AERCO International Boiler Benchmark 1500

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.

Instrument and equipment settings: Verify factory settings

1. Set the ON/OFF switch on the control panel, 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 (Figure 7-1).

4. Refer to the partial exploded view in Figure 7-2. 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.

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 buildup is an indication that the combustion settings of the unit should be checked. Refer to Chapter 4 for combustion calibration procedures.

Close the leak detection ball valve located at the high gas pressure switch

Upload a photo of the closed leak detection ball valve

Remove the 1/4“ plug from the leak detection ball valve

Upload a photo of the removed 1/4“ plug

Install a 0 – 16” W.C. manometer (or W.C. gauge) where the 1/4” plug was removed

Upload a photo of the installed manometer

Slowly open the leak detection ball valve

Start the unit in Manual mode at a valve position (firing rate) between 25 and 30%

Record the gas pressure reading on the manometer

Warning: The O2 sensor may be hot. Allow the unit to cool sufficiently before starting the procedure.

Set the ON/OFF switch on the control panel to the OFF position and disconnect AC power from the unit.

Remove the top shroud from the unit by grasping the top handle and lifting straight up.

Disconnect the O2 sensor lead wire by pushing in on the release tab and pulling apart the connector.

Loosen and remove the O2 sensor and crush washer from the burner plate using a 15/16 open-end wrench.

Inspect the O2 sensor. If eroded, the sensor should be replaced. Otherwise clean the sensor with a fine emery cloth.

Reinstall the O2 sensor and crush washer on the burner plate.

Reconnect the sensor lead wire.

Reinstall the shroud on the unit.

Warning: This procedure requires trained personnel!

Is the unit's ON/OFF switch in the OFF position?

Set the unit in manual mode and set the valve position

Air/Fuel Valve cover removed by rotating counterclockwise?

One of the two wires (#171 or #172) removed from the Purge Switch?

Did the unit shut down and display PRG SWITCH OPEN DURING PURGE?

Wire replaced on the Purge Switch and CLEAR button depressed?

Warning: This procedure requires trained personnel!

Set valve position between 25% and 30%

Jumper across the REMOTE INTL’K IN terminals removed

Unit shut down and displayed INTERLOCK OPEN

Interlock connection reconnected

INTERLOCK OPEN message cleared and unit restarted

Sign off on the Remote Interlock Test