TECHNICAL INSTRUCTIONS

Transcription

1 TECHNICAL INSTRUCTIONS 12-Month Maintenance Procedures These instructions apply to the following BMK boiler models (Standard & Dual Fuel): Benchmark 1.5LN Benchmark 2.0LN Benchmark 3.0LN Benchmark 750 Benchmark 1000 Benchmark 1500 Benchmark 2000 Benchmark 2500 Benchmark 3000 For AERCO Benchmark Boilers (Kit# ) 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 these materials. Revised 11/20/2014 VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 1 of 28

2 Table of Contents 1. GENERAL Maintenance Kit INFORMATION Annual Maintenance Procedure Overview Maintenance Kit Contents Kit Tools & Materials Requirements Tools Test Equipment Expendable Materials BMK1.5LN / 2.0LN / 3.0LN Preliminary Procedures Burner Maintenance BMK1.5/2.0/ Burner Maintenance Procedures - BMK3.0LN Igniter-Injector Replacement - BMK3.0LN Flame Detector Replacement - BMK Burner Maintenance - BMK1.5LN/2.0LN Igniter-Injector Replacement - BMK1.5/ Flame Detector Replacement - BMK1.5/ BMK750 & BMK Replacing the Igniter-Injector and Flame Detector Condensate Trap Maintenance BMK1500 & BMK Replacing the Igniter-Injector and Flame Detector Condensate Trap Maintenance BMK2500 & BMK Replacing the Igniter-Injector and Flame Detector Condensate Trap Maintenance Condensate Trap Maintenance All Models Condensate Trap Installation Locations Replacing the Condensate Trap O-Ring New Style Trap Replacing the Condensate Trap O-Ring & Orifice Gasket Old Style Trap Low Water Cutoff (Lwco) Integrity Test Low Water Cutoff (LWCO) - Capacitor Electrical Short Test Low Water Cutoff (LWCO) - Standard C-More Test Final Reassembly & Testing - ALL MODELS Reassembly and Set-Up Following Annual Maintenance Final Testing Following Annual Maintenance VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 2 of 28

3 1. GENERAL MAINTENANCE KIT INFORMATION 1.1 Annual Maintenance Procedure Overview The Annual Maintenance procedure includes the following actions: Replace igniter-injector and flame detector (with gasket). Clean and inspect the condensate trap. Replace trap O-ring (and orifice gasket for older style trap). Test the Low Water Cutoff (LWCO) probe for electrical shorts Maintenance Kit Contents The Annual Maintenance Kit P/N is comprised of the following components: Maintenance Kit Contents Flame Detector P/N (1 each) Igniter- Injector P/N (1 each) Flame Detector Gasket P/N (1 each) Condensate Trap O-Ring P/N (1 each) Condensate Trap Orifice Gasket P/N (1 each) P/N Annual Maintenance Kit Bill of Materials Item Qty P/N Description IGNITER/INJECTOR REPLACEMENT KIT: 1 x IGNITER-INJECTOR P/N x NUT, COMPRESSION P/N x WASHERS, CLOCKING (INDEXING) P/N x LUBRICANT, ANTI-SEIZE P/N Flame Detector Flame Detector Gasket Condensate Trap O-Ring Condensate Trap Orifice Gasket (0.25 I.D.) VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 3 of 28

4 The Igniter/Injector replacement assembly kit (P/N 58023) is comprised of the parts as shown in Figure 1. Figure 1: Igniter/Injector Assembly (P/N 58023) Components Kit Tools & Materials Requirements Tools Only common hand tools are required to perform the annual maintenance tasks described in this bulletin Test Equipment No test equipment is required to perform the annual maintenance tasks included in this Technical Service Bulletin. However, following completion of these tasks, the Benchmark Boiler should be tested using the combustion calibration procedures specified in the applicable O & M Manuals Expendable Materials The expendable materials required to perform the annual maintenance procedures described in this bulletin include such items as: Anti-seize lubricant (P/N 58023) for igniter-injector threads (included in replacement kit). Cleaning solvents and materials for cleaning condensate trap. WARNING! High voltages are used to power these boilers and so it is required that all power applied to these boilers is removed first before performing any of the procedures described in this document. Serious personal injury or death may occur if this warning is not observed. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 4 of 28

5 2. BMK1.5LN / 2.0LN / 3.0LN 2.1 Preliminary Procedures Prior to performing the procedures in sections 5 and 6, perform the following preliminary set-up and disassembly procedures: NOTE This section applies only to BMK1.5LN, BMK2.0LN, BMK3.0LN boilers using the integrated igniter/injector assembly (P/N 58023). 1. At the front panel of the unit, set the ON/OFF switch on the C-More Control Panel to the OFF position. 2. Disconnect electrical power to the unit by turning off the external circuit breaker. 3. Turn off the external gas supply shutoff valve. 4. Remove the top panel(s) of the unit. Benchmark 1.5LN and 2.0LN Models contain one (1) top panel. Benchmark 3.0LN Models contain two (2) top panels. See Figure Remove the side panels of the unit. Benchmark 1.5LN and 2.0LN Models contain one (1) panel on each side. Benchmark 3.0LN Models contain two (2) panels on each side. See Figure To prevent burns, allow the unit to cool to a safe temperature before proceeding. Figure 2-1: Removable Covers for BMK1.5/2.0 (Left) and BMK3.0 (Right) VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 5 of 28

6 2.2 Burner Maintenance BMK1.5/2.0/3.0 Annual maintenance for the Benchmark Low NOx burners consists of replacing the igniterinjector and the flame detector (with gasket) in the burner assembly. All Benchmark Low NOx models utilize identical igniter-injectors (P/N 66026) and flame detector (P/N 66006) with gasket, (P/N 81048). Two basic low NOx burner designs are used in Benchmark Low NOx Boiler Models: Benchmark 3.0LN burner assemblies utilize aluminum burner housings and a mesh burner insert. The igniter-injector and flame detector are installed on the outlet flange of the burner housing. Figure 2-2 and 2-3 show a Benchmark 3.0LN burner assembly. Benchmark 1.5LN and Benchmark 2.0LN burner assemblies use compact designs which also include the blower and air/fuel valve for their respective boiler models. Although the outward appearance of these two burner assemblies look virtually identical, the Benchmark 2.0LN utilizes a larger diameter steel burner plate and a longer burner insert than the Benchmark 1.5LN burner assembly. The Benchmark 1.5LN and 2.0LN burner assemblies are shown in Figure 2-4. A version with RSI (Regulated Staged Ignition) is shown in Figure 2-5 to show how the RSI line is attached to the Staged Ignition assembly. The igniter-injector replacement procedures for Benchmark 3.0LN model differs slightly from the replacement procedures for Benchmark 1.5LN and 2.0LN units. These differences are due to mounting orientations and replacement torque differences. However, the corresponding replacement procedures for Benchmark 1.5LN and 2.0LN models are in fact identical. Therefore, the burner maintenance procedures are divided into two (2) paragraphs. Paragraph 5.1 covers Benchmark 3.0LN model. Paragraph 5.2 covers Benchmark 1.5LN and 2.0LN models. Figure 2-2: Benchmark 3.0LN Burner Assembly Top View VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 6 of 28

7 Figure 2-3: BMK 3.0LN Burner Assembly Isometric View (Removed from Boiler) Figure 2-4: BMK 1.5LN and BMK 2.0LN Burner Assemblies (Removed from Boiler) VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 7 of 28

8 NOTE Newer BMK 1.5 and BMK 2.0 units may have an RSI (Regulated Staged Ignition) line installed at the Staged Ignition Assembly. Instructions for maintenance are the same. Figure 2-5 shows the configuration of the RSI on BMK 1.5 and BMK 2.0 boilers. Figure 2-5: BMK 1.5LN and BMK 2.0LN Burner Assemblies (Showing RSI Line Installed at Staged Ignition Assembly) 2.3 Burner Maintenance Procedures - BMK3.0LN Igniter-Injector Replacement - BMK3.0LN The igniter-injector is installed on the burner housing outlet flange as shown in Figures 2-2, 2-3, 2-4, 2-5, and 2-6. In addition to providing the ignition spark required to light the burner, this component also contains a gas injector tube which connects to the staged ignition assembly. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 8 of 28

9 Figure 2-6: Benchmark3.0LN Burner Assembly Front View Igniter-injector replacement for a BMK 3.0LN is accomplished as follows: 1. Disconnect the cable from the igniter-injector. 2. 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. Disconnect the staged ignition assembly from the igniter-injector. 3. Next, loosen and remove the igniter-injector from the burner housing using a 1" open-end wrench. 4. Prior to installing the replacement igniter-injector, high temperature, conductive, anti-seize lubricant must be applied to the igniter-injector threads. A small tube of this lubricant is included in the igniter-injector replacement kit (P/N 58023). NOTE The igniter-injector replacement kit (P/N 58023) contains a compression nut with a built-in ferrule. In addition, 3 clocking (indexing) washers are included. These washers may be needed to properly position the gas injector tube of the igniter-injector as described in the following step. 5. Install the replacement igniter-injector in the burner housing and hand-tighten. If necessary, use the indexing washers provided in the kit to properly position the gas injector tube within the 120 angle shown in Figure 2-7. Torque the igniter-injector to 80 to 90 in-lbs. However, if the burner housing was replaced just prior to replacing the igniterinjector, torque to 15 ft.-lbs., then loosen and re-tighten to 6.5 to 7.5 ft.-lbs. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 9 of 28

10 Figure 2-7: Benchmark 3.0LN Burner Assembly Partial Top View 7. 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. Position the staged ignition solenoid so it is not contacting any other components of the burner assembly or heat exchanger. 8. Reconnect the igniter-injector cable. This completes the replacement of the igniter-injector Flame Detector Replacement - BMK3.0 Fire Detector and gasket replacement for the BMK 3.0LN is accomplished as follows: 1. Disconnect the lead wire from the flame detector. 2. Remove the two (2) screws securing the flame detector to the burner housing (Figure 2-6). The flame detector is secured to the burner housing with one (1) #10-32 screw and one (1) #8-32 screw. 3. Remove the flame detector and gasket from the burner housing flange. 4. Install the replacement flame detector (P/N 66006) and gasket (P/N 81048) provided in the maintenance kit. 5. Reconnect the flame detector wire lead. This completes the flame detector replacement. 2.4 Burner Maintenance - BMK1.5LN/2.0LN The burner maintenance procedures for the Benchmark 1.5LN and 2.0LN are identical. Replace the boiler igniter-injector and flame detector as described in paragraphs and respectively Igniter-Injector Replacement - BMK1.5/2.0 The igniter-injector is installed on the steel burner plate of each Benchmark 1.5LN and 2.0LN unit as shown in Figure 2-6. In addition to providing the ignition spark required to light the burner, this component also contains a gas injector tube which connects to the staged ignition assembly of each boiler. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 10 of 28

11 Igniter-injector replacement for the BMK 1.5LN and BMK 2.0LN is accomplished as follows: 1. Disconnect the cable from the igniter-injector. 2. Refer to the partially exploded view in Figure 2-8. 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. Disconnect the staged ignition assembly from the igniter-injector. Figure 2-8: BMK 1.5LN/2.0LN Igniter-Injector & Flame Detector Mounting Details 3. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end wrench. 4. Prior to installing the replacement igniter-injector, high temperature, conductive, anti-seize lubricant must be applied to the igniter-injector threads. A small tube of this lubricant is included in the igniter replacement kit (P/N 58023). NOTE The igniter replacement kit (P/N 58023) contains a compression nut with a built-in ferrule. In addition, 3 clocking (indexing) washers are included. These washers may be needed to properly position the gas injector tube of the igniter-injector as described in the following step. 5. Reinstall the igniter-injector in the burner plate. If necessary, install 1, 2 or 3 clocking washers to properly position the gas injector tube within the 120 angle shown in Figure 2-9. Torque the igniter-injector to 15 ft-lbs. Do not over tighten. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 11 of 28

12 Figure 2-9: Benchmark 1.5LN or 2.0LN Igniter-Injector Orientation 6. 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. Position the staged ignition solenoid so it is not contacting any other components of the burner assembly or heat exchanger. 7. Reconnect the igniter-injector cable. This completes the replacement of the igniterinjector Flame Detector Replacement - BMK1.5/2.0 The flame detector (P/N 66006) and gasket (P/N 81048) are installed on the burner plate (see Figures 2-4, 2-5 and 2-8). Component replacement is accomplished as follows: 1. Disconnect the lead wire from the flame detector. 2. Remove the two (2) screws securing the flame detector to the burner plate (Figure 2-8). The flame detector is secured to the plate with one (1) #10-32 screw and one (1) #8-32 screw. 3. Remove the flame detector and gasket from the burner plate. 4. Install the replacement flame detector (P/N 66006) and gasket (P/N 81048) provided in the maintenance kit. Secure the detector in place using the two screws removed in step Reconnect the flame detector wire lead. This completes the flame detector replacement. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 12 of 28

13 3. BMK750 & BMK Replacing the Igniter-Injector and Flame Detector The instructions in this section show how to replace the igniter-injector, flame detector, and flame detector gasket for the BMK750 and BMK1000 boilers. Replacing the IGNITER-INJECTOR AND FLAME DETECTOR 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. Shut off the external gas supply valve to the unit. 3. Remove the panels from the top and sides of the unit, exposing the intake manifold and blower plenum. 4. Disconnect the electrical cable from the igniter-injector terminal (Figure 3-1). Blower Flame detector Flame detector Gasket O 2 Sensor Staged Ignition Solenoid Igniter-Injector Terminal Igniter-Injector Burner Plate Burner Upper Head Figure 3-1: Igniter-Injector & Flame Detector Locations 5. 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 (Figure 3-2). O 2 Sensor Elbow Staged Ignition Solenoid Compression Nut Igniter Terminal Igniter-Injector Figure 3-2: Igniter-Injector Disassembly VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 13 of 28

14 Replacing the IGNITER-INJECTOR AND FLAME DETECTOR - Continued 6. Use a 1" wrench to remove the igniter-injector from the burner plate. 7. Disconnect the flame detector lead wire, remove the two (2) #10-32 Phillips head screws securing the flame detector to the burner plate (Figure 3-3), and then remove the flame detector and gasket and discard them. Retain screws for reassembly. Flame Detector Figure 3-3: Flame Detector Replacement Flame Detector Gasket 8. Install the new igniter-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 igniter-injector to in-lbs. DO NOT over tighten. O 2 Sensor Gas Injector Tube 120 Igniter- Injector Figure 3-4: Igniter-Injector Orientation (viewed from above looking down) 9. 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. 10. Reconnect the igniter-injector cable. 11. Install the new flame detector and flame detector gasket, included with the kit, onto the burner plate, securing them with the Phillips head screws removed during disassembly (see Figure 3-3). 12. Reconnect the flame detector lead wire. 3.2 Condensate Trap Maintenance See Chapter 6 for condensate trap maintenance procedures. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 14 of 28

15 4. BMK1500 & BMK Replacing the Igniter-Injector and Flame Detector The instructions below replace the igniter-injector and flame detector. Replacing the IGNITER-INJECTOR AND FLAME DETECTOR 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. Shut off the external gas supply valve to the unit. 3. Remove the panels from the top and sides of the unit, exposing the intake manifold and blower plenum. 4. Disconnect the electrical cable from the igniter-injector terminal (Figure 4-1). Burner Plate O2 Sensor Flame Detector & Gasket Staged Ignition Solenoid Blower Plenum Igniter-Injector Figure 4-1: Gasket, Igniter-Injector & Flame Detector Locations 5. 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. Discard the old compression nut. 6. 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. Staged Ignition Solenoid Igniter-Injector Elbow Compression Nut Indexing Washers (0-3 as needed) Figure 4-2: Igniter-Injector Disassembly Flame Detector VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 15 of 28

16 Replacing the IGNITER-INJECTOR and FLAME DETECTOR - Continued 7. Use a 1" wrench to remove the igniter-injector from the blower plenum and discard it. 8. Install the new igniter-injector, included with the kit, onto the blower plenum. 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 igniter-injector to in-lbs. DO NOT over tighten. O 2 Sensor Gas Injector Tube 120 Igniter-Injector Figure 4-3: Igniter-Injector Orientation (viewed from above looking down) 9. 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. 10. Reconnect the igniter-injector cable. 11. Disconnect the flame detector lead wire. 12. Disconnect the flame detector lead wire and then remove the two (2) #10-32 Phillips head screws securing the flame detector to the blower plenum. Flame Detector Gasket Flame Detector Figure 4-4: Flame detector Replacement 13. Remove the flame detector and gasket from the blower plenum and discard them. 14. 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. 4.2 Condensate Trap Maintenance See Chapter 6 for condensate trap maintenance procedures. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 16 of 28

17 5. BMK2500 & BMK Replacing the Igniter-Injector and Flame Detector The instructions below replace the igniter-injector (P/N 58023). Replacing the IGNITER-INJECTOR and FLAME DETECTOR 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. Shut off the external gas supply valve to the unit. 3. Remove the panels from the top and sides of the unit, exposing the intake manifold and blower plenum. 4. Disconnect the electrical cable from the igniter-injector terminal (Figure 5-1). Blower Plenum Staged Ignition Solenoid O2 Sensor Igniter-Injector Burner Plate Flame Detector & Gasket Figure 5-1: Igniter-Injector & Flame Detector Locations 5. 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. Staged Ignition Solenoid Igniter-Injector Indexing Washers (0-3 as needed) Figure 5-2: Igniter-Injector Disassembly Elbow Compression Nut Flame Detector VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 17 of 28

18 Replacing the IGNITER-INJECTOR and FLAME DETECTOR - Continued 6. Use a 1" wrench to remove the igniter-injector from the blower plenum and discard it. 7. Install the new igniter-injector, included with the kit, onto the blower plenum. 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 igniter-injector to in-lbs. DO NOT over tighten. O 2 Sensor Gas Injector Tube 120 Igniter-Injector Figure 5-3: Igniter-Injector Orientation (viewed from above looking down) 8. 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. 9. Reconnect the igniter-injector cable. 10. Disconnect the flame detector lead wire. 11. Disconnect the flame detector lead wire and then remove the two (2) #10-32 Phillips head screws securing the flame detector to the blower plenum. Flame Detector Gasket Flame Detector Figure 5-4: Flame detector Replacement 12. Remove the flame detector and gasket from the blower plenum and discard them. 13. 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. 5.2 Condensate Trap Maintenance See Chapter 6 for condensate trap maintenance procedures. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 18 of 28

19 6. CONDENSATE TRAP MAINTENANCE ALL MODELS There are two types of condensate traps in service; an older and a newer style. The instructions in this section apply ONLY to the NEWER style condensate trap. For the older-style trap, see the next section. 6.1 Condensate Trap Installation Locations Below are images of the condensate trap installations by model. Trap Installations BMK750 / 1000 / 1500 / 2000 / 2500 / 3000 EXHAUST MANIFOLD ADAPTOR THUMBSCREW UNION (OLD STYLE ONLY) 3/4 NPT NIPPLES TOP COVER THUMB SREWS (4) CONDENSATE TRAP (NEW STLE SHOWN) 3/4 NPT NIPPLE HOSE CLAMP TO FLOOR DRAIN 1 DIAM. HOSE Figure 6-1: BMK750 / Condensate Trap Installation ADAPTOR THUMBSCREW TOP COVER THUMB SREWS (4) EXHAUST MANIFOLD CONDENSATE TRAP (NEW STLE SHOWN) 3/4 NPT NIPPLE HOSE CLAMP TO FLOOR DRAIN 1 DIAM. HOSE Figure 6-2: BMK1500 / 2000 / 2500 / 3000 Condensate Trap Installation VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 19 of 28

20 Trap Installations BMK1.5LN / 2.0LN / 3.0LN Figure 6-3: BMK1.5LN - Older and Newer Condensate Trap Installations Figure 6-4: BMK2.0LN - Older and Newer Condensate Trap Installations Figure 6-5: BMK3.0LN - Older and Newer Condensate Trap Installations VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 20 of 28

21 6.2 Replacing the Condensate Trap O-Ring New Style Trap These instructions show how to 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. Replacing the Condensate Trap O-Ring - New Style 1. Disconnect the external condensate trap from the exhaust manifold drain pipe by loosening the thumb screw on the trap inlet. 2. Remove the hose connection from the outlet side of the condensate trap. 3/4" NPT Port THUMB SCREWS (4) COVER CONDENSATE TRAP O-RING INLET FLOAT GUIDE FLOAT INLET ADAPTER INLET O-RINGS OUTLET Figure 6-6: Newer-Style Condensate Trap Cross Section 3. Loosen the four (4) thumbscrews securing the top cover to the condensate trap. 4. Remove the old O-ring from the trap. 5. Remove the float and attached float guide from the condensate trap. 6. Thoroughly clean the trap, float, and float guide. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap. 7. After the above items have been inspected and thoroughly cleaned, reassemble the float and float guide into the trap. 8. Install the new O-ring from the kit (P/N 84017). 9. Secure the top cover to the trap with the four thumb screws removed in Step Reassemble the drain hose connection to the outlet of the trap, and then reconnect trap inlet to the exhaust manifold drain by tightening the thumbscrew on the trap inlet. See Figure 6-1 through 6-5. Important! When reinstalling the condensate trap, ensure that the trap inlet is level with or below the condensate outlet of the boiler. Use a suitable support to insure that the bottom surface of the trap is horizontal and level. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 21 of 28

22 6.3 Replacing the Condensate Trap O-Ring & Orifice Gasket Old Style Trap These instructions explain how to replace the condensate trap O-ring (P/N 84017), located under the condensate trap s cover, the condensate trap orifice gasket (P/N 81092), and check and clean the trap. The condensate trap is attached to the exhaust manifold s condensate drain pipe using two nipples and a union. Replacing the Condensate Trap O-Ring & Orifice Gasket: Old Style 1. Disconnect the condensate trap from the exhaust manifold by removing the union between the connecting nipples (Figure 11). 2. Remove the drain hose connection from the outlet side of the condensate trap. 3. Loosen the four (4) thumbscrews securing the top cover to the condensate trap. Important! When reinstalling the condensate trap, ensure that the trap inlet is level with or below the condensate outlet of the boiler. Use a suitable support to insure that the bottom surface of the trap is horizontal and level. INLET ORIFICE GASKET OUTLET THUMB SCREWS (4) COVER CONDENSATE TRAP O-RING FLOAT GUIDE FLOAT Figure 13: Older-Style External Condensate Trap Cross Section 4. Remove the old O-ring from the trap and discard. 5. Remove the float and float guide from the condensate trap. 6. Remove the old orifice gasket from the trap and discard. 7. Thoroughly clean the trap, float, and float guide then inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap. 8. After the above items have been inspected and thoroughly cleaned, install the new orifice gasket from the kit (P/N 81092), and then reinstall the float and float guide into the trap. 9. Install the new O-ring from the kit (P/N 84017). 10. Secure the top cover to the trap with the four thumb screws removed in Step Reassemble all piping and hose connections to the condensate trap inlet and outlet, and reconnect trap to exhaust manifold drain. See Figure 6-3 through 6-5. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 22 of 28

23 7. LOW WATER CUTOFF (LWCO) INTEGRITY TEST The LWCO probe features a capacitor assembly that should be tested for electrical shorts after performing all other annual maintenance tasks. 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 controls. The LWCO probe is located on the hot water outlet pipe of each BMK boiler model as shown in Figure 7-1. Hot Water Outlet Pipe Hot Water Outlet Pipe LWCO Probe BMK1.5LN Hot Water Outlet Pipe BMK2.0LN LWCO Probe BMK3.0LN LWCO Probe Hot Water Outlet Pipe Hot Water Outlet Pipe Hot Water Outlet Pipe LWCO Probe LWCO Probe BMK750 / 1000 BMK1500 / 2000 BMK2500 / 3000 LWCO Probe Figure 7-1: LWCO Probe Location for all BMK Boiler Models VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 23 of 28

24 Refer to Figure 7-2 for an illustration of the LWCO probe/capacitor assembly components. LWCO Probe LWCO Probe Terminal Plastic Acorn Nut Capacitor Assembly (Covered By Large Shrink Tubing) Connector (to Shell Harness) Figure 7-2: LWCO Probe Assembly Components 7.1 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. 1. Turn OFF AC power to the unit. LWCO Capacitor Electrical Short Test 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. (Continued) VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 24 of 28

25 LWCO Capacitor Electrical Short Test - Continued 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 7-3). Unplug Shell Harness Cable from P5 Connector Figure 7-3: 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 Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed from the C-More controller) as shown on right in Figure 7-4. Connect 1 st Lead to LWCO Connect 2 nd Lead to PIN #6 Ohmmeter LWCO Probe Assembly 19-Pin Shell Harness Cable Connector Figure 7-4: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 25 of 28

26 LWCO Capacitor Integrity Test Cont. 5. Confirm that the ohmmeter does NOT read a short. NOTE If the ohmmeter reads a short, the capacitor assembly needs to be replaced. Replacement instructions can be found in the 24- Month Maintenance instructions or contact AERCO technical support for more information. 6. Remove both ohmmeter probes and reconnect the Shell Harness connector to the P5 connector on the rear of the C-More controller. 7.2 Low Water Cutoff (LWCO) - Standard C-More Test Perform the standard Low Water Cutoff test using the C-More controls as described below. 1. Turn on the AC power to the unit. Standard Low Water Cutoff C-More Test 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. 8. FINAL REASSEMBLY & TESTING - ALL MODELS Upon completion of all annual maintenance tasks, reassemble the unit and perform the tests specified in paragraphs 7.1 and 7.2 of the appropriate manual. 8.1 Reassembly and Set-Up Following Annual Maintenance Following completion of the all required inspections and replacements, perform the following reassembly and setup procedures: 1. Turn ON the external circuit breaker to the unit. 2. At the front panel of the unit, set the ON/OFF switch on the C-More Control Panel to the ON position. 3. Press the LOW WATER LEVEL RESET button to reset the low water cutoff. 4. Press the CLEAR switch to reset the FAULT LED and clear any displayed error message. 5. Replace any sheet cover panels previously removed from the boiler. VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 26 of 28

27 8.2 Final Testing Following Annual Maintenance Upon completion of the annual maintenance procedures specified in this bulletin, perform the Combustion Calibration Tests specified in the applicable O & M Manual listed below: Benchmark Model Benchmark 1.5LN Benchmark 1.5LN, Dual-Fuel Benchmark 2.0LN Benchmark 2.0LN, Dual-Fuel Benchmark 3.0LN Benchmark 3.0LN, Dual Fuel Benchmark 750 / 1000 Benchmark 1500 / 2000 Benchmark 1500 / 2000 Dual-Fuel Benchmark 2500 / 3000 Benchmark 2500 / 3000 Dual-Fuel O & M Manual GF-120 GF-121 GF-123 GF-127 GF-116 GF-117 GF-130 GF-142 GF-144 GF-137 GF-145 VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 27 of 28

28 Change Log: Date Description Changed By 09/19/2014 Rev-A: Created Curtis Harvey 11/20/2014 Rev B: : removed item from kit and instructions in section 2.5 Chris Blair AERCO Technical Support: (Mon Fri, 8am-5pm EST) 1 (800) ( AERCO International, Inc., 2014 VD2: 11/20/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 28 of 28