AERCO International Boiler Benchmark 1500

Warning: This maintenance check requires trained personnel with PPE!

If boiler is not operational, report the issues to the maintenance team and stop the procedure

Switch off the boiler and disconnect AC power from the unit.

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

Locate the air filter attached to the air/fuel valve inlet.

Using a flat-tip screwdriver or 5/16” nut driver, loosen the clamp securing the filter to the inlet flange of the air/fuel valve. Remove the filter and clamp.

Clean the filter in hot soapy water to remove oil and dirt. Dry the filter and then spray with a light coating of oil, such as WD-40, prior to reinstallation.

Install the replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat-tip screwdriver or 5/16” nut driver.

Warning: To avoid personal injury, ensure that the following guidelines are strictly observed before servicing: Disconnect the AC supply by turning off the service switch and AC supply circuit breaker. Shut off the gas supply at the manual shut-off valve provided with the unit. Allow the unit to cool to a safe water temperature to prevent burning or scalding.

Disconnect the external condensate trap by loosening the union pipe connection between the trap and the exhaust manifold drain pipe.

Remove the connections on the inlet and outlet sides of the condensate trap.

Loosen the four (4) thumbscrews securing the cover on the condensate trap. Remove the cover.

Remove the float from the condensate trap.

Remove the O-ring and orifice gaskets from the trap. These items should be replaced annually.

Thoroughly clean the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap.

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.

Gauges, monitors and indicators: Visual inspection and record readings in operator log

Instrument and equipment settings: Visual check against factory recommended specifications

Sign off on the daily boiler test

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.

Flue, vent, stack or intake air duct: Visually inspection condition and check for obstructions

Disable the blower output drive voltage

Start the unit in the Manual Mode at a valve position between 25% and 30%.

The unit should shut down and lockout, showing AIRFLOW FAULT DURING PURGE in the display.

The unit should perform one IGNITION RETRY cycle and then shut down, since the blower is disabled. The unit will then display AIRFLOW FAULT DURING PURGE.

Re-enable the blower output drive voltage

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.