Watts AERCO 58015-04 Owner's manual

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 1 of 20
Maintenance Kit 58015-04 Contents
Latest Release: 10/12/2017 (Replaces TSB-2009-15)
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.
TECHNICAL INSTRUCTIONS
Benchmark®3.0LN 24-Month Maintenance Kit# 58015-04
This kit applies to units with an Ignitor and a separate gas injector.
For units with an Ignitor-Injector (P/N 58023), see Kit 58025-04 and TID-0065.
ITEM 7
Condensate
Trap O-Ring
P/N 84017
ITEM 1
Igniter
P/N GP-122435-S
ITEM 2
Flame
Detector
P/N 66034
ITEM 3
Flame Detector
Gasket
P/N 81048
ITEM 8
Condensate Trap
Orifice Gasket
P/N 81092
ITEM 4
Gas Injector
Gasket
P/N 81047
ITEM 5
Exhaust
Manifold Seal
P/N 49102
ITEM 6
Burner Gasket
P/N 81030
ITEM 9
Exhaust
Manifold Orifice
Gasket
P/N 81098
ITEM 10
Burner Housing
Gasket
P/N 81019
ITEM 11
LWCO Kit
P/N 69126

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 2 of 20
Table of Contents
1. INTRODUCTION............................................................................................................ 3
2. CONTENTS OF KIT 58015-04....................................................................................... 3
3. TOOLS, TEST EQUIPMENT & MATERIALS REQUIRED............................................. 3
3.1 Tools ........................................................................................................................ 3
3.2 Test Equipment ........................................................................................................ 3
3.3 Materials................................................................................................................... 4
4. PRELIMINARY INSPECTION PROCEDURES .............................................................. 4
5. WATERSIDE INSPECTION OF BENCHMARK 3.0 HEAT EXCHANGER ..................... 5
6. FIRESIDE INSPECTIONS & COMPONENT REPLACEMENTS .................................... 7
6.1 Fireside Inspection of Benchmark 3.0 Heat Exchangers........................................... 7
6.1.1 Burner Inspection................................................................................................................7
6.1.2 Burner Reassembly.............................................................................................................9
6.1.3 Igniter Replacement..........................................................................................................10
6.1.4 Flame Detector Replacement ...........................................................................................11
6.1.5 Exhaust Manifold Inspection.............................................................................................11
6.1.6 External Condensate Trap Maintenance ..........................................................................14
6.2 Replacing the LWCO Probe/Capacitor Assembly....................................................16
6.3 Low Water Cutoff (LWCO) Capacitor Integrity Test .................................................16
6.3.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test............................................17
7. FINAL REASSEMBLY AND TESTING .........................................................................19
7.1 Reassembly and Set-Up Following Completion of Inspections ................................19
7.2 Final Testing Following Inspections.........................................................................19
AERCO Technical Support:
(Mon–Fri, 8am-5pm EST)
1 [phone]
www.aerco.com

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 3 of 20
1. INTRODUCTION
This Technical Instruction Document provides the procedures to perform waterside and fireside
inspections of the heat exchangers contained in Benchmark 3.0LN and 3.0LN Dual-Fuel Boilers.
The replacement parts required to perform the waterside and fireside inspections on the
Benchmark 3.0LN and 3.0LN Dual-Fuel Boilers are provided in the 24 - Month Inspection Kit,
part number 58015-04, listed and described in section 2.
2. CONTENTS OF KIT 58015-04
The items included in the 24 Month Inspection Kit required for Benchmark 3.0LN and 3.0LN
Dual-Fuel Boilers are listed in Table 1.
Table 1. Benchmark 3.0LN: 24 Month Inspection Kit, Part Number 58015-04
ITEM QTY PART NO. DESCRIPTION
1 1 GP-122435-S IGNITER
2 1 66034 FLAME DETECTOR
3 1 81048 FLAME DETECTOR GASKET
4 1 81047 GAS INJECTOR GASKET
5 1 49102 EXHAUST MANIFOLD SEAL
6 2 81030 BURNER GASKETS
7 1 84017 CONDENSATE TRAP O-RING
8 1 81092 CONDENSATE TRAP ORIFICE GASKET (.25" I.D.)
9 1 81098 EXHAUST MANIFOLD ORIFICE GASKET
10 1 81019 BURNER HOUSING GASKET
11 1 69126 LWCO / CAPACITOR ASSEMBLY KIT
3. TOOLS, TEST EQUIPMENT & MATERIALS REQUIRED
The items required to perform the inspections, replacements and tests specified in this
document are listed in section 3.1, 3.2 and 3.3 which follow.
3.1 Tools
Common hand tools, plus the items listed below are required:
•Small Wire Brush
•Spark Gap Feeler Gauge
3.2 Test Equipment
No test equipment is required to perform the 24 - month inspections include in this document.
However, following completion of these inspections, the Benchmark Boiler should be tested
using the combustion calibration procedures provided in O & M Manual GF-116, or GF-117. See
section 7.2 for instructions.

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 4 of 20
3.3 Materials
Expendable materials required to perform the procedures described in this document are not
included in the 24 -Month Inspection Kits. These materials may include such items as:
•Pipe joint compound
•Teflon tape
•Cleaning solvents and materials
•High-temperature anti-seize compound
4. PRELIMINARY INSPECTION PROCEDURES
Perform the preliminary set-up and disassembly procedures in this section before performing
the waterside and fireside inspections included in this document.
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.
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. Close the water supply and return valves to the unit.
5. Refer to Figure 1 and remove the top and side panels of the unit.
6. With the top and side panels removed, the burner, heat exchangers and exhaust
manifold can be accessed to prepare the boiler for the required waterside and fireside
inspections described in sections 5 and 6.

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 5 of 20
Figure 1. Benchmark 3.0 Low NOx (LN) Boiler
5. WATERSIDE INSPECTION OF BENCHMARK 3.0 HEAT EXCHANGER
Benchmark 3.0LN units contain both a primary heat exchanger and a secondary heat
exchanger, as shown in Figure 2. Perform the waterside inspection as follows:
1. Ensure that the preliminary set-up and disassembly procedures in section 4 have been
performed to provide access to the unit‘s heat exchangers.
2. Allow the unit to cool prior before proceeding.
3. At the rear of the unit (Figure 3), slowly open the drain valve and drain the boiler water
from both heat exchangers.
4. Open the P&T relief valve, or loosen/remove the shell sensor to allow air to enter the
heat exchangers during draining.
5. After the heat exchangers have been drained, remove the 2-1/2 inch access port plugs
on the right side of the primary and secondary heat exchangers, as shown in Figure 2.
6. If waterside inspection is required by your local inspector, follow the inspector's
instructions. Upon satisfactory completion of the inspection, proceed to step 7.
7. Apply pipe compound to the threads of the access port plugs and replace them using a
pipe wrench.
8. Close the drain valve at the rear of the boiler.
9. Close the P&T relief valve or reinstall/tighten the shell sensor removed in step 4.
10. Open the water supply and return valves to the unit and refill the heat exchangers. This
completes the waterside inspection for the unit.

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 6 of 20
PRIMARY HEAT
EXCHANGER SECONDARY
HEAT EXCHANGER
ACCESS
PORT
ACCESS
PORT
DRAIN
VALVE
EXHAUST
MANIFOLD
Figure 2. Benchmark 3.0LN - (Right Side View)
DRAIN
VALVE
EXHAUST
MANIFOLD
WATER INLET
CONNECTION
HOT WATER OUTLET
CONNECTION
GAS
INLET
CONNECTING
MANIFOLD
Figure 3. Benchmark 3.0LN - (Rear View)

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 7 of 20
6. FIRESIDE INSPECTIONS & COMPONENT REPLACEMENTS
Benchmark 3.0LN heat exchanger fireside inspections include removal of the burner and
exhaust manifold assembly from the boiler. In addition, the 24 Month Inspection Kit includes the
recommended replacement parts for annual maintenance, which should also be performed at
this time. Therefore, the procedures in this section are organized as follows:
Fireside Inspections:
•Burner Inspection
•Exhaust Manifold Inspection
Annual Maintenance Replacements:
•Burner Component Replacement
•Condensate Trap Component Replacements
The procedures for the above inspections and replacements are provided in the following
sections.
6.1 Fireside Inspection of Benchmark 3.0 Heat Exchangers
Perform the fireside inspections of the low NOx burner (section 6.1.1) and exhaust manifold
(section 6.1.5).
6.1.1 Burner Inspection
The burner assembly is located at the top of the primary heat exchanger as shown in Figure 4.
1. Ensure that all preliminary set-up and disassembly procedures in section 4 have been
completed.
WARNING!
THE BURNER ASSEMBLY MAY BE EXTREMELY HOT. TO
AVOID BURNS, ALLOW IT TO COOL SUFFICIENTLY BEFORE
ATTEMPTING TO REMOVE IT FOR INSPECTION.
2. Disconnect the lead wire from the flame detector, shown in Figure 5, below.
3. Remove the two (2) screws securing the flame detector to the burner housing flange and
then remove the flame detector and gasket.
4. Disconnect the igniter cable from the igniter (Figure 5), then unscrew and remove the
igniter.
5. Remove the two (2) 10-32 screws securing the staged ignition assembly to the burner
housing and then separate the staged ignition assembly from the burner. Remove the gas
injector gasket (P/N 81070) from the burner, as it will be replaced during reassembly.
6. Disconnect the burner housing from the blower by removing the six (6) 1/4-20 screws
using a 3/8” wrench.
7. Remove the eight (8) 3/8-16 nuts and washers from the burner flange (Figure 5) using a
9/16” wrench.
8. Remove the burner housing from the burner flange by pulling straight up.
NOTE
The burner housing weighs approximately 20 pounds.
9. Remove the grounding screw.

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 8 of 20
10. If there is an extension ring around the burner, remove it.
11. Remove the burner and two (2) burner gaskets by pulling straight up. Figure 6 shows an
exploded view of the Benchmark 3.0LN burner assembly.
AIR/FUEL
VALVE
BURNER
HOUSING
BURNER
HEAT
EXCHANGER
EXHAUST
MANIFOLD
AIR
INLET
Figure 4. Benchmark 3.0LN - Top View
3/8-16
NUTS (8)
BURNER
HOUSING
BURNER
STAGED
IGNITION
ASSEMBLY
GROUNDING
SCREW
1/4-20
SCREWS
(6)
10-32
SCREWS (2)
SPARK
IGNITER
FLAME
DETECTOR
Figure 5. Benchmark 3.0LN Burner Disassembly – Top View
(GP-122435-S)
(66034)
FLAME DETECTOR GASKET
(81048)

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 9 of 20
6.1.2 Burner Reassembly
Referring to Figure 6, below, reassemble the burner assembly as described below. The
following parts from the kit will be used during this procedure:
•Burner Gasket P/N 81030 (2)
•Burner Housing Gasket P/N 81019
•Gas Injector Gasket P/N 81047
Figure 6. Benchmark 3.0LN Burner Assembly Exploded View
1. Replace both burner gaskets with two new burner gaskets (P/N 81030), one above and
one below the burner flange. IMPORTANT!
When installing new burner gaskets, it is imperative that the
gaskets be properly aligned to assure that the cutouts for the
observation port, igniter-injector, and flame detector line up with
those in the heat exchanger top plate, burner flange and burner
housing. Failure to properly align these items may result in
damage to the gaskets or interference with the components.
2. Place the burner back into the heat exchanger.
GAS INJECTOR
GASKET
(81047)
FLAME DETECTOR
(66034)
IGNITOR
(GP-122435-S)
BURNER GASKET
(81030)
BURNER FLANGE
BURNER HOUSING
GASKET
(81019)
BURNER GASKET
(81030)
BURNER HOUSING
10-32 SCREWS (2)
STAGED IGNITION
ASSEMBLY

Benchmark 3.0LN 24-Month Maintenance Kit 58015-04
Technical Instruction Document TID-0135_0C
10/12/2017 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone] Page 10 of 20
3. Place the new burner housing gasket (P/N 81019) on top of the blower,ensuring is
positioned correctly in relation to the burner housing’s mounting holes.
4. Position the burner housing on the blower and the burner flange, aligning it with both
burner and blower.
5. Reinstall the the six (6) 1/4-20 screws that connect the burner housing to the blower, but
only hand-tighten them at this point, to ensure proper positioning.
6. If there was an extension ring around the burner at disassembly, replace it.
7. Add one 3/8” flat washers to each of the eight (8) mounting studs coming up through the
burner flange, removed in section 6.1.1, step 7.
IMPORTANT!
It is imperative that the burner housing is fully tighten to the top of the heat
exchanger BEFORE its other end is bolted to the blower.
8. Apply Loctite 246 to the mounting studs and then loosely tighten the eight (8) 3/8-16 nuts
attaching the burner housing to the burner, and then torque the eight nuts in a star (or
alternating) pattern to 35 ± 5 ft./lbs.to to ensure a uniform seal.
9. Fully tighten the the six (6) 1/4-20 screws hand-tighten in step 5 to fully connect the burner
housing to the blower. DO NOT ATTEMPT to pull the burner housing down to meet the
blower. If there is a gap, adjust the blower mounting plate till the blower contacts the
housing.
10. Check to ensure that the grounding screw is reinstalled. Also, ensure that conductive,
high-temperature, anti-seize compound is applied to the threads of the ground screw.
11. Reinstall the staged ignition assembly with the new gas injector gasket (P/N 81070) on the
burner housing using the two (2) 10-32 screws removed in section 6.1.1, step 5.
12. After servicing is complete, perform a water bubble test during purge to ensure the burner
gaskets are providing a good seal, as specified in section 7.2.
6.1.3 Igniter Replacement
Complete the instructions below on Benchmark 3.0 LN units to reinstall the igniter (P/N GP-
122435-S).
1. Using a spark gap feeler gauge, check to ensure that the igniter is gapped at 1/8".
2. Prior to installation, a high-temperature anti-seize compound must be applied to the
igniter threads.
3. Reinstall the igniter in the location shown in Figure 9. Do not over-tighten. A slight
snugging up is sufficient.
4. Reconnect the igniter cable.