the floor drain. 3. Remove the cover from the condensate trap, secured with four (4) thumbscrews (see Figure 6). 4. Replace the O-ring from under the cover with the new condensate trap O-ring, included with the kit. 5. Remove the float and float guide from the condensate trap. 6. Thoroughly clean the trap and float, and inspect the drain piping for blockage and then reinstall the float and float guide. If the trap cannot be thoroughly cleaned, replace the trap. 7. Reassemble the float and float guide and then secure the cover with the four thumb screws. INLET OUTLET Figure 6 Newer-Style External Condensate Trap Cross Section 8. Reconnect the condensate trap to the outlet piping 9. Reconnect the condensate trap to the exhaust manifold drain by tightening the thumbscrew on the trap inlet. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 5 of 6

4.4 Replacing the Condensate Trap O-Ring & Orifice Gasket Old Style Trap The instructions in this section apply ONLY to the OLDER style condensate trap.

6 4.4 Replacing the Condensate Trap O-Ring & Orifice Gasket Old Style Trap The instructions in this section apply ONLY to the OLDER style condensate trap. These instructions replace the condensate trap O-ring (p/n 84017), located under the condensate trap s cover, and the condensate orifice gasket (p/n 81092). The condensate trap is attached to the exhaust manifold s condensate drain pipe (see Figure 5). 1. Disconnect the external condensate trap from the exhaust manifold. 2. Remove the connection on the outlet side of the condensate trap. 3. Remove the cover from the condensate trap, secured with four (4) thumbscrews. Cover Thumb Screws (4) Condensate Trap O-Ring Inlet Float Orifice Gasket Figure 7. Older-Style External Condensate Trap Cross Section 4. Replace the O-ring from under the cover with the new condensate trap O-ring, included with the kit. 5. Remove the float and float guide from the condensate trap and then remove the orifice gasket. 6. Thoroughly clean the trap and float, and inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap. 7. Install the new orifice gasket, included with the kit, and then reinstall the float guide, float, cover and thumb screws. 8. Reconnect the condensate trap to the outlet piping and then reconnect it to the exhaust manifold drain. 4.5 Putting the Unit Back in Service 1. Reconnect AC power to the unit. 2. Set the ON/OFF switch on the control panel to the On position. 3. Check your work prior to reinstalling the panels, including checking that all connections are tight and do not leak. 4. Replace all panels removed during the installation of this kit. Change Log Outlet Date Description Changed By 04/03/2014 Rev B: Changed kit number, removed Air Filter per PIR 1005 Chris Blair 06/06/2014 Rev C: Replaced fuel rod with per PIR Chris Blair 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 6 of 6

TECHNICAL INSTRUCTIONS

TECHNICAL INSTRUCTIONS Annual Maintenance Kit Instructions For Benchmark 6000 Boilers Kit Number 58025-11 Main Flame Detector P/N 65150 Ignitor Rod P/N 66100 Compression Nut with Ferrule 3/8 OD P/N 56071