Watts Aerco BMK 750, Aerco BMK 2500, Aerco BMK 3000, Aerco BMK 5000, Aerco BMK 6000 Operation And Service Manual

...

Download

Operation and Serv ice Manual

Other documents for this product include :

OMM-0137_D • GF-211 • 7/16/2019

Benchmark® Platinum Boilers With Edge Controller

Natural Gas, Propane Gas and Dual Fuel Modulating & Condensing Boilers

Models 750 through 6000

OMM-0136, GF-210 210 Installation and Startup Man ual OMM-0138, GF-212 Reference Manual OMM-0139, GF-213 Edge Controller Manual TAG-0019, GF-2070 Boiler Application Guide

TAG-0022, GF-2050 Vent-Combustion Air Guide TAG-0047, GF-2030 Benchmark Gas Guide TAG-0048, GF-2060 Benchmark Power Guide

Applies to serial numbers:

G-19-0300 and above – B MK 750 – 3000 N-19-0100 and above – BMK 5000 & 6000

Benchmark Platinum-Edge: Operation-Service Manual

CONTENTS

FOREWORD ...................................................................................................... 5

SECTION 1: SAFETY PRECAUTIONS ................................................................... 9

1.1 WARNINGS & CAUTIONS ..................................................................................................................... 9

1.2 EMERGENC Y SHUT D OWN ................................................................................................................. 10

1.3 PROLONGED SHUTDOWN ................................................................................................................. 10

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ............................................................... 11

SECTION 2: EDGE CONTROLLER OPERATION .................................................. 13

2.1 INTRODUCTION ................................................................................................................................... 13

2.2 LOGIN AND PASSWORD ENTRY ....................................................................................................... 14

SECTION 3: START SEQUENCE ........................................................................ 15

3.1 INTRODUCTION ................................................................................................................................... 15

3.2 START SEQUENCE ............................................................................................................................. 15

3.3 START/STOP LEVELS ......................................................................................................................... 23

3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT ..................................................................... 24

3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input .............................................................................. 24

3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input ...................................................................................... 25

3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input ...................................................................................... 26

3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input ...................................................................................... 27

3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input ...................................................................................... 28

3.4.6 Benchmark 5000 Air/Fuel Valve Position and Energy Input ........................................................................... 29

3.4.7 Benchmark 6000 Air/Fuel Valve Position and Energy Input ........................................................................... 30

SECTION 4: INITIAL START-UP ........................................................................ 31

4.1 INITIAL START-UP REQUIREMENTS ................................................................................................. 31

4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION ........................................................ 32

4.2.1 Required Tools & Instrumentation ................................................................................................................. 32

4.2.2 Installing Gas Supply Manometer ................................................................................................................... 32

4.2.3 Accessing the Analyzer Probe Port ................................................................................................................. 35

4.3 FUEL TYPES AND COMBUSTION CALIBRATION ............................................................................. 36

4.4 COMBUSTION CALIBRATION ............................................................................................................. 36

4.4.1 NATURAL GAS Manual Combustion Calibration ............................................................................................. 37

4.4.2 PROPANE GAS COMBUSTION CALIBRATION .................................................................................................. 42

4.5 REASSEMBLY ...................................................................................................................................... 47

4.6 DUAL FUEL SWITCHOVER ................................................................................................................. 48

4.7 OVER-TEMPERATURE LIMIT SWITCHES ......................................................................................... 49

4.7.1 Adjusting the Automatic Reset Limit Switch Temperature ............................................................................ 49

4.7.2 Resetting the Manual Reset Limit Switch ....................................................................................................... 50

4.7.3 Changing the Readout Between Fahrenheit and Celsius ................................................................................ 50

SECTION 5: SAFETY DEVICE TESTING .............................................................. 51

5.1 TESTING OF SAFETY DEVICES ......................................................................................................... 51

5.2 LOW GAS PRESSURE TEST .............................................................................................................. 52

5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500 ................................................................................................... 52

5.2.2 LOW GAS PRESSURE TEST: BMK 3000 – 6000 Only ........................................................................................ 54

5.3 HIGH GAS PRESSURE TEST ............................................................................................................. 57

5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500 .................................................................................................. 57

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 2 of 146

Benchmark Platinum-Edge: Operation-Service Manual

CONTENTS

5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 – 6000 Only ........................................................................................ 59

5.4 LOW WATER LEVEL FAULT TEST ..................................................................................................... 62

5.5 WATER TEMPERATURE FAULT TEST .............................................................................................. 63

5.6 INTERLOCK TESTS ............................................................................................................................. 64

5.6.1 Remote Interlock Test..................................................................................................................................... 64

5.6.2 Delayed Interlock Test .................................................................................................................................... 64

5.7 FLAME FAULT TEST ............................................................................................................................ 65

5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES .............................. 66

5.8.1 Blower Proof Switch Test ................................................................................................................................ 66

5.8.2 Blocked Inlet Switch Test ................................................................................................................................ 68

5.9 SSOV PROOF OF CLOSURE SWITCH CHECK ................................................................................. 69

5.10 PURGE SWITCH OPEN DURING PURGE ........................................................................................ 70

5.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................................. 72

5.12 SAFETY PRESSURE RELIEF VALVE TEST ..................................................................................... 72

SECTION 6: STANDALONE MODES OF OPERATION ......................................... 73

6.1 OUTDOOR RESET MODE ................................................................................................................... 73

6.1.1 Outdoor Air Temperature Sensor Installation ................................................................................................ 73

6.1.2 Outdoor Reset Mode Startup ......................................................................................................................... 74

6.2 CONSTANT SETPOINT MODE ........................................................................................................... 75

6.3 REMOTE SETPOINT MODE ................................................................................................................ 75

6.4 DIRECT DRIVE MODES....................................................................................................................... 76

6.5 AERCO CONTROL SYSTEM (ACS) .................................................................................................... 77

6.6 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 78

6.6.1 Combination Control System Field Wiring ...................................................................................................... 79

6.6.2 Combination Control System Setup and Startup ............................................................................................ 79

SECTION 7: BOILER SEQUENCING TECHNOLOGY ............................................ 81

7.1 INTRODUCTION ................................................................................................................................... 81

7.1.1 Installation Notes............................................................................................................................................ 82

7.2 BST QUICK START CHART ................................................................................................................ 82

7.3 BST IMPLEMENTATION INSTRUCTION ............................................................................................ 83

7.3.1 Option 1 Constant Setpoint: Direct Wired Header Sensor ............................................................................. 83

7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Sensor .......................................................................... 85

7.3.3 Option 3 Outdoor Reset: Direct Wired Header Sensor & Direct Wired Outdoor Sensor ............................... 87

7.3.4 Option 4 Outdoor Reset: Modbus Header Sensor & Modbus Outdoor Sensor .............................................. 89

7.3.5 Option 5 Remote Setpoint: Direct Wired Header Sensor & 4-20ma Setpoint Drive ...................................... 91

7.3.6 Option 6 Remote Setpoint: Direct Wired Header Sensor & Modbus Setpoint Drive ..................................... 93

7.3.7 Option 7 Remote Setpoint: Modbus Header Sensor & 4-20ma Setpoint Drive ............................................. 95

7.3.8 Option 8 Remote Setpoint: MODBUS Header Sensor & MODBUS Setpoint Drive ......................................... 97

SECTION 8: MAINTENANCE ............................................................................ 99

8.1 MAINTENANCE SCHEDULE ............................................................................................................... 99

8.2 IGNITER-INJECTOR – BMK 750 - 3000 ............................................................................................ 100

8.3 PILOT IGNITION ROD – BMK 5000 & 6000 ...................................................................................... 102

8.4 FLAME DETECTOR ........................................................................................................................... 102

8.5 O2 SENSOR ........................................................................................................................................ 103

8.5.1 Air Eductor Air Pump Maintenance – BMK 5000 & 6000 ........................................................................... 104

8.6 SAFETY DEVIC E T ESTING ............................................................................................................... 105

8.7 BURNER INSPECTION ...................................................................................................................... 105

8.8 CONDENSATE DRAIN TRAP ............................................................................................................ 108

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 3 of 146

Benchmark Platinum-Edge: Operation-Service Manual

CONTENTS

8.9 AIR FILTER CLEANING AND REPLACEMENT ................................................................................ 109

8.10 REFRACTORY REPLACEMENT – BMK 5000 & 6000 ONLY ......................................................................... 109

8.10.1 Rear Refractory Replacement .................................................................................................................... 110

8.10.2 Front Refractory Replacement .................................................................................................................. 112

8.11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD ................................................................. 113

8.11.1 Benchmark 5000/6000 Long Term Blower Storage .................................................................................... 113

8.12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN .................................................... 115

8.13 RECOMMENDED PERIODIC TESTING .......................................................................................... 116

8.14 RECOMMENDED SPARES ............................................................................................................. 118

SECTION 9: AERTRIM OPERATION ................................................................ 119

9.1 AERTRIM INTRODUCTION ............................................................................................................... 119

9.2 AERTRIM ACTI VATION ..................................................................................................................... 119

9.3 OPERATION DETAILS ....................................................................................................................... 120

9.4 AERTRIM O2 SENSOR AUTO CALIBRATION .................................................................................. 122

9.5 AERTRIM MENU VAL U ES AND DEFAULTS..................................................................................... 123

9.6 AERTRIM MAINTENANCE AND TROUBLESHOOTING ................................................................... 129

SECTION 10: TROUBLESHOOTING .................................................................. 131

10.1 INTRODUCTION ............................................................................................................................... 131

10.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ................................................ 143

NOTES: .................................................................................................. 145

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 4 of 146

Benchmark Platinum-Edge: Operation-Service Manual

INPUT RANGE (BTU/HR.)

OUTPUT RANGE (BTU/HR.)

FORWARD

FOREWORD

The AERCO Benchmark (BMK) 750 through 6000 natural gas and propane fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads. These BMK models provide extremely high efficiency operation and are ideally suited for modern low temperature, as well as, conventional heating systems.

The Benchmark models operate within the following input and output ranges:

IMPORTANT!

Unless otherwise specified:

• All descriptions provided in this document apply to the Benchmark Platinum Series of boiler.

• All measurements apply to both natural gas and propane models, unless otherwise

specified.

Benchmark Boiler Intake and Output Ranges

MODEL

MINIMUM MAXIMUM MINIMUM MAXIMUM

BMK 750 50,000 (14.6 kW) 750,000 (220 kW) 47,750 (14 kW) 716,250 (210 kW)

BMK 1000 50,000 (14.6 kW) 1,000,000 (293 kW) 48,300 (14.15 kW) 968,000 (284 kW)

BMK 1500 75,000 (22 kW) 1,500,000 (440 kW) 64,500 (18.9 kW) 1,395,000 (409 kW)

BMK 2000 100,000 (29.3 kW) 2,000,000 (586 kW) 86,000 (25.2 kW) 1,860,000 (545 kW)

BMK 2500 167,000 (48.9 kW) 2,500,000 (732 kW) 144,000 (42.2 kW) 2,395,000 (702 kW)

BMK 3000 200,000 (58.6 kW) 3,000,000 (879 kW) 174,000 (51.0 kW) 2,874,000 (842 kW)

BMK 5000 400,000 (117 kW) 5,000,000 (1465 kW) 348,000 (102 kW) 4,750,000 (1392 kW)

BMK 6000 400,000 (117 kW) 6,000,000 (1758 kW) 348,000 (102 kW) 5,700,000 (1670 kW)

The output of the boiler is a function of the unit’s firing rate (valve position) and return water temperature.

When installed and operated in accordance with this Instruction Manual, the BMK 750 – 2000 and 5000 & 6000 comply with the NOx emission standards outlined in: South Coast Air Quality Management District (SCAQMD), Rule 1146.2. In addition, the BMK 2500 – 6000 comply with the Bay Area Air Quality Management District regulation 9, Rule 7.

Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting flexibility with minimum installation space requirements. These boilers are Category II and IV, positive pressure appliances. Single and/or multiple breeched units are capable of operation in the following vent configurations:

• Room Combustion Air:

o Vertical Discharge o Horizontal Discharge

• Ducted Combustion Air:

o Vertical Discharge o Horizontal Discharge

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 5 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Symbol rate, or simply the number of distinct symbol changes British Thermal Unit. A unit of energy approximately equal to the

Double Block and Bleed, a gas trains containing 2 Safety Shutoff

A control system developed by AERCO and currently used in all

FORWARD These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In

addition, the BMK 750 & 1000 models are also approved for PVC and CPVC, vent systems (excluding the state of Massachusetts).

The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration.

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

A (Amp) Ampere ACS AERCO Control System, AERCO’s boiler management systems ADDR Address AGND Anal og Ground ALRM Alarm ANSI American National Standards Institute, ASME American Society of Mechanical Engineers AUX Auxiliary

BAS

Baud Rate

Building Automation System, often used interchangeably with EMS (see below)

(signaling events) transmitted per second. It is not equal to bits per

second, unless each symbol is 1 bit long. BMK (Benchmark) AERCO’s Benchmark series boilers BMS or BMS II AERCO Boiler Management Systems

BLDG (Bldg) Building BST AERCO on-board Boiler Sequencing Technology

BTU

heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C) BTU/HR BTUs per Hour (1 BTU/hr = 0.29 W)

CCS Combination Control System CFH Cubic Feet per Hour (1 CFH = 0.028 m3/hr) CO Carbon Monoxide COMM (Comm) Communication Cal. Calibration CNTL Control CPU Central Processing Unit

DBB

Valves (SSOVs) and a solenoid operated vent valve. DIP Dual In-Line Package, a type of switch

ECU Electronic Control Unit (O2 sensor) Edge Controller

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 6 of 146

Benchmark Platinum boilers.

Benchmark Platinum-Edge: Operation-Service Manual

EMS

Energy Management System; often used interchangeably with BAS

Low Nitrogen Oxide

MA (mA)

Milliampere (1 thousandth of an ampere)

MAX (Max)

Maximum

MBH

1000 BTUs per Hour

duplex data transmission protocol developed by AEG

NO (N.O.)

Normally Open

NOx

Nitrogen Oxide

NPT

National Pipe Thread

Oxygen

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

FM Factor y Mutual. Used to define boiler gas trains. GF-xxxx Gas Fired (an AERCO document numbering system) GND Ground HDR Header Hex Hexadecimal Number (0 – 9, A – F) HP Horse Power HX Heat Exchanger Hz Hertz (Cycles Per Second) I.D. Inside Diameter IGN Ignition IGST Board Ignition/Stepper Board, contained in Edge Controller INTLK (INTL’K) Interlock I/O Input/Output I/O Box Input/Output (I/O) Box currently used on Benchmark boilers IP Internet Protocol ISO International Organization for Standardization Lbs. Pounds (1 lb = 0.45 kg) LED Light Emitting Diode

MIN (Min) Minimum Modbus®

A serial, half-

Modicon NC (N.C.) Normally Closed

O.D. Outside Diameter OMM, O&M Operation and Maintenance Manual onAER

AERCO’s on-line remote monitoring s y stem PCB Printed Circuit Board PMC Board Primary Micro-Contr oller (PMC) board, contained in the Edge P/N Part Number

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 7 of 146

Benchmark Platinum-Edge: Operation-Service Manual

POC

Proof of Closure

duplex (FDX) transmission of data based

SPDT

Single Pole Double Throw, a type of switch

SSOV

Safety Shut Off Valve

TEMP (Temp)

Temperature

prevent reflections that may cause invalid data in the

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

PPM Part s per Million PSI Pounds per Square Inch (1 PSI = 6.89 kPa) PTP Point-to-Point (usually over RS232 networks) P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater PVC Poly Vinyl Chloride, a common synthetic plastic PWM Pulse Width Modulation REF (Ref) Reference RES. Resistive RS232

(or EIA-232) RS485

(or EIA-485)

A standard for serial, full-

on the RS232 Standard

A standard for serial, half-duplex (HDX) transmission of data based

on the RS485 Standard RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield

A resistor placed at each end of a daisy-chain or multi-drop network Terminating Resistor

in order to

communication Tip-N-Tell A device that indicates if a package was tipped during shipping UL A business that tests and validates products VAC Volts, Alternating Current VDC Volts, Direct Current VFD Variable Frequency Drive VPS Valve Proving System W Watt W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 millionth of an ampere)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 8 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 1: SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions. In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. W here applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

See section 1.4 for important information regarding installation of units within the Commonwealth of Massachusetts.

IMPORTANT!

This manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.

WARNING!

• Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.

• Fluids under pressure may cause injury to personnel or damage to equipment when

released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully decrease all trapped pressures to zero before performing maintenance.

• Before attempting to perform any maintenance on the unit, shut off all g as and electrical inputs to the unit.

• The exhaust vent pipe of the unit operates under a positive pressure and therefore must be completely sealed to prevent leakage of combustion products into living spaces.

• Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK 2500/3000) or 208, 460 or 575 VAC (BMK 5000 & 6000) and 24 vo lts AC may be used

in this equipment. Therefore the cover on the unit’s power box (located behind the front panel door) must be installed at all times, except during maintenance and servicing.

• A single-pole (120 VAC units) or three-pole (220 VAC and higher units) switch must be installed on the electrical supply line of the unit. The switch must be installed in an easily accessible position to quickly and safely disconnect electrical service. Do not affix switch to unit sheet metal enclosures.

CAUTION!

• Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be rinsed thoroughly with clean water after leak checks have been completed.

• DO NOT use this boiler if any part has been under water. Call a qualified service technician to inspect and replace any part that has been under water.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 9 of 146

Benchmark Platinum-Edge: Operation-Service Manual

VALVE

CLOSED

SECTION 1: SAFETY PRECAUTIONS

1.2 EMERGENCY SHUTDOWN

If overheating occurs or the gas supply fails to shut off, close the manual shutoff valve (Figure 1-

1) located external to the unit.

NOTE:

The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

VALVE

OPEN

Figure 1-1: External Manual Gas Shutoff Valve

In addition, to ensure safety an emergency shutdown procedure that addresses the following points should be designed and implement at the site:

• For automatically operated unattended boilers located in a boiler room, provide a manually operated remote shutdown switch or circuit breaker located just inside or outside each boiler room door. Design the system so activation of the emergency shutdown switch or circuit breaker will immediately shut off the fuel supply to the unit(s).

• For automatically operated unattended boilers in a location other than a boiler room, provide a manually operated remote shutdown switch or circuit breaker marked for easy identification at a location readily accessible in the event of boiler mis-operation.

• Design the system so activation of the emergency shutdown switch or circuit breaker will immediately shut off the fuel.

• For boilers monitored and/or operated from a continuously occupied control room, provide an emergency shutdown switch in the control room that is hard-wired to immediately shut off the fuel upon activation.

1.3 PROLONGED SHUTDOWN

If there is an emergency, turn off the electrical power supply to the boiler and close the manual gas valve located upstream from the unit. The installer must identify the emergency shut-off device.

If the unit is being shut down for an extended period of time, such as a year or more, complete the instructions in Section 8.11: Shutting Boiler Down For Extended Period.

When returning a unit to service after a prolonged shutdown, it is recommended that the instructions in Section 4: Initial Startup Procedures and Section 5: Safety Device Testing be performed to verify that all system-operating parameters are correct.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 10 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Requirements For Massachusetts Installations

Boiler Installations within the Commonwealth of Massachusetts must conform to the

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,

alled on each additional level of the dwelling,

be the responsibility of the property owner to secure the services of qualified licensed

the above requirements; provided, however, that during said thirty (30) day period, a

Each carbon monoxide detector as

accordance with the above provisions shall comply with NFPA 720 and be

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)

SECTION 1: SAFETY PRECAUTIONS

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS

following requirements:

• Boiler must be installed by a plumber or a gas fitter who is licensed within the

Commonwealth of Massachusetts.

• Prior to unit operation, the complete gas train and all connections must be leak

tested using a non-corrosive soap.

• The vent termination must be located a minimum of 4 feet above grade level. If

side-wall venting is used, the installation must conform to the following requirements extracted from 248 CMR 5.08 (2):

building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is inst building or structure served by the side wall horizontal vented gas fueled equipment. It shall

professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with

battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS: required in

ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 11 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Requirements For Massachusetts Installations

observes carbon monoxide detectors and signage installed in accordance with the

venting system design or venting system components with the equipment, the instructions

When the manufacturer of a Product Approved side wall horizontally vented gas fueled

nd the

SECTION 1: SAFETY PRECAUTIONS

4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector

provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a

provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, a instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 12 of 146

Benchmark Platinum-Edge: Operation-Service Manual

temperature

1 2 3 6 7

11 4 5

SECTION 2: OPERATION

SECTION 2: EDGE CONTROLLER OPERATION

2.1 INTRODUCTION

This section provides a brief outline of how to gain access to Benchmark Boiler’s Edge Controller functionality. Full instructions for using the Edge Controller to setup, configure and operate a Benchmark Boiler are included in the Edge Controller Manual.

NOTE: The Edge Controller Manual is document number OMM-0139, GF-213.

The Edge Controller is shown below. This panel contains all of the controls, indicators and displays necessary to operate, adjust and troubleshoot the boiler.

The Edge Controller’s front panel consists of a touchscreen display along with a variety of indicators and buttons.

Multi-Function Bar, shows either:

• Fire Rate

• Valve Position

Parameter Indicator for both temperature read-outs:

• LEFT: Inlet or Setpoint temperature

• RIGHT: Outlet or System Header

Temperature scale indicator: Fahrenheit

or Celsius Configurable temperature read-outs (2):

• LEFT: Inlet or Setpoint

• RIGHT: Outlet or System Header

Operation Mode Indicators (2):

• LEFT: Demand or Manual

• RIGHT: Manager or Client (BST

6 Edge Controller Touchscreen 7 Soft Keys 8 onAER Indicator Light

Ready Light

10 Enable/Disable Switch

Low Water Level Buttons (2):

• TEST: Initiates Low Water test

• RESET: Resets unit after Low Water

temperature

only)

test

Figure 2-1 Edge Controller Front Panel

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 13 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 2: OPERATION

2.2 Login and Password Entry

The Edge Controller has multiple levels of password protection.

Level Password Description

1 No password The default. Many parameters are visible but “Read Only.” 2 159

A higher-level password is reserved AERCO Master Technicians (AMT). It is distributed on an individual basis.

To enter a password:

1. On the Edge Controller, go to Password screen appears.

2. Use the number keypad to enter the password (each number appears as a X), then pr es s Save. You will have access to the functionality associated with the level of the password entered.

Allows routine maintenance to be performed. Appropriate for AERCO Trained technicians (ATT).

Main Menu  Advanced Setup  Access. The Enter

Figure 2.2: Enter Password Screen

3. Once you have successfully logged into the system, the Main Menu appears. All Edge functionality is accessed through one of the six Main Menu items.

Figure 2-3: Edge Controller Main Menu

NOTE:

Full instruct ions for using the Edge Controller are in the Edge Controller Manual (GF-213).

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 14 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 3 - START SEQUENCE

SECTION 3: START SEQUENCE

3.1 INTRODUCTION

The information in this section provides a guide to starting the Benchmark Boiler using the Edge Controller. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel may void the equipment warranty. In addition, the following WARNINGS and CAUTIONS must be observed at all times.

WARNING!

• All of the installation procedures in Section 2: Installation of the Benchmark Platinum- Edge: INSTALLATION Manual (GF-210) must be completed before the initial start-up of

the unit.

• Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK 2500/3000) or 208, 460 or 575 VAC (BMK 5000 & 6000) and 24 vo lts AC may be used

in this equipment. It must be serviced only by factory certified service technicians.

• Do not attempt to dry fire the unit. Starting the unit without a full water level can seriously damage the unit and may result in injury to personnel or property damage. This situation will void any warranty.

• Initial startup of the unit must be be performed by AERCO factory trained personnel. Operation prior to initial startup by factory trained personnel may void the equipment warranty. In addition, the following WARNINGS and CAUTIONS must be observed at all times.

3.2 START SEQUENCE

When the Edge Controller Enable/Disable switch is set to t he Enable position, it checks all prepurge safety switches to ensure they are closed. These switches include:

• High Water Temperature switch

• High Gas Pressure switch

• Low Gas Pressure switch

• Low Water Level switch

• Safety Shut-Off Valve (SSOV) Proof of Closure (POC) switch

NOTE:

The Blocked Inl et and downstream B lower Proof switches are not checked prior to starting the pre-purge.

If all of the above switches are closed, the READY light (above the Enable/Disable switch) will light when the switch is in the Enable position and the unit will be in the STANDBY mode.

NOTE:

If any of the Pre-Purge safety device switches are open, or the required conditions are not observed throughout the start sequence, appropriate fault messages will be displayed.

When there is a demand for heat, the following events occur:

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 15 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SSOV

NATURAL GAS INLET

SECTION 3 - START SEQUENCE

Start Sequence

1. The Controller’s red DEMAND LED status indicator will light.

2. The unit checks all five pre-purge safety switches listed at the beginning of this section. The Edge Controller’s ignition sequence screen walks you through the ignition screens and demonstrates (or highlights) which switches are not met. SSOV locations are shown in Figure 3-1a thro ugh 3-1d.

TO AIR/FUEL VALVE

MANUAL SHUT-OFF VALVE

LOW GAS PRESSURE SWITCH

Figure 3-1a: BMK 750 & 1000 SSOV Location (P/N 22322 shown)

AIR/FUEL

MANUAL SHUT-OFF VALVE

VALVE

SSOV

HIGH GAS PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

Figure 3-1b: BMK 1500 & 2000 SSOV Location (P/N 22314 shown)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 16 of 146

Benchmark Platinum-Edge: Operation-Service Manual

VALVE

NATURAL GAS INLET

LOW GAS SWITCH

NATURAL GAS INLET

SECTION 3 - START SEQUENCE

Start Sequence

SSOV

TO AIR/FUEL

MANUAL SHUT-OFF VALVE

VALVE

LOW GAS PRESSURE SWITCH

Figure 3-1c: BMK 2500: SSOV Location (P/N 22318 shown)

TO AIR/FUEL

MANUAL

SHUT-OFF VALVE

HIGH GAS PRESSURE

SWITCH

Figure 3-1d: BMK 3000: SSOV L o cation (P/N 22310 shown)

SSOV

PRESSURE

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 17 of 146

Benchmark Platinum-Edge: Operation-Service Manual

STEPPER MOT OR

100

UPSTREAM

TO AIR/FUEL

GAS INLET

MANUAL SHUT-

DOWNSTREAM

HIGH GAS

UPSTREAM LOW GAS

SECTION 3 - START SEQUENCE

Start Sequence

SSOV

SSOV WITH

VALVE

OFF VALVE

POC

- BMK 6000: 10.5” W.C., 2.6 kPa

- BMK 5000: 11.0” W.C., 2.7 kPa

PRESSURE SWITCH

- BMK 6000: 8.5” W.C., 2.1 kPa

- BMK 5000: 8.0” W.C., 2.0 kPa

Figure 3-1e: BMK 5000-6000: SSOV Location

3. The Auxiliary Delay occurs for a configurable length of time and the Delayed Interlocks are closed.

4. Once all required safety device switches are closed, a purge cycle is initiated and the following events occur:

a. The Blower relay energizes and turns on the blower. b. The Air/Fuel Valve rotates to the full-open purge position and closes purge position

switch. The dial on the Air/Fuel Valve (Figure 3-2a and 3-2b) will read 100 to indicate that it is full-open (100%).

c. The Fire Rate bargraph on the Controller’s front face shows 100%.

AIR INLET

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 18 of 146

Figure 3-2a: BMK 750 & 1000 Air/Fuel Valve in Purge Position

BLOWER

Benchmark Platinum-Edge: Operation-Service Manual

TO BLOWER

STEPPER MOTOR

AIR IN

SECTION 3 - START SEQUENCE

Start Sequence

PURGE

VALVE POSITION

DIAL AT 100%

Figure 3-2b: BMK 1500 – 6000 Air/Fuel Valve In Purge Position

5. Next, the Blower Proof and Blocked Inlet switches close (Figure 3-4a and 3-4b). On the Ignition Sequence screen the Purging indicator turns grey while purging is underway (Figure 3-3) and Purge Timer displays the purge cycle’s elapsed time in seconds.

Figure 3-3: Ignition Sequence Screen – Purging

BLOWER PROOF SWITCH

BLOCKED INLET SWITCH

Figure 3-4a: BMK 750 & 1000 Blower Proof Switch

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 19 of 146

Benchmark Platinum-Edge: Operation-Service Manual

fire (Ignition) position and closes the ignition

cycle turns on the

the Ignition

AIR/FUEL VALVE OUTLET TO BLOWER

BLOWER

SWITCH

TRAIN

SECTION 3 - START SEQUENCE

Start Sequence

PROOF

AIR/FUEL VALVE INLET FROM GAS

BLOCKED

INLET

SWITCH

Figure 3-4b: BMK 1500 – 6000 Blower Proof Switch

6. Upon completion of the purge cycle, the Controller initiates an ignition cycle and the following events occur:

a) The Air/Fuel Valve rotates to the low-

switch. The Dial on the Air/Fuel Valve (Figure 3-5) will read between 25 and 35 to indicate that the valve is in the low fire position.

b) The Spark Cleaning cycle begins (default duration = 7 sec.) and the Ignition Sequence

screen’s Spark Cleaning indicator (Figure 3-3) turns grey. This ignition transformer to produce a spark (with no gas flowing) to remove moisture and carbon buildup from the spark element. For the duration of this cycle, the Controller displays the Cleaning Igniter status message.

c) Following the Spark Cleaning cycle, power is applied to the gas S afety Shut -off Val ve

(SSOV). When the SSOV indicates the Gas Valve is OPEN (POC) and Sequence screen’s Ignition indicator (Figure 3-3) turns grey.

d) If no spark is present 3 seconds into the ignition trial, the Controller aborts th e Igni tion

Cycle and shuts down the boiler. Refer to Section 10: Troubleshooting in this g uide for guidance if this occurs.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 20 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TO BLOWER

AIR IN

25% to 35%

STEPPER MOTOR

SECTION 3 - START SEQUENCE

Start Sequence

IGNITION

VALVE POSITIO N

DIAL AT

Figure 3-5: Air/Fuel Valve In Ignition Position

7. Up to 4 seconds are allowed for ignition to be detected. The ignition circuit is turned off one second after flame is detected.

8. After 2 seconds of continuous flame, the flame strength is indicated. After 5 seconds, the Unit Status screen appears.

9. With the unit firing properly, it will be controlled by the temperature control circuitry. The boiler’s fire rate or valve position (depending on which was chosen in Section 6.2.2: Front Panel Configuration of the Edge Controller Manual) will continuously display on the Controller’s bargraph.

10. Once the demand for heat has been satisfied, the Edge Controller will turn off the SSOV

gas valve. The blower relay will be deactivated and the Air/Fuel Valve wil l be closed. Standby is displayed.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 21 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Operating State

Pre-purge

PFEP

MFEP

Standby

T = 0

T = 30

T = 37

T = 44

Run

Component

PFEP

MFEP

C-More Controller

Scanner Power

Ignition Power

SSOV Power

Pilot Valve Closed

Pilot Valve Open

Ignition Transformer Off

Ignition Transformer On

UV Scanner Powered

UV Scanner "Ignored"

UV Scanner In Use

Relay 1 Coil

Relay 1 C-NC

Relay 1 C-NO

Relay 2 Coil Power from R1

Relay 2 Coil Power from SKP 15 POC

Relay 2 C-NC

Relay 2 C-NO

SKP15 Power from R1 Contacts

SKP15 Power from R2 contact and POC C-NO

SKP15 Proof of Closure C-NC

SKP15 Proof of Closure C-NO

SKP25

Power through R1

Power through R2 and AUX

Proof of Closure C-NC

Proof of Closure C-NO

SECTION 3 - START SEQUENCE

BMK 5000 & 6000 Function Timing Chart For Proved Pilot Control System

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 22 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 3-1a: Start/Stop Levels – NATURAL GAS

Level:

Position

TABLE 3-1b: Start/Stop Levels – PROPANE GAS

750

1000

1500

2000

2500

3000

5000

6000

Level:

SECTION 3 - START SEQUENCE

3.3 START/STOP LEVELS

The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows:

Start

Stop

Ignition

Start

Stop

Ignition Position

BMK

750

22% 22% 20% 24% 24% 20% 24% 24%

18% 18% 16% 18% 16% 14% 18% 18%

35% 35% 29% 29% 29% 29% 35% 50%

BMK

22% 22% 20% 24% 26% 22% 24% 24%

18% 18% 16% 18% 18% 14% 18% 18%

35% 35% 29% 29% 29% 29% 35% 50%

BMK 1000

BMK

BMK 1500

BMK

BMK 2000

BMK

BMK 2500

BMK

BMK 3000

BMK

BMK 5000

BMK

BMK 6000

BMK

Normally, these settings do not require adjustment. Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 23 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 3-2a: BMK 750/1000 Air/Fuel Valve Position – NATURAL GAS

CAPACITY)

BMK 750

BMK 1000

BMK 750

BMK 1000

0% 0 0

10% 0 0

18% (Stop Level)

50,000 (14.7 kW)

6.7%

20%

52,000 (15.2 kW)

54,000 (15.8 kW)

6.9%

5.4%

30%

108,000 (31.7 kW)

140,000 (41.0 kW)

14%

40%

246,000 (72.1 kW)

297,000 (87.0 kW)

33%

30%

50%

369,000 (108.1 kW)

443,000 (126.9 kW)

49%

44%

60%

465,000 (136.3 kW)

564,000 (165.3 kW)

62%

56%

70%

554,000 (162.4 kW)

660,000 (193.4 kW)

74%

66%

80%

637,000 (186.7 kW)

789,000 (231.2 kW)

85%

79%

90%

733,000 (214.8 kW)

933,000 (273.4 kW)

98%

93%

100%

750,000 (219.8 kW)

1,000,000 (293.1 kW)

100%

TABLE 3-2b: BMK 750/1000 Air/Fuel Valve Position – PROPANE GAS

BMK 750

BMK 1000

BMK 750

BMK 1000

0% 0 0

10% 0 0

18% (Stop Level)

50,000 (14.7 kW

6.7%

5.0%

20%

71,000 (20.8 kW)

9.5%

7.1%

30%

128,000 (37.5 kW)

181,000 (53.0 kW)

17%

18%

40%

373,000 (109.3 kW)

400,000 (117.2 kW)

50%

40%

50%

508,000 (148.9 kW)

562,000 (164.7 kW)

68%

56%

60%

565,000 (165.6 kW)

703,000 (206.0 kW)

75%

70%

621,000 (182.0 kW)

791,000 (231.8 kW)

83%

79%

80%

660,000 (193.4 kW)

865,000 (253.5 kW)

88%

87%

90%

723,000 (211.9 kW)

963,000 (282.2 kW)

96%

100%

750,000 (219.8 kW)

1,000,000 (293.1 kW)

100%

SECTION 3 - START SEQUENCE

3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT

The Tables below show the relationship between the energy input and Air/Fuel Valve position for the BMK models covered in this document.

3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input

AIR/FUEL VALVE

POSITION (%

OPEN)

Air/Fuel Valve

Position (%

Open)

ENERGY INPUT

(BTU/HR)

Energy Input

(BTU/Hr)

BOILER ENERGY

INPUT (% OF FULL

Boiler Energy Input (% of Full Capacity)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 24 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 3-3a: BMK 1500 Air/Fuel Valve Position – NATURAL GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT

(% OF FULL CAPACITY)

16% (Stop Level)

75,000 (22.3 kW)

5.0%

20%

127,000 (37.2 kW)

8.5%

30%

366,000 (107.2 kW)

24.4%

40%

629,000 (184.3 kW)

41.9%

50%

822,000 (240.9 kW)

54.7%

60%

977,000 (286.2 kW)

65.0%

70%

1,119,000 (327.9 kW)

74.5%

80%

1,255,000 (367.7 kW)

83.5%

90%

1,396,000 (409.0 kW)

92.9%

100%

1,502,000 (440.1 kW)

100%

TABLE 3-3b: BMK 1500 Air/Fuel Valve Position – PROPANE GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT

(% OF FULL CAPACITY)

18% (Stop Level)

75,000

5.0%

20%

93,700

6.2%

30%

254,000

16.9%

40%

505,000

33.7%

50%

680,000

45.3%

60%

807,000

53.8%

70%

947,000

63.1%

80%

1,157,000

77.1%

90%

1,379,000

91.9%

100%

1,503,000

100%

SECTION 3 - START SEQUENCE

3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 25 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 3-4a: BMK 2000 Air/Fuel Valve Position – NATURAL GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT (% OF FULL CAPACITY)

18% (Stop Level)

100,000 (29.3 kW)

5.7%

20%

143,000 (41.9 kW)

11%

30%

388,000 (113.7 kW)

23%

40%

759,000 (222.4 kW)

37%

50%

1,069,000 (313.2 kW)

51%

60%

1,283,000 (375.9 kW)

61%

70%

1,476,000 (432.5 kW)

74%

80%

1,675,000 (490.1 kW)

83%

90%

1,833,000 (537.1 kW)

93%

100%

2,000,000 (586.0 kW)

100%

TABLE 3-4b: BMK 2000 Air/Fuel Valve Position – PROPANE GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT

(% OF FULL CAPACITY)

18% (Stop Level)

100,000

5.0%

20%

126,600

6.3%

30%

363,000

18.2%

40%

677,000

33.9%

50%

898,000

44.9%

60%

1,070,000

53.5%

70%

1,242,000

62.1%

80%

1,523,000

76.2%

90%

1,845,000

92.3%

100%

2,000,000

100%

SECTION 3 - START SEQUENCE

3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 26 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 3-5a: BMK 2500 Air/Fuel Valve Position – NATURAL GAS, Single Fuel

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT

(% OF FULL CAPACITY)

16% (Stop Level)

167,000 (48.9 kW)

6.7%

30%

430,000 (126.0 kW)

17%

40%

770,000 (225.7 kW)

31%

50%

1,070,000 (313.6 kW)

43%

60%

1,440,000 (422.0 kW)

58%

70%

1,815,000 (531.9 kW)

73%

80%

2,030,000 (594.9 kW)

81%

90%

2,300,000 (674.1 kW)

92%

100%

2,500,000 (732.7 kW)

100%

TABLE 3-5b: BMK 2500 Air/Fuel Valve Position – PROPANE GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT

(% OF FULL CAPACITY)

18% (Stop Level)

155,000

6.2%

30%

400,000

16%

40%

808,000

32%

50%

1,055,000

42%

60%

1,330,000

53%

70%

1,671,000

67%

80%

1,998,000

80%

90%

2,280,000

91%

100%

2,500,000

100%

SECTION 3 - START SEQUENCE

3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 27 of 146

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 3-6a: BMK 3000 Air/Fuel Valve Position – NATURAL GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR.)

BOILER ENERGY INPUT (% OF FULL CAPACITY)

14% (Stop Level)

200,000 (58.6 kW)

6.7%

30%

520,000 (152 kW)

17%

40%

880,000 (258 kW)

29%

50%

1,270,000 (372 kW)

42%

60%

1,680,000 (492 kW)

56%

70%

2,100,000 (615 kW)

70%

80%

2,390,000 (700 kW)

80%

90%

2,650,000 (777 kW)

88%

100%

3,000,000 (879 kW)

100%

TABLE 3-6b: BMK 3000 Air/Fuel Valve Position – PROPANE GAS

AIR/FUEL VALVE POSITION

(% OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY INPUT

(% OF FULL CAPACITY)

18% (Stop Level)

200,000

6.7%

30%

520,000

17%

40%

920,000

31%

50%

1,270,000

42%

60%

1,570,000

52%

70%

1,960,000

65%

80%

2,330,000

78%

90%

2,700,000

90%

100%

3,000,000

100%

SECTION 3 - START SEQUENCE

3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 28 of 146

Benchmark Platinum-Edge: Operation-Service Manual

BMK 5000 Air/Fuel Valve Position and Energy Input

Air Fuel Valve

Boiler Energy Input

BTU/Hr

% of Full Capacity

10%

18% (Stop Level)

400,000 (117 kW)

30%

997,217 (292 kW)

20%

40%

1,667,848 (489 kW)

33%

50%

1,992,380 (584 kW)

40%

60%

2,486,881 (729 kW)

50%

70%

2,981,381 (874 kW)

60%

80%

3,780,230 (1108 kW)

76%

90%

4,375,500 (1282 kW)

88%

100%

5,000,000 (1465 kW)

100%

BMK 5000 Gas Pressure De-Rating Chart

Gas Pressure @ SSOV

in inches W.C. (kPa)

Inlet

Outlet

56” (13.9 kPa)

6.8” (1.70 kPa)

5,000,000 (1465 kW)

5.7

14” (3.49 kPa)

6.8” (1.70 kPa)

5,000,000 (1465 kW)

5.7

10” (3.23 kPa)

6.8” (1.70 kPa)

5,000,000 (1465 kW)

5.7

SECTION 3 - START SEQUENCE

3.4.6 Benchmark 5000 Air/Fuel Valve Position and Energy Input

Position

(% Full Open)

Energy Input in

BTU/hr

Oxygen

(%O

)

DeRating

(% Full Fire)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 29 of 146

Benchmark Platinum-Edge: Operation-Service Manual

BMK 6000 Air/Fuel Valve Position and Energy Input

Air Fuel Valve

Boiler Energy Input

BTU/Hr

% of Full Capacity

10%

18% (Stop Level)

385,000 (113 kW)

20%

400,000 (117 kW)

30%

540,000 (158 kW)

40%

770,000 (226 kW)

13%

50%

1,160,000 (340 kW)

19%

60%

1,650,000 (484 kW)

28%

70%

2,386,000 (699 kW)

40%

80%

3,515,000 (1030 kW)

59%

90%

4,650,000 (1362 kW)

78%

BMK 6000 Gas Pressure De-Rating Chart

in inches W.C. (kPa)

Inlet

Outlet

56” (13.9 kPa)

8” (1.99 kPa)

6,000,000 (1758 kW)

5.40

14” (3.49 kPa)

8” (1.99 kPa)

6,000,000 (1758 kW)

5.40

13” (3.23 kPa)

8” (1.99 kPa)

5,860,000 (1717 kW)

5.45

SECTION 3 - START SEQUENCE

3.4.7 Benchmark 6000 Air/Fuel Valve Position and Energy Input

Position

(% Full Open)

Gas Pressure @ SSOV

Energy Input in

BTU/hr

Oxygen

(%O

)

DeRating

(% Full Fire)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 30 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 4 – INITIAL START-UP

SECTION 4: INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

The following are the prerequisites for the initial start-up of the Benchmark boiler:

• Complete the installation per the Benchmark Platinum-Edge: INSTALLATION Manual

(GF-210), including gas supply piping, vent installation and condensate drain piping. Starting a unit without the proper piping, venting, or electrical systems can be dangerous and may void the product warranty.

• Set proper controls and limits (see Section 2: EZ Setup or Section 6: Advanced Setup in

the Edge Controller Manual).

Initial start-up consists of the following:

• Combustion calibration (Section 4.4: Combustion Calibration)

• Test safety devices (Section 5: Safety Device Testing)

Start-up must be successfully completed before putting the unit into service. The start-up instructions below should be followed precisely in order to operate the unit safely and at high thermal efficiency and low flue gas emissions.

Initial unit start-up must be performed by AERCO factory trained personnel, who are trained in the start-up and service of Benchmark boilers.

An AERCO Gas Fired Startup Sheet, included with each Benchmark unit, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO via e-mail at: STARTUP@AERCO.COM.

WARNING!

DO NOT ATTEMPT TO DRY FIRE THE UNIT. Starting the unit without a full water level can seriously damage the unit and may result in injury to personnel and/or property damage. This situation will void any warranty.

NOTE:

AERCO recommends that the Standby Blower Voltage parameter be kept at 2. 0 0 volts (the default set at the factory) to prevent flue gas recirculation.

To check, go to the Controller’s Main Menu  Advanced Setup  Performance  Fire Control  Operating Control and verify that the Standby Blower Voltage parameter is set to 2.00 V.

However, individually vented units in positive pressure boiler rooms may set Standby Blower Voltage between 2.00 and 0 volts to compensate.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 31 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Gas Supply Manometer Ins t alla t ion Instructions BMK 750 - 3000

Gas Supply Manometer Ins t alla t ion Instructions BMK 5000 - 6000

SECTION 4 – INITIAL START-UP

4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION

To properly perform combustion calibration, the proper instruments and tools must be used and correctly attached to the unit. The following sections outline the necessary tools and instrumentation as well as their installation.

4.2.1 Required Tools & Instrumentation

The following tools and instrumentation are necessary to perform combustion calibration:

• Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and

Nitrogen Oxide (NO x) resolution to 1 PPM

• 0 to 16 inch W.C. (0 to 4.0 kPa) manometer or equivalent gauge and plastic tubing

• 1/4 inch NPT-to-barbed fittings for use with gas supply manometer

• Small and large flat blade screwdrivers

• Tube of silicone adhesive

4.2.2 Installing Gas Supply Manometer

A 16” W.C. (4.0 kPa) gas supply manometer (or gauge) is used in the following ways:

• Mounted on the upstream side of the SSOV to verify that the gas supply pressure is within the required range of 4” W.C. and 14” W.C.

• Mounted on the downstream side of the SSOV to monitor the gas pressure during the Combustion Calibration procedure, described in Sections 4.4.1 (Natural Gas) and 4.4.2 (Propane).

Figures 4-1a through 4-1e s how where the gas supply manometer is installed on both the upstream and downstream locations.

1. Turn off the main gas supply upstream of the unit.

2. Remove the top panel and/or front panel from the boiler to access the gas train.

3. Remove the 1/4” NPT plug from the leak detection ball valve on the upstream or downstream side of the SSOV, as needed during testing, as shown in Figure 4-1a – 4-1d.

4. Install an NPT-to-barbed fitting into the tapped plug port.

5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16” W.C. (4.0 kPa) manometer.

1. Turn off the main gas supply upstream of the unit.

2. Remove the front panel from the boiler to access the gas train.

3. Connect the manometer directly to the Low and High Gas Pressure Switches, as shown in Figure 4-1e.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 32 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SSOV

1/4” NTP PLUG

calibration reading )

1/4” NTP PLUG

calibration reading )

SECTION 4 – INITIAL START-UP

TO AIR/FUEL VALVE

MANUAL SHUTOFF VALVE

(Install manometer here for

downstream combustion

(Install manometer here for upstream combustion

LEAK DETECTION BALL VALVE

NATURAL GAS INLET

Figure 4-1a: 1/4 Inch Gas Plug Location – BMK 750 & 1000 (P/N 22322 shown)

MANUAL

SHUT-OFF

VALVE

AIR/FUEL

VALVE

NATURAL GAS INLET

SSOV

HIGH GAS PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

(Install manometer here for

downstream combustion

calibration reading)

Figure 4-1b: 1/4 Inch Gas Plug Location – BMK 1500 & 2000 (P/N 22314 shown)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 33 of 146

1/4” NPT PLUG

LEAK DETECTION

BALL VALVES

1/4” NPT PLUG (Install manometer here for upstream combustion calibration reading)

Benchmark Platinum-Edge: Operation-Service Manual

VALVE

1/4” NPT PLUG

NATURAL GAS INLET

SECTION 4 – INITIAL START-UP

(Install manometer here

for downstream

combustion calibration

reading)

HIGH GAS PRESSURE SWITCH

NATURAL GAS INLET

SSOV

LEAK DETECTION

BALL VALVE

MANUAL SHUT-

OFF VALVE

TO AIR/FUEL

LOW GAS PRESSURE SWITCH

LEAK DETECTION BALL VALVE

1/4” NPT PLUG (Install manometer here for upstream combustion calibration reading)

Figure 4-1c: BMK 2500 1/4 Inch Gas Plug Location – BMK 2500 (P/N 22318 shown)

SSOV

AIR/FUEL

VALVE

MANUAL

SHUT-OFF VALVE

HIGH GAS

PRESSURE WITCH

LEAK DETECTION

BALL VALVE

(Install manometer here for downstream

combustion calibration reading)

1/4” NPT PLUG

1/4” NPT PLUG (Install manometer here for upstream combustion calibration reading)

LOW GAS PRESSURE SWITCH

LEAK DETECTION BALL VALVE

Figure 4-1d: 1/4 Inch Gas Plug Location – BMK 3000 (P/N 22310 shown)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 34 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Analyzer Probe Port Access Instructions

PRIMARY HOT

ANALYZER PROB E

CONDENSATE DRAIN

DRAIN VALVE

TO AIR/FUEL VALVE

HIGH GAS PRESSURE SWITCH

MANUAL

VALVE

UPSTREAM LEAK

GAS PORT

DOWNSTREAM

SSOV WITH POC

GAS PORT Alternative location for

LOW GAS

SECTION 4 – INITIAL START-UP

SHUT-OFF

manometer if hose

barb is preferred

(Install manometer here for

downstream combustion

calibration reading)

DETECTION BALL VALVE

(Install manometer here for upstream combustion calibration reading)

PRESSURE SWITCH

Figure 4-1e: Port Location for Combustion Calibration – BMK 5000-6000

4.2.3 Accessing the Analyzer Probe Port

Benchmark units contain a 1/4” NPT port on the side of the exhaust manifold, as shown in Figure 4-2. Prepare the port for the combustion analyzer probe as follows:

1. Refer to Figure 4-2 and remove the 1/4” NPT plug from the exhaust manifold.

2. If necessary, adjust the stop on the combustion analyzer probe so it will extend mid-way into the flue gas flow. DO NOT install the probe at this time.

PORT

Figure 4-2: Analyzer Probe Port Location (BMK 1500 shown)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 35 of 146

WATER INLET

Benchmark Platinum-Edge: Operation-Service Manual

BRASS HEX HEAD

SECTION 4 – INITIAL START-UP

4.3 FUEL TYPES and COMBUSTION CALIBRATION

All BMK Platinum models are preconfigured at the factory to use either natural gas or propane gas, and BMK models 1500 to 6000 are available in dual fuel versions (natural gas and propane).

Both fuel types require different combustion calibration values, and so care must be taken to ensure to follow the instructions for the fuel being used.

• Natural Gas combustion calibration: Section 4.4.1

• Propane combustion calibration: Section 4.4.2

Instructions for switching between fuel types in dual fuel models are presented in Section 4.6.

4.4 COMBUSTION CALIBRATION

The Benchmark boiler is combustion calibrated with either standard combustion (NOx emissions of <20 ppm) or Ultra-Low NOx (NOx <9 ppm) on the BMK 750 to 2000 only at the factory, whichever was ordered, prior to shipping. The g as pressure must be within the ranges shown in Table 4-2 for each model of boiler at full fire.

Recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU content, gas supply piping and supply regulators. Combustion Calibration Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.

IT IS IMPORT ANT TO PERFORM THE COMBUSTION CALIBRATION PROCEDURE BELOW TO PROVIDE OPTIMUM PERFORMANCE AND KEEP RE ADJUS TMENTS TO A MINIMUM.

(Remove to access Gas Pressure Adjustment Screw).

TAC SCREW

Figure 4-3: Gas Pressure Adjustment Screw and TAC Screw Location

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 36 of 146

Benchmark Platinum-Edge: Operation-Service Manual

NAT URAL G AS Manual Combust ion Calibration Instructi ons

SECTION 4 – INITIAL START-UP

4.4.1 NATURAL GAS Manual Combustion Calibration

These instructions apply only to units running NATURAL GAS .

1. Ensure the Edge Controller’s Enable/Disable switch is set to Disable.

2. Open the water supply and return valves to the unit and ensure that the system pumps are running.

3. Open the NATURAL GAS supply valve to the unit.

4. Turn external AC power to the unit ON.

5. On the Controller, go to: Main Menu  Calibration  Manual Combustion. If necessary, enter a technician level password.

6. The first Manual Combustion Calibration screen appears lists the three steps that must be completed before continuing.

Figure 4-4: First Manual Combustion Calibration Screen

7. Connect the gas pressure manometer to the upstream side of the gas train’s SSOV (see Section 4.2.2), and connect the Combustion Analyzer and Multimeter (per Section 4.2.3), and ensure that the heating loop is capable of dissipating sufficient heat at full fire.

8. Verify that the incoming (upstream) gas pressure to the unit is within the allowable range (see the Benchmark Pre-Installation Gas Supply Guide (TAG-0047, GF-2030)).

9. Once you have completed the previous step, move the manometer (or use a secondary one) to the the downstream side of the SSOV and press Next to continue.

10. Choose the NOx requirement for this installation: None, <= 20 PPM or <=9 PPM.

Figure 4-5: Choose NOx Requirement

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 37 of 146

Benchmark Platinum-Edge: Operation-Service Manual

NAT URAL G AS Manual Combust ion Calibration Instructi ons

TABLE 4-1: REFERENCE Gas Pressure Range @ 100% Fire Rate

Model

Single Fuel

Dual Fuel

BMK 750

2.0” ± 0.2” W.C. (0.50 ± 0.05 kPa)

BMK 1000

2.4” ± 0.4” W.C. (0.60 ± 0.10 kPa)

BMK 2000

3.4” ± 0.2” W.C. (0.85 ± 0.05 kPa)

6.3” ± 0.1” W.C. (1.57 ± 0.02 kPa)

BMK 2500

2.0” ± 0.1” W.C. (0.50 ± 0.02 kPa)

5.8” ± 0.1” W.C. (1.44 ± 0.02 kPa)

BMK 5000

6.3” ± 0.2” W.C. (1.56 ± 0.05 kPa)

BMK 6000

7.9” ± 0.2” W.C. (1.97 ± 0.05 kPa)

PRE-SET CALIBRATION CONTROLS

FINE VALVE POSITION CONTROLS

SECTION 4 – INITIAL START-UP

11. The main Manual Combustion Calibration screen appears. It provides two methods to ramp the unit’s valve position up or down:

• Method 1: Toggle through the pre-set calibration points till you reach the desired

valve position, then press Go to go to that point (left image below).

• Method 2: Enable Fine VP Step, then manually press the + or – buttons once per

1% to bring the unit to the desired valve position (right image below).

PRESET CALIBRATION POINTS METHOD FINE VP STEP METHOD

Figure 4-6: Manual Combustion Calibration Screens

12. Set the Controller’s Enable/Disable switch to Enable.

13. Change the valve position to 30%, press the Go button, then verify that the unit has ignited and is operating as expected.

14. Use the  (Right) arrow key to change the valve position to 100%, then press Go.

15. Verify that the gas pressure on the downstream side of the SSOV is within the required range shown in Table 4-1. If it isn’t, remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw (Figure 4-3). Make adjustments using a flat-tip screwdriver, slowly rotating the gas pressure adjustment (in 1/4-turn increments) clockwise to increase gas pressure or counterclockwise to reduce it. The resulting gas pressure reading on the downstream manometer should fall in the range listed below.

BMK 1500 3.6” ± 0.1” W.C. (0.90 ± 0.02 kPa) 3.6” ± 0.1” W.C. (0.90 ± 0.02 kPa)

BMK 3000 2.1” ± 0.2” W.C. (0.52 ± 0.05 kPa) 6.0” ± 0.2” W.C. (1.49 ± 0.05 kPa)

16. With the valve position still at 100%, insert the combustion analyzer probe into the exhaust manifold probe opening (see Figure 4-2a – 4-2c in Section 4.2.3) and allow enough time for the combustion analyzer reading to stabilize.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 38 of 146

Benchmark Platinum-Edge: Operation-Service Manual

NAT URAL G AS Manual Combust ion Calibration Instructi ons

17. Compare the combustion analyzer’s oxygen (O2) reading to the O2 value in the Reading

TABLE 4-2: NATURAL GAS Calibration Target Values @ 100% Valve Position

Standard NOx

Ultra-Low NOx

O2 %

NOx

O2 %

NOx

750

5.5% ± 0.2%

≤20 ppm

6.0% ± 1.0%

≤9 ppm

<100 ppm

1500

5.2% ± 0.2%

≤20 ppm

5.7% ± 1.0%

≤9 ppm

<100 ppm

2500

5.6% ± 0.2%

≤20 ppm

- - <100 ppm

3000

5.1% ± 0.2%

≤20 ppm

- - <100 ppm

5000/6000

5.5% ± 0.5%

≤20 ppm

6.0% ± 1.0%

≤9 ppm

<100 ppm

SECTION 4 – INITIAL START-UP

column (Figure 4-6). If they differ, go to the Main Menu  Calibration  Input/Output  Oxygen Sensor screen and adjust the O2 Offset parameter, up to ±3%, to make the on board O analyzer is correctly calibrated, and the on-board O analyzer, the sensor may be defective and need to be replaced.

18. Compare the O2 value in the Target and Reading columns. If they don’t match, adjust the Blower Voltage until the O or press on the field and type the value directly.

19. If adjusting the blower voltage is not sufficient to get the O2 Reading column to match the Target column, then repeat Step 15 to adjust the gas pressure up or down within the range shown in the table, then repeat Step 18. Continue repeating Steps 15 and 18 until the gas pressure is within the range in Table 4-1 and the O Target column.

20. Enter the downstream manometer’s gas pressure reading in the Downstream Gas Pressure field. Note, this field appears only when Valve Position % = 100%.

21. Compare the measured nitrogen oxide (NOx) and carbon monoxide (CO) readings to the Target values (shown in Table 4-2 as a reference only). If you chose the NOx <=9 ppm in step 9, use the values in the Ultra-Low NOx columns. If you are not in a “NOx-limited” area and/or do not have a NOx measurement in your analyzer, set the O the Standard NOx column in the table below.

sensor match the value from the combustion analyzer. If your combustion

sensor cannot be made to match the

value in both columns match; use either the + or – controls,

Reading column to matches the

to the value in

Model

1000 5.5% ± 0.2% ≤20 ppm

2000 6.0% ± 0.2% ≤20 ppm

3000 DF 5.3% ± 0.2% ≤20 ppm

6.0% ± 1.0% ≤9 ppm <100 ppm

- - < 100 ppm

NOTE: These instructions assume that the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C). If NOx readings exceed the target values in Table 4-1, above, or Table 4-

3, below, increase the O2 level up to 1% higher than the Target value. You must then record the increased O2 value on the Combustion Calibration sheet.

22. On Benchmark 3000 - 6000 units only, record th e manifold (downstream) gas pressure at 100%. This value will be used in Section 5.2.2: Low Pressure Gas Test, and Section 5.3.2: High Pressure Gas Test.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 39 of 146

Benchmark Platinum-Edge: Operation-Service Manual

NAT URAL G AS Manual Combust ion Calibration Instructi ons

23. Once the O2 level is within the specified range at 100%:

TABLE 4-3a: NATURAL GAS BMK Final Valve Positions: BMK 750-1000

750 & 1000

TABLE 4-3b: NATURAL GAS Final Valve Positions: BMK 1500-2000

1500 & 2000 – Single Fuel Units

Valve Position

1500

2000

50%

6.3% ± 0.2%

<100 ppm

40%

7.0% ± 0.2%

<50 ppm

30%

7.0% ± 0.2%

<50 ppm

16%

18%

7.0% ± 0.2%

<50 ppm

TABLE 4-3c: NATURAL GAS Final Valve Positions: BMK 1500DF-2000DF

70%

6.0% ± 0.2%

≤20 ppm

<100 ppm

50%

6.3% ± 0.2%

≤20 ppm

<100 ppm

40%

7.0% ± 0.2%

≤20 ppm

<50 ppm

30%

7.0% ± 0.2%

≤20 ppm

<50 ppm

16%

8.0% ± 0.2%

≤20 ppm

<50 ppm

SECTION 4 – INITIAL START-UP

• Enter the Flame Strength, NOx and CO readings from the Combustion Analyzer and

multi-meter in the Manual Combustion Calibration screen’s Reading column.

• Enter the same values, plus the O

value, on the Combustion Calibration Data Sheet

provided with the unit.

24. Lower the Valve Position to the next calibration point using the  (Left) arrow key (if using Method 1 in step 11) or the Fine Valve Position – (Minus) key (if using Method 2).

• BMK 750 & 1000: 80%

• BMK 1500 – 6000: 70%

25. Repeat step 17, 18 and 21 at that valve position and the rest of the valve positions in Table 4-3a through 4-3d, depending on model. The O ranges shown in these tables.

Valve Position

Standard NOx Ultra-Low NOx

O2 % NOx O2 % NOx

80% 5.5% ± 0.2% ≤20 ppm 6.0% ± 1.0% ≤9 ppm <100 ppm 60% 5.5% ± 0.2% ≤20 ppm 6.0% ± 1.0% ≤9 ppm <100 ppm 45% 5.5% ± 0.2% ≤20 ppm 6.0% ± 1.0% ≤9 ppm <50 ppm 30% 5.5% ± 0.2% ≤20 ppm 6.0% ± 1.0% ≤9 ppm <50 ppm 18% 5.5% ± 0.2% ≤20 ppm 6.0% ± 1.0% ≤9 ppm <50 ppm

, NOx and CO should stay within the

Standard NOx Ultra-Low NOx

O2 % NOx O2 % NOx

70% 6.0% ± 0.2%

≤20 ppm

5.5% ± 1.0% ≤9 ppm ≤20 ppm 5.8% ± 1.0% ≤9 ppm ≤20 ppm 6.0% ± 1.0% ≤9 ppm ≤20 ppm 6.0% ± 1.0% ≤9 ppm ≤20 ppm 8.0% ± 1. 0% ≤9 ppm

BMK 1500 Dual Fuel Units

Valve % O2 % NOx CO

<100 ppm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 40 of 146

Benchmark Platinum-Edge: Operation-Service Manual

NAT URAL G AS Manual Combust ion Calibration Instructi ons

70%

6.5% ± 0.2%

≤20 ppm

<100 ppm

50%

6.5% ± 0.2%

≤20 ppm

<100 ppm

40%

6.5% ± 0.2%

≤20 ppm

<50 ppm

30%

6.5% ± 0.2%

≤20 ppm

<50 ppm

16%

5.5% ± 0.2%

≤20 ppm

<50 ppm

TABLE 4-3d: NATURAL GAS Final Valve Positions: BMK 2500 & 3000

Valve %

O2 %

Valve %

O2 %

70%

5.9% ± 0.2%

70%

5.9% ± 0.2%

≤20 ppm

<100 ppm

50%

6.0% ± 0.2%

45%

6.2% ± 0.2%

≤20 ppm

<100 ppm

40%

6.3% ± 0.2%

30%

6.0% ± 0.2%

≤20 ppm

<50 ppm

30%

6.3% ± 0.2%

20%

5.8% ± 0.2%

≤20 ppm

<50 ppm

16%

6.0% ± 0.2%

16%

6.0% ± 0.2%

≤20 ppm

<50 ppm

BMK 3000

70%

5.1% ± 0.2%

85%

5.4% ± 0.2%

≤20 ppm

<100 ppm

50%

6.1% ± 0.2%

65%

5.5% ± 0.2%

≤20 ppm

<100 ppm

40%

5.0% ± 0.2%

45%

5.7% ± 0.2%

≤20 ppm

<50 ppm

30%

6.4% ± 0.2%

30%

5.6% ± 0.2%

≤20 ppm

<50 ppm

14%

6.4% ± 0.2%

14%

6.2% ± 0.2%

≤20 ppm

<50 ppm

TABLE 4-3e: NATURAL GAS Final Valve Positions: BMK 5000, Single & DF

Single

Fuel

Dual Fuel

70%

<20 ppm

<100 ppm

<20 ppm

<50 ppm

<20 ppm

<50 ppm

TABLE 4-3e: NATURAL GAS Final Valve Positions: BMK 6000, Single & DF

Single

Fuel

Dual Fuel

<20 ppm

<100 ppm

SECTION 4 – INITIAL START-UP

BMK 2000 Dual Fuel Units

BMK 2500

Single Fuel Dual Fuel

Valve Position

Standard NOx Ultra-Low NOx

O2 % NOx O2 % NOx

5.5% ± 0.5%

6.0% ± 1.0% ≤9 ppm

50%

5.5% ± 0.5% 40% 5.5% ± 0.5% 30% 5.5% ± 0.5% 18%

6.0% ± 1.0%

<20 ppm

6.0% ± 1.0% ≤9 ppm

6.5% ± 1.5% ≤9 ppm

Valve Position

70% 85% 50% 65%

40% 45%

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 41 of 146

Standard NOx Ultra-Low NOx

O2 % NOx O2 % NOx

5.5% ± 0.5%

<20 ppm

6.0% ± 1.0% ≤9 ppm

<100 ppm

<50 ppm

<100 ppm

<50 ppm

Benchmark Platinum-Edge: Operation-Service Manual

NAT URAL G AS Manual Combust ion Calibration Instructi ons

<20 ppm

<50 ppm

PROPANE Combustion Calibra ti on Instructions

SECTION 4 – INITIAL START-UP

30% 30% 18% 18%

26. If the oxygen level at the lowest valve position is too high, and the Blower voltage is at the minimum value, you can adjust the TAC screw, which is recessed in the top of the Air/Fuel Valve (see Figure 4-3). Rotate the screw 1/2 turn clockwise (CW) to a dd fuel and reduce

the O

down to the lowest valve position after making a change to the TAC screw.

This completes the NATURAL GAS combustion calibration procedure.

to the specified level. Recalibration MUST be performed again from 60% or 50%

5.5% ± 0.5%

6.0% ± 1.0%

<20 ppm

6.0% ± 1.0% ≤9 ppm

6.5% ± 1.5% ≤9 ppm

<50 ppm

4.4.2 PROPANE GAS COMBUSTION CALIBRATION

These instructions apply only to units running PROPANE gas.

1. Set the Edge Controller’s Enable/Disable switch to Disable.

2. Open the water supply and return valves to the unit and ensure that the system pumps are running.

3. Open the PROPANE supply valve to the unit.

4. Turn external AC power to the unit ON.

5. On the Controller, go to: Main Menu  Calibration  Manual Combustion. If necessary, enter a technician level password.

6. The first Manual Combustion Calibration screen appears lists three steps that must be completed before continuing:

Figure 4-7: First Manual Combustion Calibration Screen

7. Connect the gas pressure manometer to the upstream side of the gas train’s SSOV, as shown in Section 4.2.2 and connect the Combustion Analyzer and Multimeter, as shown in Section 4.2.3, and ensure that the heating loop is capable of dissipating sufficient heat at full fire.

8. Verify that the incoming gas pressure to the unit is within the allowable range (see the Benchmark Pre-Installation Gas Supply Guide (TAG-0047, GF-2030)).

9. Once you have completed the previous step, move the manometer (or use a secondary one) to the the downstream side of the SSOV and press Next to continue.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 42 of 146

Benchmark Platinum-Edge: Operation-Service Manual

PROPANE Combustion Calibra ti on Instructions

10. For the NOx requirement choose None.

PRE-SET CALIBRATION CONTROLS

VALVE POSITION CONTROLS

SECTION 4 – INITIAL START-UP

Figure 4-8: Choose NOx Requirement

11. The main Manual Combustion Calibration screen appears. It provides two methods to ramp the unit’s valve position up or down:

• Method 1: Toggle through the pre-set calibration points till you reach the desired

valve position, then press Go to go to that point (left image below).

• Method 2: Enable Fine VP Step, then manually press the + or – buttons once per

1% to bring the unit to the desired valve position (right image below).

PRESET CALIBRATION POINT S METHOD FINE VP STEP METHOD

Figure 4-9: Manual Combustion Calibration Screens

12. Set the Controller’s Enable/Disable switch to Enable.

13. Change the valve position to 30%, press the Go button, then verify that the unit has ignited successfully and is operating as expected.

14. Use the  (Right) arrow key to change the valve position to 100%, then press Go.

15. Verify that the gas pressure on the downstream side of the SSOV is within the required range shown in Table 4-4. If it isn’t, remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw (Figure 4-3). Make adjustments using a flat-tip screwdriver, slowly rotating the gas pressure adjus tment (i n 1/4-turn increments) clockwise to increase gas pressure or counterclockwise to reduce it. The resulting gas pressure reading on the downstream manometer should fall in the range listed below.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 43 of 146

Benchmark Platinum-Edge: Operation-Service Manual

PROPANE Combustion Calibra ti on Instructions

TABLE 4-4: PROPANE Gas Pressure Range @ 100% Fire Rate

BMK 750P

3.9” W.C. ± 0.2” W.C. (0.97 kPa ± 0.05 kPa)

BMK 1000P

7.6” W.C. ± 0.2” W.C. (1.89 kPa ± 0.05 kPa)

1500DF & 1500P

1.4” W.C. ± 0.1” W.C. (0.35 kPa ± 0.02 kPa)

2000DF & 2000P

2.5” W.C. ± 0.1” W.C. (0.62 kPa ± 0.02 kPa)

3000DF & 3000P

1.6” W.C. ± 0.1” W.C. (0.40 kPa ± 0.02 kPa)

5000DF & 5000P

2.0” ± 0.2” W.C. (0.50 to 0.05 kPa)

TABLE 4-5: PROPANE Calibration Readings at 100% Valve Position

Model

Oxygen (O2) %

Nitrogen Oxide (NOx)

Carbon Monoxide (CO)

750 & 1000

5.5% ± 0.2%

≤100 ppm

<150 ppm

≤100 ppm

2000

6.0% ± 0.2%

≤100 ppm

<150 ppm

2500

5.0% ± 0.2%

≤100 ppm

<150 ppm

3000

5.2% ± 0.2%

≤100 ppm

<150 ppm

5000

5.5% ± 0.5%

≤100 ppm

<100 ppm

6000

5.0% ± 0.5%

≤100 ppm

<100 ppm

SECTION 4 – INITIAL START-UP

Model Nominal Gas Pressure

2500DF & 2500P 2.0” W.C. ± 0.1” W.C. (0.50 kPa ± 0.02 kPa)

6000DF & 6000P 4.2” ± 0.2” W.C. (1.05 to 0.05 kPa)

17. Compare the combustion analyzer’s oxygen (O

) reading to the O2 value in the Reading

column (Figure 4-9). If they differ, go to the Main Menu  Calibration  Input/Output  Oxygen Sensor screen and adjust the O2 Offset parameter, up to ±3%, to make the on board O analyzer is correctly calibrated, and the on-board O

sensor match the value from the combustion analyzer. If your combustion

sensor cannot be made to match the

analyzer, the sensor may be defective and need to be replaced.

18. Compare the O Blower Voltage until the O

value in the Target and Reading columns. If they don’t match, adjust the

value in both columns match; use either the + or – controls,

or press on the field and type the value directly.

Reading column to matches the

Target column.

20. Enter the downstream manometer’s gas pressure reading in the Downstream Gas Pressure field. Note, this field appears only when Valve Position % = 100%.

21. Compare the measured nitrogen oxide (NOx) and carbon monoxide (CO) readings to the Target values (shown in the Table 4-5 as a reference only). If you are not in a “NOxlimited” area and/or do not have a NOx measurement in your analyzer, set the O value in the Oxygen (O

) % column in the table below.

to the

1500 5.2% ± 0.2%

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 44 of 146

<150 ppm

Benchmark Platinum-Edge: Operation-Service Manual

PROPANE Combustion Calibra ti on Instructions

TABLE 4-6a: PROPANE Final Valve Positions: BMK 750 – 3000

BMK 750/1000

80%

5.5% ± 0.2%

<100 ppm

<150 ppm

60%

5.5% ± 0.2%

<100 ppm

<150 ppm

45%

5.5% ± 0.2%

<100 ppm

<150 ppm

30%

6.3% ± 0.2%

<100 ppm

18%

5.5% ± 0.2%

<100 ppm

BMK 1500

70%

5.2% ± 0.2%

<100 ppm

<150 ppm

50%

5.3% ± 0.2%

<100 ppm

<150 ppm

40%

6.2% ± 0.2%

<100 ppm

<150 ppm

30%

7.0% ± 0.2%

<100 ppm

18%

8.5% ± 0.2%

<100 ppm

SECTION 4 – INITIAL START-UP

NOTE: These instructions assume that the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C). If NO x r eadings exceed the target values in Table 4-4, above, or Table 4-

6, below, increase the O2 level up to 1% higher than the Target value. You must then record the increased O2 value on the Combustion Calibration sheet.

23. Once the O2 level is within the specified range at 100%:

• Enter the Flame Strength, NOx and CO readings from the Combustion Analyzer

and multi-meter in the Manual Combustion Calibration screen’s Reading column.

• Enter the same values, plus the O

value, on the Combustion Calibration Data Sheet

provided with the unit.

24. Lower the Valve Position to the next calibration point using the  (Left) arrow key (if using Method 1 in step 11) or the Fine Valve Position – (Minus) key (if using Method 2).

• BMK 750P & 1000P: 80%

• BMK 1500/2000/2500 DF & P: 70%

• BMK 3000 DF & P: 85%

• BMK 5000P & 6000P: 70%

• BMK 5000DF & 6000DF: 85%

25. Repeat step 17, 18 and 21 at that valve position and the rest of the valve positions in Table Table 4-6a and 4-6b, depending on model. The O

, NOx and CO should stay within the

ranges shown in these tables.

Valve Position Oxygen (O2) % Nit r ogen oxide (NOx) Carbon Monoxide (CO)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 45 of 146

Benchmark Platinum-Edge: Operation-Service Manual

PROPANE Combustion Calibra ti on Instructions

BMK 2000

70%

6.5% ± 0.2%

<100 ppm

<150 ppm

50%

6.5% ± 0.2%

<100 ppm

<150 ppm

40%

6.5% ± 0.2%

<100 ppm

<150 ppm

30%

6.5% ± 0.2%

<100 ppm

18%

5.5% ± 0.2%

<100 ppm

BMK 2500

70%

5.4% ± 0.2%

<100 ppm

<150 ppm

45%

5.6% ± 0.2%

<100 ppm

<150 ppm

30%

6.0% ± 0.2%

<100 ppm

22%

5.8% ± 0.2%

<100 ppm

18%

6.0% ± 0.2%

<100 ppm

BMK 3000

85%

5.2% ± 0.2%

<100 ppm

<150 ppm

65%

5.4% ± 0.2%

<100 ppm

<150 ppm

45%

6.0% ± 0.2%

<100 ppm

<150 ppm

30%

6.4% ± 0.2%

<100 ppm

18%

6.4% ± 0.2%

<100 ppm

TABLE 4-6b: PROPANE Final Valve Positions: BMK 5000 & 6000

value on the Combustion Calibration sheet.

SECTION 4 – INITIAL START-UP

Valve Position Oxygen (O2) % Nit r ogen oxide (NOx) Carbon Monoxide (CO)

Valve Position

Single-Fuel Dual-Fuel

Oxygen (O

) %

Nitrogen Oxide

(NO

)

Carbon

Monoxide (CO)

BMK 5000

70% 70% 50% 50%

40% 40% 30% 30%

5.5% ± 0.5% <100 ppm <150 ppm

18% 18% 6.0% ± 1.0% <100 ppm <150 ppm

BMK 6000

70% 85% 50% 65%

40% 45% 30% 30%

5.5% ± 0.5% <100 ppm <150 ppm

18% 18% 6.0% ± 1.0% <100 ppm <150 ppm

NOTE: If NOx readings exceed the target values in Table 4-6a and 4-6b, increase the O2 level up to 1% higher than the listed calibration range shown in the table. Record the increased O2

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 46 of 146

Benchmark Platinum-Edge: Operation-Service Manual

PROPANE Combustion Calibra ti on Instructions

Reassembly Instructions

SECTION 4 – INITIAL START-UP

the O

down to the lowest valve position after making a change to the TAC screw.

This completes the PROPANE gas combustion calibration procedure.

to the specified level. Recalibration MUST be performed again from 60% or 50%

4.5 REASSEMBLY

Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation.

1. Set the Enable/Disable switch in the Disable position.

2. Disconnect AC power from the unit.

3. Shut off the gas supply to the unit.

4. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound.

5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold and then replace the 1/4” NPT plug in the vent hole.

6. Replace all previously removed sheet metal enclosures on the unit.

This concludes reassembly of the unit after combustion calibration.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 47 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Switchover from NATURAL GAS to PROPANE Instructions

Switchover from PROPANE to NATURAL GAS Instruc t ions

FUEL SELECTOR

SWITCH

I/O BOARD

and cover

SECTION 4 – INITIAL START-UP

4.6 DUAL FUEL SWITCHOVER

All Benchmark Dual Fuel models contain a fuel selector switch, located to the right of the I/O board, behind the front panel.

Figure 4-10: Dual Fuel Switch

1. Set the Edge Controller’s Enable/Disable switch to Disable.

2. Close the external Natural Gas supply valve.

3. Open the external Propane gas supply valve.

4. Locate the Fuel Selector Switch (see Figure 4-10), behind the front door.

5. Set the Fuel Selector Switch from NAT GAS to PROPANE.

6. Replace the front door panel previously removed from the boiler.

1. Set the Edge Controller’s Enable/Disable switch to Disable.

2. Close the external Propane Gas supply valve.

3. Open the external Natural Gas supply valve.

4. Locate the Fuel Selector Switch (see Figure 4-10), behind the front door.

5. Set the Fuel Selector Switch from PROPANE to NAT GAS.

6. Replace the front door panel previously removed from the boiler.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 48 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Temperature Adjustment Instructions

MANUAL RESET

AUTO-RESET

SECTION 4 – INITIAL START-UP

4.7 OVER-TEMPERATURE LIMIT SWITCHES

The unit contains two configurable over-temperature limit controls, positioned behind the unit’s front panel, under the Edge Controller:

• Automatic Reset: If the unit’s operating temperature exceeds the limit set on the switch,

the unit goes into an alarm mode and shuts the unit down. When the temperature falls 10 degrees below the limit, the unit automatically resumes operation without operator intervention. The limit range is manually adjustable from 32°F to 200°F (0°C to 93°C). The default value is 190°F (88°C).

• Manual Reset: If the unit’s operating temperature exceeds the limit set on the switch,

the switch goes into an alarm mode and shuts the unit down. The unit cannot be restarted until the switch is reset manually. The limit is preset to 210°F (98.9°C) and should not be changed.

Note the following points:

• Both switches display the temperature to which the switch is set (the temperature limit),

not the actual temperature it is reading.

• Both switches can display temperatures in Fahrenheit or Celsius.

• The Auto-Reset switch is preset to 190ºF (88°C), but can be adjusted as needed to

suite local conditions, as described below.

SWITCH

Figure 4-11: Over-Temperature Li mit Switches

4.7.1 Adjusting the Automatic Reset Limit Switch Temperature

Perform the following steps to adjust the Automatic Reset Limit Switch temperature setting.

1. Power the unit ON and remove the front panel to expose the Over-Temperature Limit switches.

2. Press the Automatic Reset L imit Switch’s SET button: SP appears in the display.

3. Press the SET button again. The current setting stored in memory is displayed.

4. Press the ▲ or ▼ arrow buttons to change the display to the desired temperature setting.

5. When the desired temperature is displayed, press the SET button

6. Press both the SET and ▼ arrow buttons together at the sam e time. T his step stores the setting in memory.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 49 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Temperature Adjustment Instructions

Resetting the Manual Res e t Li mi t Swit c h Ins tr uc t ions

Changing the Readout Betw e e n Fahr e nhe it and Celsius Instructions

Figure 4-14: Changing the Display to Celsius

INCREASE

DECREASE TEMPERATURE

RESET

INCREASE DECREASE

SECTION 4 – INITIAL START-UP

TEMPERATURE

Figure 4-12: Auto-Reset Over-Temperature Limit Switch

4.7.2 Resetting the Manual Reset Limit Switch

Perform the following steps to rest the Manual Reset Limit Switch after it has gone into Alarm mode, and after

1. Power the unit ON and remove the front panel to expose the Over-Temperature Limit switches.

the temperature has fallen at least 10 degrees below the limit.

2. Press the Manual Reset Limit Switch’s RST (Reset) button.

3. You can now restart the unit.

Figure 4-13: Manual Reset Over-Temperature Limit Switch

4.7.3 Changing the Readout Between Fahrenheit and Celsius

Perform the following steps to change the temperature reading between Fahrenheit or Celsius.

1. Press and hold both the Increase and Decrease arrows at the same time for about 4 seconds. The display show the temperature in Celsius and °F changes to °C.

2. To change the display back to Fahrenheit, repeat step 1.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 50 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 5 – SAFETY DEVICE TESTING

SECTION 5: SAFETY DEVICE TESTING

5.1 TESTING OF SAFETY DEVICES

Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustionrelated safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed.

Operating controls and safety devices should be tested on a regular basis or following service or replacement. All testing must conform to local codes such as ASME CSD-1.

NOTES:

• Manual and Auto modes of operation are required to perform the following tests. For a full explanation, see Section 4.1: Manual Run in the Edge Controller Manual (GF-213).

• It is necessary to remove the front door and side panels from the unit to perform t he tests described below.

WARNING!

Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK 2500/3000) or 208, 460 or 575 VAC (BMK 5000 & 6000) and 24 volts AC may be used in

this equipment. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 51 of 146

Benchmark Platinum-Edge: Operation-Service Manual

LOW Gas Pressure Test Instructions: BMK 750 – 2500

TABLE 5-1: LOW Gas Pressure, ± 0.2” W.C. (± 50 Pa)

Benchmark Model

Natural Gas

Propane

BMK 750/1000 FM & DBB Single-Fuel

2.6” W.C. (648 Pa)

7.5” W.C. (1,868 Pa)

SECTION 5 – SAFETY DEVICE TESTING

5.2 LOW GAS PRESSURE TEST

Complete the instructions in Section 5.2.1 for BMK 750 – 2500 units, or in Section 5.2.2 for BMK 3000 – 6000 units, which have different Low and High Gas Pressure switches.

5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500

To simulate a low gas pressure fault, refer to Figure 5-1a to 5-1c and perform the following steps:

1. Remove the front panel from the boiler to access the gas train components.

2. Close the leak detection ball valve located at the Low Gas Pressure switch.

3. Remove the 1/4" NPT plug from the ball valve at the Low Gas Pressure switch.

4. Install a 0 - 16” W.C. (0 – 4.0 kPa) manometer or gauge where the 1/4" plug was removed.

5. Slowly open the 1/4" ball valve near the Low Gas Pressure switch.

6. On the Controller, go to Main Menu  Diagnostics  Manual Run.

7. Enable the Manual Mode parameter. The Comm LED will go of f and the MANUAL LED will light.

8. Adjust the Air/Fuel Valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

9. While the unit is firing, slowly close the external manual gas shut-off valve upstream of the unit (not shown).

10. The unit should shut down and display a Fault Lockout - Gas Pressure Fault message at approximately the pressure shown in Table 5-1 (the pressure setting of the Low Gas Pressure switch):

BMK 1500/2000 FM & DBB Single-Fuel 3.6” W.C. (897 Pa) – BMK 1500/2000 Dual-Fuel 4.4” W.C. (1,096 Pa) 2.6” W.C. (648 Pa) BMK 1500/2000 DBB Dual-Fuel 2.6” W.C. (648 Pa) 2.6” W.C. (648 Pa)

BMK 2500 FM & DBB Single-Fuel 3.6” W.C. (897 Pa) – BMK 2500 Dual-Fuel 7.5” W.C. (1,868 Pa) 3.6” W.C. (897 Pa) BMK 2500 DBB Dual-Fuel 7.5” W.C. (1,868 Pa) 3.6” W.C. (897 Pa)

11. Close the ball valve near the Low Gas Pressure switch (opened in Step 5).

12. Fully open the external manual gas shut-off valve (not shown) and press the Controller’s CLEAR button.

13. The fault message should clear, the FAULT indicator should go off, and the unit should restart.

14. Upon test completion, close the ball valve, remove the manometer and replace the 1/4" NPT plug removed in step 3.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 52 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SSOV

GAS INLET

TO AIR/FUEL

VALVE

LOW GAS PRESSURE SWITCH

NATURAL GAS INLET

1/4” NPT PLUG

LOW GAS BALL VALVE

(P/N 22314 shown)

SECTION 5 – SAFETY DEVICE TESTING

MANUAL SHUT-OFF

HIGH GAS PRESSURE

SWITCH

1/4” NPT PLUG Install manometer here for LOW gas pressure fault test.

Figure 5-1a: BMK 750/10 00 LOW Gas Pressure Test Components

VALVE

(P/N 22322 shown)

LOW GAS PRESSURE LEAK DETECTION BALL VALVE (shown closed)

MANUAL SHUT-OFF VALVE

Install manometer here for LOW gas pressure fault test.

Figure 5-1b: BMK 1500/2000 LOW Gas Pressure Test Components

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 53 of 146

AIR/FUEL

VALVE

HIGH GAS

PRESSURE

SWITCH

SSOV

LOW GAS PRESSURE SWITCH

Benchmark Platinum-Edge: Operation-Service Manual

LOW Gas Pressure Test Instructions: BMK 3000 – 6000 Only

Propane Gas pressure ____ x 0.5 + 0.6 = ______ min gas pressure

LOW GAS BALL VALVE

NATURAL GAS INLET

(P/N 22190 shown)

SECTION 5 – SAFETY DEVICE TESTING

HIGH GAS PRESSURE SWITCH

SSOV

TO AIR/FUEL

VALVE MANUAL SHUT-OFF VALVE

LOW GAS PRESSURE SWITCH

1/4” NPT PLUG Install manometer here for LOW gas pressure fault test.

Figure 5-1c: BMK 2500 LOW Gas Pressure Test Components

5.2.2 LOW GAS PRESSURE TEST: BMK 3000 – 6000 Only

To simulate a low gas pressure fault on BMK 3000 – 6000 units, refer to Figure 5-2a and 5-2b, below, and perform the following steps:

1. Close the external gas supply ball valve upstream of the unit (not shown).

2. Remove the front panel from the boiler to access the gas train components.

3. Locate the port on the top of the Low Gas Pressure switch and loosen the screw inside a few turns to open it. Do not remove this screw completely. Alternatively, you can remove the 1/4 inch plug shown in Figure 5-2a and 5-2b and install a hose barb fitting in that location.

4. Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 – 16” W.C. ( 0 – 4.0 kPa) manometer.

5. Apply the reading of the manifold pressure taken in Step 21 of Section 4.4.1 (Natural Gas units) or Step 21 of Section 4.4.2 (Propane units) and plug it into the following formula, which calculates the minimum allowable gas pressure:

FM Natural Gas pressure ____ x 0.5 + 0.7 = ______ min gas pressure

BMK 3000

BMK 5000 & 6000

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 54 of 146

DBB Natural Gas pressure ____ x 0.5 + 1.6 = ______ m in gas pressure

FM Natural Gas pressure ____ x 0.5 + 6.0 = ______ min gas pressure Propane Gas pressure ____ x 0.5 + 3.7 = ______ min gas pressure

Benchmark Platinum-Edge: Operation-Service Manual

LOW Gas Pressure Test Instructions: BMK 3000 – 6000 Only

MANUAL SHUT-

OFF VALVE

SSOV

LOW Gas

Alternative

Pressure Port

NATURAL GAS INLET

(P/N 22310 shown)

SECTION 5 – SAFETY DEVICE TESTING

6. Remove the cover from the Low Gas Pressure switch and set the dial indicator to 2 (the minimum).

7. Open the external gas supply ball valve upstream of the unit.

8. On the Controller, go to: Main Menu  Diagnostics  Manual Run and then enable t he Manual Mode control.

9. Adjust the Air/Fuel Valve position to 100% using the + (Plus) and – (Minus) controls.

10. While the unit is firing, read the CO value on the combustion analyzer and slowly decrease the incoming gas supply pressure until the CO reading is approximately 300 ppm.

11. Take a reading of the inlet gas pressure. If the inlet pressure is below the minimum calculated in step 5, above, then increase the pressure to match the calculated minimum.

12. Slowly turn the indicator dial on the Lo w Gas Pressure switch until the unit shuts down due to a gas pressure fault.

13. Readjust the inlet gas pressure to what it was prior to the test.

14. Press the Edge Controller’s CLEAR button to clear the fault.

15. The fault message should clear, the red FAULT LED go off, and the unit should restart.

16. For Dual Fuel units, repeat the previous procedure on the Propane gas train, starting with the Propane Low Gas Pressure Switch.

AIR/FUEL

VALVE

Pressure Port

Install manometer here for

Low Gas Pressure test

HIGH GAS

PRESSURE

SWITCH

LOW Gas

Figure 5-2a: LOW and HIGH Gas Pressure Test Components – BMK 3000

LOW GAS PRESSURE SWITCH

LOW GAS BALL VALVE

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 55 of 146

Benchmark Platinum-Edge: Operation-Service Manual

LOW Gas Pressure Test Instructions: BMK 3000 – 6000 Only

MANUAL

NATURAL GAS Low Gas

Install manometer here

Alternative

PROPANE Low Gas

Dual Fuel gas train showing both Natural Gas and

Propane gas trains

SECTION 5 – SAFETY DEVICE TESTING

SHUT-OFF

VALVE

AIR/FUEL

VALVE

location

Pressure Test Port

Install manometer here

Figure 5-2b: Low Gas Pressure Switch Locations & Test Ports – BMK 6000

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 56 of 146

Benchmark Platinum-Edge: Operation-Service Manual

HIGH Gas Pressure Test Instructions: BMK 750 – 2500

TABLE 5-2: HIGH Gas Pressure, ± 0.2” W.C. (± 50 Pa)

Benchmark Model

Natural Gas

Propane

BMK 750/1000 FM & DBB Single-Fuel

4.7” W.C. (1.17 KPa)

BMK 1500/2000 Single-Fuel

4.7” W.C. (1.17 KPa)

–

BMK 1500/2000 DBB Single-Fuel

4.7” W.C. (1.17 KPa)

–

BMK 1500/2000 Dual-Fuel

4.7” W.C. (1.17 KPa)

BMK 1500/2000 DBB Dual-Fuel

3.5” W.C. (0.87 kPa)

BMK 2500 FM & DBB Single-Fuel

3.0” W.C. (0.75 kPa)

–

BMK 2500 Dual-Fuel

7.0” W.C. (1,74 kPa)

2.6” W.C. (0.65 kPa)

SECTION 5 – SAFETY DEVICE TESTING

5.3 HIGH GAS PRESSURE TEST

Complete the instructions in Section 5.3.1 for BMK 750 – 2500 units, or in Section 5.3.2 for BMK 3000 – 6000 units, which have different High Gas Pressure switches.

5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500

To simulate a high gas pressure fault, refer to Figure 5-3a through Figure 5-3c and perform the following steps:

1. Close the leak detection ball valve located at the High Gas Pressure switch.

2. Remove the 1/4" NPT plug from the High Gas pressure leak detection ball valve shown in Figures 5-3a through 5-3c.

3. Install a 0 - 16” W.C. (0 – 4.0 kPa) manometer or gauge where the 1/4" plug was removed.

4. Slowly open the leak detection ball valve.

5. On the Controller, go to: Main Menu  Diagnostics  Manual Run.

6. Enable the Manual Mode control.

7. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

8. With the unit running, monitor the gas pressure on the manometer installed in step 2 and record the gas pressure reading.

9. Slowly increase the gas pressure using the adjustment screw on the SSOV while counting the number of turns you make.

10. The FAULT indicator should start flashing and the unit should shut down and display a Fault Lockout - Gas Pressure Fault messag e at appro ximately the value shown in Table 5-2 (the pressure setting of the High Gas Pressure switch). If the unit does not trip off within 0.2” W.C. of the pressure shown, the switch needs to be replaced.

BMK 2500 DBB Dual-Fuel 7.0” W.C. (1,74 kPa) 2.6” W.C. (0.65 kPa)

11. Reduce the gas pressure by returning the SSOV adjustment screw back to its original position before starting step 9 (the value recorded in step 8). This pressure should be within the range used during combustion calibration, shown in Table 4-1 (Natural Gas) and Table 4-4 (Propane gas).

12. Press the CLEAR button on the Edge Controller to clear the fault.

13. The fault message should clear, the FAULT indicator should go off and the unit should restart (if in Manual mode).

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 57 of 146

Benchmark Platinum-Edge: Operation-Service Manual

HIGH Gas Pressure Test Instructions: BMK 750 – 2500

SSOV

GAS INLET

HIGH GAS PRESSURE

BALL VALVE

1/4” NTP PLUG

Test)

HIGH GAS BALL VALVE

1/4" NPT PLUG

NATURAL GAS INLET

VALVE

(P/N 22322 shown)

(P/N 22314 shown)

SECTION 5 – SAFETY DEVICE TESTING

14. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4" NPT plug removed in step 2.

MANUAL SHUT-OFF

VALVE

TO AIR/FUEL

VALVE

HIGH GAS PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

(Install manometer here for High Gas Pressure

Figure 5-3a: BMK 750/1000 HIGH Gas Pressure Test Components

HIGH GAS

AIR/FUEL

MANUAL

SHUT-OFF

VALVE

SSOV

PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

(Install manometer here for HIGH gas pressure fault test)

Figure 5-3b: BMK 1500/2000: HIGH Gas Pressure Fault Test

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 58 of 146

Benchmark Platinum-Edge: Operation-Service Manual

HIGH Gas Pressure Test Instructions: BMK 750 – 2500

HIGH Gas Pressure Test Instructions: BMK 3000 – 6000 ONLY

NATURAL GAS INLET

SWITCH

(P/N 22190 shown)

SECTION 5 – SAFETY DEVICE TESTING

1/4” NPT

PLUG

(install

manometer

here for HIGH

GAS

PRESSURE

FAUL T T EST)

HIGH GAS PRESSURE

SSOV

HIGH GAS

BALL VALVE

MANUAL

SHUT-OFF

VALVE

TO AIR/FUEL VALVE

LOW GAS PRESSURE SWITCH

Figure 5-3c: BMK 2500: HIGH Gas Pressure Fault Test

5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 – 6000 Only

To simulate a high gas pressure fault, refer to Figure 5-4a and 5-4b and perform the following steps:

1. Shut off the external gas supply by closing the external gas supply ball valve.

2. Locate the port on the side of the High Gas Pressure switch and loosen the screw in the port a few turns to open it. Do not completely remove the screw. Alternatively, you can remove the 1/4 inch plug shown in Figure 5-4a and 5-4b and install a hose barb fitting in that location.

3. Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 – 16” W.C. ( 0 – 4.0 kPa) manometer.

4. Apply the reading of the manifold pressure taken in Step 21 of Section 4.4.1 (natural gas units) or Step 21 of Section 4.4.2 (propane units) and plug it into the following formula, which calculates the maximum allowable gas pressure:

BMK 3000 BMK 5000

& 6000

Natural Gas Pressure  ______ x 1.5 = ______ max gas pressure Natural Gas Pressure  ______ x 1.5 = ______ max gas pressure

Propane Gas Pressure  ______ x 1.5 = ______ max gas pressure

5. Remove the cover from the High Gas Pressure switch and set the dial indicator to 20 (the maximum).

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 59 of 146

Benchmark Platinum-Edge: Operation-Service Manual

HIGH Gas Pressure Test Instructions: BMK 3000 – 6000 ONLY

6. Open the external gas supply ball valve upstream of the unit.

Figure 5-4a: HIGH Gas Pressure Test Components – BMK 3000

MANUAL SHUT-

OFF VALVE

HIGH Gas

Pressure test

HIGH GAS

SWITCH

Alternative

SSOV

NATURAL GAS INLET

(P/N 22310 shown)

SECTION 5 – SAFETY DEVICE TESTING

7. On the Controller, go to: Main Menu  Diagnostics  Manual Run and then enable the Manual Mode control.

8. Use the + (Plus) and – (Minus) controls to bring the unit up to 100%.

9. Slowly increase the manifold gas supply pressure by turning the Gas Pressure Adjustment Screw in the Downstream SSOV (Figure 5-2) while reading the CO level on the combustion analyzer. Adjust the manifold pressure until the CO reading is approximately 300 ppm. Note the number of turns you make, as you will turn it back to its original position in step 13, below.

10. Take a reading of the manifold gas pressure. If the manifold pressure is greater than the maximum calculated in step 3, then use the Gas Pressure Adjustment Screw to decrease the manifold pressure until it is at the maximum allowed.

11. Slowly turn the indicator dial on the High Gas Pressure switch until the unit shuts down due to a gas pressure fault. This is the setpoint.

12. Press the RESET button on the High Gas Pressure switch (see Figure 5-4, below).

13. Readjust the manifold gas supply pressure to what it was before it was increased in step 9.

14. Press the CLEAR button on the Edge Controller to clear the fault.

15. Fire the unit back up to insure gas pressure out of the SSOV is set as it was originally.

16. Upon test completion, close the ball valve and remove the manometer fitting from the port, and then turn the port screw clockwise till the port is closed.

17. For Dual Fuel gas trains, repeat this procedure on the Propane gas train, starting with opening the port on the Propane High Gas Pressure Switch, as shown in Figure 5-4b.

AIR/FUEL

Pressure Port

Install manometer

here for High Gas

VALVE

HIGH GAS

BALL VALVE

HIGH Gas

Pressure Port

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 60 of 146

PRESSURE

LOW GAS PRESSURE SWITCH

Benchmark Platinum-Edge: Operation-Service Manual

HIGH Gas Pressure Test Instructions: BMK 3000 – 6000 ONLY

DOWNSTREAM

NATURAL GAS HIGH Gas

PROPANE Gas Pressure Port

Install manometer here for High Gas Pressure test

Alternative location for manometer if hose barb is preferred

PROPANE HIGH GAS

NATURAL GAS HIGH GAS

- BMK 5000 – 11.0” W.C., 2.7 kPa

Alternative location barb is preferred

SECTION 5 – SAFETY DEVICE TESTING

for manometer if hose

Pressure Port

Install manometer here for High

Gas Pressure test

PRESSURE SWITCH

- BMK 6000 – 10.5” W.C., 2.6 kPa

SSOV WITH POC SWITCH

PRESSURE SWITCH

- BMK 6000 – 10.5” W.C., 2.6 kPa

- BMK 5000 – 4.5” W.C., 1.1 kPa

Figure 5-4b: High Gas Pressure Switch Locations & Test Ports – BMK 6000

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 61 of 146

Benchmark Platinum-Edge: Operation-Service Manual

LOW Water Fault Test Instructions

SECTION 5 – SAFETY DEVICE TESTING

5.4 LOW WATER LEVEL FAULT TEST

To simulate a low water level fault, proceed as follows:

1. Set the Controller’s Enable/Disable switch to Disable.

2. Close the water shut-off valves in the supply and return piping to the unit.

3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may be opened to aid in draining.

4. Continue draining the unit until a Low Water Level fault message is displayed and the FAULT indicator flashes.

5. On the Controller, go to: Main Menu  Diagnostics  Manual Run.

6. Enable the Manual Mode control.

7. Raise the valve position above 30% using the + (Plus) and – (Minus) controls.

8. Set the Controller’s Enable/Disable switch to Enable. The READY light should remain off and the unit should not start. If the unit does start, shut the unit off immediately and refer fault to qualified service personnel.

9. Close the drain and pressure relief valve used in draining the unit.

10. Open the water shut-off v a lve in the return piping to the unit.

11. Open the water supply shut-off valve to the unit to refill.

12. After the shell is full, press the LOW WATER LEVEL – RESET button to reset the low water cutoff.

13. Press the CLEAR button to reset the FAULT LED and clear the displ ay ed error message.

14. Set the Enable/Disable switch to Enable. The unit is now ready for operation.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 62 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Water Temperature Fault Test Instructions

OUTLET INDICATOR

OUTLET TEMPERATURE

AUTOMATIC

TEMPERATURE ADJUSTMENT CONTROLS

SECTION 5 – SAFETY DEVICE TESTING

5.5 WATER TEMPERATURE FAULT TEST

A high water temperature fault is simulated by adjusting the Automatic Reset OverTemperature switch.

1. Start the unit in the normal operating mode and allow the unit to stabilize at its setpoint.

2. On the Automatic Reset Over-Temperature switch, note the current setting, then: a. Press the Set button two times, to activate a setting change. b. Use the Down arrow to lower the setting to a temperature below the Outlet

temperature displayed on the Controller’s front face (see Figure 5-5b).

c. Press the Set and Down arrow at the same time to save that temperature setting.

MANUAL

RESET

SWITCH

RESET SWITCH

Figure 5-5a: Over Temperature Limit Switches

NOTE:

If the Controller’s is not configured to display outlet temperature, go to the Main Menu  Advanced Setup  Unit  Front Panel Configuration screen and set t he Upper-Right Display parameter to Water Outlet.

TEMPERATURE

Figure 5-5b: Edge Controller Front Face

3. Once the Automatic Reset Over-Temperature switch setting is approximately just below the actual outlet water temperature, the unit should shut down, the FAULT indicator should start flashing, and a High Water Temp Switch Open fault message should be displayed. It should not be possible to restart the unit.

4. Repeat Step 2 to return the Automatic Reset switch, but press the Up arrow to it to its original setting.

5. The unit should start once the setting is above the actual outlet water temperature.

6. Repeat steps 1 – 4 on the Manual Reset switch. However, unlike the Automatic Reset switch, the unit will not restart automatically when the original temperature is restored. You must press the RST (Reset) button to restart the unit.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 63 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Remote Interlock Test I ns tr uc t ions

terminals, remove one side of the jumper.

Delayed Interlock 1 and 2 Test Instructions

SECTION 5 – SAFETY DEVICE TESTING

5.6 INTERLOCK TESTS

The unit is equipped with three interlock circuits, called the Remote Interlock, and Delayed Interlock. These circuits are connected to the I/O board’s connector strip J6, labeled Remote Interlock, Delayed Interlock 1 and Delayed Interlock 2 (see Section 2.11.1: I/O Board

Connections in the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210). These circuits can shut down the unit in the event an interlock is opened. These interlocks are shipped from the factory jumpered (closed). However, they may be utilized in the field as a remote stop and start, an emergency cut-off, or to prove that a device such as a pump, gas booster, or louver is operational.

5.6.1 Remote Interlock Test

1. Remove the cover from the I/O Box and locate the Remote Interlock terminals on connector strip J6.

2. On the Controller, go to: Main Menu  Diagnostics  Manual Run.

3. Enable the Manual Mode control.

4. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

5. If there is a jumper across the Remote Interlock If the interlock is being controlled by an external device, either open the interlock via the external device or disconnect one of the wires leading to the external device.

6. The unit should shut down and the Controller should display Interlock Open.

7. Once the interlock connection is reconnected, the Interlock Open message should automatically clear and the unit should restart.

5.6.2 Delayed Interlock Test

1. Remove the cover from the I/O Box and locate the Delayed Interlock 1 terminals on connector strip J6.

2. On the Controller, go to: Main Menu  Diagnostics  Manual Run.

3. Enable the Manual Mode control.

4. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

5. If there is a jumper across the Delayed Interlock 1 terminals, remove one side of the jumper. If the interlock is connected to a proving switch of an external device, disconnect one of the wires leading to the proving switch.

6. The unit should shut down and display a Delayed Interlock Open fault message. The FAULT LED should be flashing.

7. Reconnect the wire or jumper removed in step 5 to restore the interlock.

8. Press the CLEAR button to reset the fault

9. The unit should start.

10. Repeat the above for the Delayed Interlock 2 terminals.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 64 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Flame Fault Test Instructions

SECTION 5 – SAFETY DEVICE TESTING

5.7 FLAME FAULT TEST

Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows:

1. Set the Controller’s Enable/Disable switch to Disable.

2. On the Controller, go to: Main Menu  Diagnostics  Manual Run.

3. Enable the Manual Mode control.

4. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

5. Close the gas train’s Manual Shutoff valve located between the Safety Shut-Off Valve (SSOV) and the Air/Fuel Valve, as shown on Figure 5-3a to 5-3c, above.

6. It may be necessary to jump out the High Gas Pressure switch.

7. Set the Controller’s Enable/Disable switch to Enable to start the unit.

8. The unit should purge and light the Pilot flame and then shut down after reaching the main Burner Ignition cycle and display Flame Loss During Ign.

9. Open the Manual Shutoff valve closed in step 5 and press the CLEAR soft key.

10. Restart the unit and allow it to prove flame.

11. Once flame is proven, close the Manual Shutoff valve located between the SSOV and the Air/Fuel Valve (see Figure 5-3a to 5-3c, above).

12. The unit should shut down and do one of the following: a. BMK 750 – 2000 units: the unit will execute an IGNITION RETRY cycle by performing

the following steps:

• The unit will execute a shutdown purge cycle for a period of 15 seconds and

display Wait Fault Purge.

• The unit will execute a 30 second re-ignition delay and display Wait Retry Pause.

• The unit will then execute a standard ignition sequence and display Wait Ignition

Retry.

• Since the Manual Shutoff valve is still closed, the unit will fail the ignition retry

sequence. Therefore it will shut down and display Flame Loss During Ign following the IGNITION RET RY c ycle.

b. BMK 2500 – 3000 units: the unit will Lockout and Flame Loss During Run will flash in

the display.

13. Open the manual gas valve closed in step 11.

14. Press the CLEAR button. The unit should restart and fire.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 65 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 5 – SAFETY DEVICE TESTING

5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES

These tests check the operation of the Blower Pro of switch and Blocked Inlet switch shown in Figure 5-6a, 5-6b and 5-6c.

5.8.1 Blower Proof Switch Test

BLOWER

PROOF

SWITCH

MANUAL SHUT-OFF VALVE

BLOCKED

INLET

SWITCH

SSOV

Figure 5-6a: Blower Proof & Blocked Inlet Switch Locations – BMK 1500 – 3000

BLOCKED INLET SWITCH

BLOWER PROOF

SWITCH

MANUAL SHUT-OFF VALVE

Figure 5-6b: Blower Proof & Blocked Inlet Switch Locations – BMK 750 &1000

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 66 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Blower Proof Switch Test Instructions

BLOCKED INLET SWITCH

BLOWER PROOF SWITCH

HEX SCREWS HOLDING

SECTION 5 – SAFETY DEVICE TESTING

MANUAL SHUT-

OFF VALVE

WYE DUCT TO A/F VALVE (1 OF 3)

Figure 5-6c: Blower Proof & Blocked Inlet Switch Locations – BMK 5000 & 6000

1. Set the Controller’s Enable/Disable switch to Disable.

2. Depending on the model, remove the side and/or front panels to gain access to the Blower Proof Switch (see Figures above for location).

3. Use a Phillips head screw drive to remove the front cover from the switch to reveal the switch setting indicator dial (0.3 in the Figure below).

SETTING

INDICATOR

COVER WITH LABEL COVER REMOVED

Figure 5-7: Blower Proof Switch

4. Set the Controller’s Enable/Disable switch to Enable and wait for the boiler to go into the Purge sequence.

5. After about 5 seconds, with air flowing into the combustion chamber, slowly turn the dial clock-wise (to higher value) until the unit trips off with an Air Flow Fault During Purge message. Optionally, you could attach a manometer and measure the setting at the trip point.

6. After the boiler shuts down, reset the dial indicator to its original position, shown on the switch cover label, then replace the switch cover.

7. Reset the boiler.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 67 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Blocked Inlet Switch Test Instructions

Blower Proof

the Flame

TO WIRE HARNESS

FLAME DETECTOR CONNECTOR

SECTION 5 – SAFETY DEVICE TESTING

5.8.2 Blocked Inlet Switch Test

This test will be run in simulated fire mode, with the Blocked Inlet switch isolated from the rest of the control circuitry.

1. Set the Controller’s Enable/Disable switch to Disable.

2. Remove the air filter(s) (see Figure 5-6a, 5-6b or 5-6c, above).

WARNING!

The blower suction is very strong and can pull nearby objects into the blower’s fan blades. Do NOT allow anything to be pulled into the blower! Do not wear anything that could get caught and pull you into the blower.

3. Turn off the gas supply ball valve to the boiler and then complete the following steps:

a) Use jumper wires to jump out the Low Gas Pressure switch and the

switch. b) Remove the black connector boot from the Flame Detector. c) Create a connector similar to the one shown below and connect it to

Detector’s black connector boot. Keep the alligator clip away from bare metal parts

until step 4b.

CONNECTOR BOOT

Figure 5-8: Connecting the Flame Signal Generator

4. On the Controller, go to: Main Menu  Diagnostics  Manual Run and then put the unit in Manual Mode, then complete the following:

a) Ramp the boiler up to 100% fire rate and then set the Controller’s Enable/Disable

switch to Enable.

b) When the Controller gets into the ignition phase, it will show Ignition Trial. At that

point attach the alligator clip (see Figure 5-8) to any bare metal surface or ground. The Controller displays Flame Proven and begins to ram p u p to 1 00% fire rat e. N ote that no gas or flame is present in the boiler at this time.

5. Wait for the boiler to ramp up to at least 90% before continuing.

6. Cover the combustion air inlet opening with a solid, flat object, such as a piece of thick plywood or a thick metal plate.

7. The unit should shut down and display Airflow Fault During Run. This step confirms proper operation of the Blocked Inlet switch.

8. Remove the cover from the air inlet opening and reinstall the Combustion Air Duct or air filter.

9. Remove the jumper wires installed in step 3 and replace the black connector boot on the Flame Detector.

10. Press the CLEAR button. The unit should restart.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 68 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SSOV Proof Of Closure Switch Check Instructions

SSOV

SECTION 5 – SAFETY DEVICE TESTING

5.9 SSOV PROOF OF CLOSURE SWITCH CHECK

The SSOV, shown in Figure 5-9, contains the Proof of Closure switch. The Proof of Closure switch circuit is checked as follows:

1. Set the Controller’s Enable/Disable switch to Disable.

2. On the Controller, go to: Main Menu  Diagnostics  Manual Run, and then put the unit in Manual Mode.

3. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

4. Remove the cover from the SSOV by loosening the screw shown in Figure 5-9. Lift off the cover to access the terminal wiring connections.

5. Disconnect wire #148 from the SSOV to “open” the Proof Of Closure swit ch c irc uit.

6. The unit should fault and display SSOV Switch Open.

7. Replace wire #148 and press the CLEAR button.

8. Set the Controller’s Enable/Disable switch to Enable to start the unit.

9. Remove the wire again when the unit reaches the purge cycle and Purging is displayed.

10. The unit should shut down and display SSOV Fault During Purge.

11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart.

ACTUATOR

COVER

ACTUATOR COVER SCREW

Figure 5-9: SSOV Actuator Cover Location

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 69 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Purge Switch Open During Purge Check Instructions

AIR/FUEL VALVE COVER

BLOCKED

SECTION 5 – SAFETY DEVICE TESTING

5.10 PURGE SWITCH OPEN DURING PURGE

The Purge switch (and Ignition switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:

1. Set the Controller’s Enable/Disable switch to Disable.

2. On the Controller, go to: Main Menu  Diagnostics  Manual Run, and then put the unit in Manual Mode.

3. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

4. Remove the Air/Fuel Valve cover by rotating the cover counterclockwise to unlock it (see Figure 5-10).

5. Remove one of the two wires (#171 or #172) from the Purge switch (Figure 5-11a – 5-11c).

6. Set the Controller’s Enable/Disable switch to Enable to start the unit.

7. The unit should begin its start sequence, then shut down and display Prg Switch Open During Purge.

8. Replace the wire on the Purge switch and depress the CLEAR button. The unit should restart.

BLOWER PROOF

(Rotate Counter-Clock-

Wise to Remove)

INLET SWITCH

Figure 5-10: Air/Fuel Valve Cover Location – BMK 1500 Shown

SWITCH

AIR/FUEL VALVE

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 70 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Purge Switch Open During Purge Check Instructions

TO BLOWER

Purge Position

AIR IN

VALVE

Ignition Position

Ignition Position Switch

Purge Position Switch

AIR IN

TO BLOWER

SECTION 5 – SAFETY DEVICE TESTING

Figure 5-11a: Air/Fuel Purge and Ignition Locations – BMK 750/1000

Switch

170

169

AIR/FUEL VALVE SWITCH WIRING

BREAKOUT

172

171

POSITION DIAL

Switch

Figure 5-11b: Air/Fuel Purge and Ignition Locations – BMK 1500 – 3000

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 71 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Purge Switch Open During Purge Check Instructions

Ignition Switch Open Duri ng Ignition Check Instructi ons

PURGE

IGNITION

DIAL

AIR IN

TO BLOWER

SECTION 5 – SAFETY DEVICE TESTING

POSITION SWITCH

Figure 5-11c: Air/Fuel Purge and Ignition Locations – BMK 5000 & 6000

5.11 IGNITION SWITCH OPEN DURING IGNITION

The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:

1. Set the Controller’s Enable/Disable switch switch to Disable.

2. Go to Main MenuDiagnostics Manual Run and then put the unit in Manual Mode.

3. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls.

4. Remove the Air/Fuel Valve cover (Figure 5-10, above) by rotating the cover counterclockwise.

5. Remove one of the two wires (#169 or #170) from the Ignition switch (see Figure 5-11a – 5-11c, above).

6. Set the Controller’s Enable/Disable switch to Enable to start the unit.

7. The unit should begin its start sequence and then shut down and display Ign Switch Open During Ignition.

8. Replace the wire on the Ignition switch and press the CLEAR button. The unit should restart.

5.12 SAFETY PRESSURE RELIEF VALVE TEST

Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 72 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 6 – MODES OF OPERATION

SECTION 6: STANDALONE MODES OF OPERATION

The descriptions and instructions in this chapter apply to Standalone units only; the unit cannot be a BST Client or BST Manager. For instructions on configuring BST modes of operation, see Chapter 7: Boiler Sequencing Technology, below

Benchmark standalone boilers are capable of being operated in any one of six different modes. The following sections provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation. All temperature related parameters are at their factory default values, which work well in most applications. However, it may be necessary to change certain parameters to customize the unit to the system environment. After reading this section, parameters can be customized to suit the needs of the specific application.

6.1 OUTDOOR RESET MODE

The the Outdoor Reset mode of operation is based on outside air temperatures. As the outside air temperature decreases, the supply header temperature will increase and vice versa. For this mode, it is necessary to install an outside air sensor.

6.1.1 Outdoor Air Temperature Sensor Installation

The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected. The sensor must be shielded from the sun's direct rays, as well as direct impingement by the elements. If a cover or shield is used, it must allow free air circulation. The sensor may be mounted up to 200 feet (61m) from the unit. connections are made at the Input/Output (I/O) Box on the front of the boiler.

The Outdoor Ai r Temp Sensor must be connected to the t h e I/O board str ip J3, terminals 1 (labeled Outside Temp +) and 2 (Outside Temp –). Use shielded 18 to 22 AWG wire for connections.

For additional information on wiring see to Section 2.11.1: I/O Board Connections in the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210).

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 73 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Outdoor Reset Mode Setup Instructions

SECTION 6 – MODES OF OPERATION

6.1.2 Outdoor Reset Mode Startup

Startup in the Outdoor Reset mode is accomplished as follows:

NOTE:

A design engineer typically provides outdoor air temperature and supply header temperature data.

1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration, Unit Mode = Off.

2. On the Controller, go to: Main Menu  Advanced Setup  Unit  Application Configuration.

3. In the SH Operating Mode parameter, choose Outdoor Reset. The parameters that appear will be used to create a temperature curve to vary the unit’s active setpoint depending on the Outside Air Temperature (OAT).

Figure 6-1: Application Configuration Screen

4. Set the following parameters to define the total outside air temperature span which will be used for Setpoint control.

• OAR Min Outside Temp: The minimum outside temperature the system can

read; it is tied to the OAR Max Setpoint. For example, if OAR Min Outside Temp is 5°F and OAR Max Setpoint is 180°F, when the outside temperature is -5°F or below, the system will supply 180°F.

• OAR Max Outside Temp: Outdoor Air Reset Maximum Outside Temperature that

the system will operate to. For example: if set to 60°F, the boiler will operate between 60°F outside temperature and OAR Min Outside Temp setting.

5. Set the following parameters to define the Setpoint curve, which will be used to yield a desired setpoint for a given outside temperature:

• OAR Max Setpoint: The maximum allowable setpoint (range = Min Setpoint up to

210°F (98.9°C)).

• OAR Min Setpoint: The minimum allowable setpoint (range = 40°F (4.4°C) up to

the Max Setpoint).

6. Set the Warm Weather Shutdown parameter to the threshold outside temperature above which the unit shuts down. For example, if set to 65°F, when the outside temperature goes above 65°F, the unit goes into standby. The unit will then restart when

temperature falls below 60°F.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 74 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Constant Setpoint Mode Setup Instructions

SECTION 6 – MODES OF OPERATION

6.2 CONSTANT SETPOINT MODE

The Constant Setpoint mode (the default) is used when a fixed header temperature is desired. Common uses of this mode of operation include water source heat pump loops, and indirect heat exchangers for potable hot water systems or processes.

No external sensors are required to operate in this mode. While it is necessary to set the desired setpoint temperature, it is not necessary to change any other temperature-related functions. The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted.

The setpoint temperature of the unit is adjustable from 40°F to 245°F (4.4°C to 118.3°C). To set the unit to Constant Setpoint mode:

1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration, Unit Mode = Off.

2. On the Controller, go to: Main Menu  Advanced Setup  Unit Application Configuration.

3. Press SH Operating Mode and choose Constant Setpt.

4. Press SH Setpoint and choose the desired setpoint.

6.3 REMOTE SETPOINT MODE

The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal.

NOTE:

See Section 2.11.1: Remote Setpoint Field Wiring in the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210) for field wiring instructions,.

When using the Remote Setpoint mode default setting, 4 - 20 mA/1 - 5 VDC, a 4 to 2 0 mA/1 to 5 VDC signal, sent by an EMS or BAS, is used to change the unit's setpoint. The 4 mA/1V signal is equal to Setpoint Low Limit, while a 20 mA /5V signal is equal t o a Setp oin t High Limit setpoint. When a 0 to 20 mA/0 to 5 VDC signal is used, 0 mA is equal to Setpoint Low Limit.

In addition to the current and voltage signals described above, the Remote Setpoint mode can also be driven by a RS-485 Modbus Network signal from an EMS or BAS.

The Remote Setpoint mode of operation can be used to drive single as well as multiple units.

NOTE:

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the PMC Board located in the Edge Controller. Contact your local AERCO representative for details.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 75 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Remote Setpoint Mode Setup Instructions

Direct Drive Mode Setup Instructions

SECTION 6 – MODES OF OPERATION To set the unit to Remote Setpoint mode:

1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration, Unit Mode = Off.

2. On the Controller, go to Main Menu Advanced Setup  Unit Application Configuration.

3. Press SH Operating Mode and choose Remote Setpt.

4. Set the Remote Setpoint parameter to one of the following:

• 4-20mA/1-5V

• BST (PWM) Input

• BAS

If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be entered in the Setup menu. Refer to the Modbus Communication Manual (OMM-0035, GF-

114) for additional information.

While it is possible to change the values of temperature related functions, the unit is factory preset with values that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function values.

• 0-20mA/0-5V

• Network

6.4 DIRECT DRIVE MODES

The unit’s air/fuel valve position (% open) can be changed by a remote signal which is typically sent from an Energy Management System (EMS) or from a Building Automation System (BAS). The Di rect Drive mode can be driven by a current or voltage signal.

The default setting f or the Direct Dr ive mode is 4-20 mA/1-5 VDC. With this setting, a 4 to 20 mA signal, sent by an EMS or BAS is used to change the unit’s valve position from 0% to 100%. A 4 mA/1V signal is equal to a 0% valve position, while a 20 mA /5V signal is equal to a 100% valve position. When a 0-20 mA/0-5 VDC signal is used, zero is equal to a 0% valve position.

In addition to the current and voltage signals described above, the Direct Drive mode can also driven by a RS-485 Modbus Network signal from an EMS or BAS. When in Direct D r ive mode, the unit is a slave to the EMS or BAS and does not have a role in temperature control. Direct Drive can be used to drive single, or multiple units.

NOTE:

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the CPU Board located in the Edge Controller. Contact your local AERCO representative for details.

To enable the Direct Drive mode:

1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration, Unit Mode = Off.

2. On the Controller, go to: Main Menu  Advanced Setup  Unit Application Configuration.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 76 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Direct Drive Mode Setup Instructions

ACS Mode Setup Instructions

SECTION 6 – MODES OF OPERATION

3. Press SH Operating Mode parameter and choose Direct Drive.

4. The Remote Signal parameter now appears. It can be set to one of the options below.

• 4-20mA/1-5V

• BST (PWM) Input

• BAS

5. If Network was selected in the previous step, the Unit Address parameter appears. Enter

a valid Comm address in this parameter .

Refer to Modbus Communication Manual (OMM-0035, GF-114) for additional information.

• 0-20mA/0-5V

• Network

6.5 AERCO CONTROL SYSTEM (ACS)

NOTE:

ACS is f or installations with between 17 and 32 boilers. It utilizes only RS-485 signaling to the boiler. For installations with 1 to 16 boilers Boiler Sequencing Technology (BST) is recommended. See Section 7: Boiler Sequencing Technology.

The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible. For this mode of operation, an ACS Header Sensor must be installed between 2 and 10 feet (0.61 and 3m) downstream of the last boiler in the boiler plant's supply water header.

ACS can control up to 32 boilers via Modbus (RS-485) network communication. For ACS programming, operation, and Header Sensor installation details, see the ACS

Operations Guide (OMM-081, GF-131). For operation via an RS-485 Modbus network, refer to Modbus Communication Manual (OMM-0035, GF-114).

To enable the ACS mode:

1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration, Unit Mode = Off.

2. On the Controller, go to: Main Menu  Advanced Setup  Unit Application Configuration.

3. Press SH Operating Mode parameter and choose Direct Dri ve.

4. Press the Remo te Signal parameter and choose Network.

5. Press the Baud Rate parameter and choose 9600.

NOTE:

See Section 2.11.1 in the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210) for field wiring instructions.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 77 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 6 – MODES OF OPERATION

6.6 COMBINATION CONTROL SYSTEM (CCS)

NOTE:

The ACS can be utilized for a Combination Control System.

A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. The theory behind this type of system is that the maximum space-heating load and the maximum domestic hot water load do not occur simultaneously. Therefore, boilers used for domestic hot water are capable of switching between constant setpoint and ACS control.

For a typical CCS, an adequate number of boilers are installed to cover the space-heating load on the design-day. However, one or more units are used for the domestic hot water load as well. These boilers are the combination units and are referred to as the combo boilers. The combo boilers heat water to a constant setpoint temperature. That water is then circulated through a heat exchanger in a domestic hot water storage tank.

Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay Panel is req uired in combination with the ACS when there are up to two isolation valves, boiler interlocks, and/or a Domestic Hot Water (DHW) pump in a Combination heating plant where AERCO boilers are being used for both Building Heat and Domestic Hot Water heating.

The following two options are available for using a combination system; one that uses only the ACS, and one that requires the optional ACS Relay Box:

• OPTION 1 - This option is selected when the ACS controls a boiler plant containing up to eight combination boilers that are Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building heat (BLDG HEAT) boilers, and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers.

• OPTION 2 – When this option is selected, the ACS Relay Panel must be used in conjunction with the ACS. For this option, the ACS controls a boiler plant containing up to eight combination boilers that are divided up into Building Priority (BLDG PRIORITY) boilers and Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building heat (BLDG HEAT) boilers, and using two hydronic isolation valves in the main header, one between the BLDG HEAT and BLDG PRIORITY boilers, and the other between the BLDG PRIORITY and the DHW PRIORITY boilers.

In Option 2, when the space-heating load is such that when all the space-heating boilers are at the 100% valve position, the ACS will then ask the ACS Relay Box for the domestic boilers to become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot water) boilers will then become space-heating boilers. If the domestic hot water load is not satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch over to space heating, but there is a call for domestic hot water, the ACS Relay Box switches the combo units back to the domestic load. The ACS in combination with the ACS Relay Box will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boilers are not able to satisfy the domestic hot water demand.

When the combo units are satisfying the domestic load, they are in the Constant Setpoint mode of operation. When the combo units switch over to space heating, their mode of operation changes to follow the ACS command. For more information concerning the operation of the ACS, consult the AERCO Control System Manual (OMM-0081, GF-131); for i nformation on mounting and wiring the ACS Relay Box, see section 2.14 in that manual.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 78 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Combination Control System Setup Instructions

SECTION 6 – MODES OF OPERATION

6.6.1 Combination Control System Field Wiring

Wiring for this system is between the ACS, the ACS Relay Box, and the terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above.

6.6.2 Combination Control System Setup and Startup

To setup a boiler for Combination mode:

1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration, Unit Mode = Off.

2. On the Controller, go to: Main Menu  Advanced Setup  Unit Application Configuration.

3. Press SH Operating Mode and choose Combination.

4. Press the Remo te Signal parameter and choose Network.

While it is possible to change other temperature-related functions for Combination mode, these functions are preset at the f actor y. These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 79 of 146

Benchmark Platinum-Edge: Operation-Service Manual

SECTION 6 – MODES OF OPERATION

(This page intentionally blank)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 80 of 146

Benchmark Platinum-Edge: Operation-Service Manual

NOTE: Use either FFWD Header Sensor

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

SECTION 7: BOILER SEQUENCING TECHNOLOGY

7.1 INTRODUCTION

The Boiler Sequencing Technology system (BST) is an integrated 16 boiler control system. It is built into the Edge Controller. It has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 16 boilers while achieving maximum operational efficiency.

BST is designed to ensure that all Boilers in the system operate at maximum efficiency. This is accomplished by lighting off boilers only when all ignited boilers reach or exceed a defined Valve Position (Fire Rate). Operating all boilers below the defined Fire Rate “Next on VP” (for Next Turn on Valve Position) insures that they are firing at their most efficient Fire Rate. One unit the BST network is defined as the “Manager” and all other units on the network are defined as “Client” units. The Manager monitors the system Header Temperature, and also monitors all Client unit’s status information, efficiently controlling all units in order to achieve and maintain the required BST Setpoint Temperature.

When there is a demand, the Manager will light off one of the boilers based on t he BST Sequencing selection in the BST Cascade Status screen. As system load increases and the valve position of the ignited unit(s) reach the Next On VP (% valve position), the Manager will light off the next available unit. A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 7-1 below.

NOTE:

or Modbus Header Sensor

Figure 7-1: Simplified BST Block Diagram

After the boiler load is satisfied, the isolation valve remains open for a progr ammed interval (default = 2 minutes) before closing. When the system load is satisfied, the Edge Controller will open the isolation valves for all of the boilers. The BST controls the valves via a 0-20 mA signal (see Section 2.11.1: I/O Board Connections in the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210)).

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 81 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Option 5 – 4-20ma Drive AND Direct Wired Header

Complete section 7.3.5

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.1.1 Installation Notes

Unlike earlier Benchmark versions with the C-More Controller, ProtoNode is no longer needed except for LonWorks or Johnson Controls N2 communications.

However, if your installation still includes a ProtoNode SSD (Client-Client Device), you must adhere to the procedure listed below. Failure to complete these steps can result in the failure of the BST system.

a) Do NOT install the ProtoNode device at the outset of the installation. If the ProtoNode

device is already installed, you must physically disconnect it from the Modbus network on the I/O board.

b) Make sure that the Modbus load and bias resistors are properly configured for the system

to operate without the ProtoNode installed.

c) Temporarily set the BST system for Constant Setpoint mode of operation (see below). d) Turn on and completely test the installation to verify that it is operating proper. e) Once the installation is working properly as a BST system, install the ProtoNode device. f) Make sure that the Modbus load and bias resistors are properly configured for the system

to operate with the ProtoNode installed.

g) Set the BST system for desired mode of operation (Setpoint mode). h) Test the system completely with the ProtoNode installed.

7.2 BST QUICK START CHART

Select the single option that suites your installation and then complete the instructions in the corresponding sub-sections of section 7.3 BST Implementation Instructions.

Constant Setpoint (choose option 1 or 2)

Option 1 – Direct Wired Header (Header Temp) Complete section 7.3.1 Option 2 – Modbus Header (Network) Complete section 7.3.2

Outdoor Reset (choose option 3 or 4)

Option 3 – Direct Wired Header AND Direct Wired Outdoor Air Complete section 7.3.3 Option 4 – Modbus Header AND Modbus Outdoor Air Complete section 7.3.4

Remote Setpoint (choose option 5 through 8)

Option 6 – Modbus Drive AND Direct Wired Header Complete section 7.3.6 Option 7 – 4-20ma Drive AND Modbus Header Complete section 7.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 7.3.8

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 82 of 146

Benchmark Platinum-Edge: Operation-Service Manual

HEADER TEMP SENSOR (P/N 24410)

5 Supply Header –

3 Shield

I/O Board Strip J3

4 Supply Header +

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3 BST Implementation Instruction

The instructions in the rest of this chapter refer to I/O board connections on the Benchmark boilers. For an I/O board diagram and terminal connections, see Section 2.11.1 in Benchmark Platinum-Edge: INSTALLATION Manual (OMM-0136, GF-210).

7.3.1 Option 1 Constant Setpoint: Direct Wired Header Sensor

OPTION 1 Instructions: Constant Setpoint with Direct Wired Header Sensor

Step 1: HEADER SENSOR WIRING – MANAGER Unit

1. On the Manager unit, connect the Header Temperature Sensor (P/N 24410) to the I/O board terminal strip J3, terminals 4 (Supply Header +) and 5 (Supply Header –).

2. Ground the shield to any Shield terminal on the I/O Board, such as Terminal 3 or 8.

NOTES:

• The Header Sensor must be installed between 2 and 10 feet (0.61 and 3.1m) downstream of the LAST boiler in the plant’s supply water header.

• Shielded pair 18 - 22 AWG cable is recommended for header sensor wiring. There is no polarity to be observed.

• The ground for the shield is at the Shield terminal on the I/O the board. The sensor end of the shield must be left free and ungrounded.

Step 2: OPTION 1 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

 Advanced Setup  BST Cascade  Application Configuration:

• Set the Unit Address parameter to the communication address of the unit.

Continued on next page

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 83 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Configuration

Unit Mode

BST Manager

Hdr Temp Sensor

Header Temp

Application

Space Heating

SH Operating Mode

Constant Setpoint

Outdoor Temp Sensor

Outdoor Sensor

Plant Setpoint

Header temperature required for the cascade

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 1 Instructions: Constant Setpoint with Direct Wired Header Sensor

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu listed in the table below.

Cascade

Application Configuration

Cascade Comm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 84 of 146

Benchmark Platinum-Edge: Operation-Service Manual

MODBUS TRANSMITTER

15 BST RS485–

HEADER TEMP SENSOR (P/N 24410)

13 BST RS485+

3 Shield

I/O BOARD STRIP J3

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Sensor

OPTION 2 Instructions: Constant Setpoint, Modbus Wired Header Sensor

Step 1: MODBUS HEADER SENSOR WIRING – ANY BOILER

1. Connect the Modbus Transmitter (P/N 65169) terminal Pin B to the I/O Board strip J3, terminal 13 (BST RS485+) and Pin A to terminal 15 (BST RS485–) on any of the Boiler units using Shielded pair 18 - 22 AWG cable.

2. Connect the Header Temperature Sensor (P/N 24410) t o pins 2 and 3 of the Modbus Transmitter units using Shielded pair 18 - 22 AWG cable.

3. Install a jumper wire between pins 1 and 2 of the Modbus Transmitter.

NOTES:

• Polarity must be observed for the RS485 connections.

• Ground the shield to any Shield terminal on the I/O Board, such as Terminal 3 or 8.

• The Header Sensor must be installed between 2 and 10 feet (0.61 and 3.1m)

downstream of the LAST boiler in the plant’s supply water header.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 2: OPTION 2 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

 Advanced Setup  BST Cascade  Application Configuration:

• Set the Unit Address parameter to the communication address of the unit.

Continued on next page

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 85 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Unit Mode

BST Manager

Hdr Temp Sensor

Header Temp

Sensor Comm Address

240

Hdr Temp Point

Application

Space Heating

SH Operating Mode

Constant Setpoint

Outdoor Temp Sensor

Outdoor Sensor

Plant Setpoint

Header temperature required for the cascade

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 2 Instructions: Constant Setpoint, Modbus Wired Header Sensor

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade Configuration

Application Configuration

Cascade Comm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 86 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Continued on next page

OUTDOOR TEMP SENSOR

I/O BOARD, STRIP J3

HEADER TEMP SENSOR (P/N 24410)

5 Supply Header-

3 Shield

I/O BOARD STRIP J3

4 Supply Header+

2 Outside Temp -

3 Shield

1 Outside Temp +

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.3 Option 3 Outdoor Reset: Direct Wired Header Sensor & Direct

Wired Outdoor Sensor

OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Sensor & Outdoor Sensor

NOTE:

Both Header Sensor and Outdoor Sensor must be wired. See the Edge Controller Manual (OMM-0139, GF-213) for more information.

Step 1: DIRECT WIRED HEADER SENSOR WIRING – MANAGER Unit

1. On the Manager unit, connect the Header Temperature Sensor (P/N 24410) to the I/O board terminal strip J3, terminals 4 (Supply Header +) and 5 (Supply Header -).

2. Connect the shield to any Shield ter m inal, such as terminal 3 or 8 on strip J3.

NOTES:

• The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m) downstream of the LAST boiler in the plant’s supply water header.

• Shielded pair 18 - 22 AWG cable is recommended for header sensor wiring. There is no polarity to be observed. The ground for the shield is at the Shield terminal on the I/O the board. The sensor end of the shield must be left free and ungrounded.

Step 2: DIRECT WIRED OUTDOOR SENSOR WIRING – MANAGER Unit

1. On the Manager Unit, connect the Outdoor Temperature Sensor (P/N 61048) to the I/O board terminal strip J3, terminals 1 (Outside Temp +) and 2 (Outside Temp -). Connect the shield to terminal 3 (Shield).

NOTES:

• Twisted shielded pair 18 - 22 AWG cable is recommended for header sensor wiring. There is no polarity to be observed. The sensor end of the shield must be lef t free and ungrounded.

• When mounting the Outdoor sensor, it must be located on the North side of the building where an average outside air temperature is expected. The sensor must be

shielded from direct sunlight as well as impingement by the elements. The outdoor sensor may be wired up to 200 feet (61m) from the boiler.

(P/N 61048)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 87 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Unit Mode

BST Manager

Hdr Temp Sensor

Header Temp

Application

Space Heating

SH Operating Mode

Outdoor Reset

Outdoor Temp Sensor

Outdoor Sensor

Plant Setpoint

Header temperature required for the cascade

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Sensor & Outdoor Sensor

Step 3 – OPTION 3 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

• Set the Unit Address parameter to the communication address of the unit.

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade Configuration

 Advanced Setup  BST Cascade  Application Configuration:

Application Configuration

Cascade Comm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 88 of 146

Benchmark Platinum-Edge: Operation-Service Manual

MODBUS TRANSMITTER

15 BST RS485–

HEADER TEMP SENSOR (P/N 24410)

13 BST RS485+

3 Shield

I/O BOARD STRIP J3

15 BST RS485–

13 BST RS485+

3 Shield

MODBUS TRANSMITTER

OUTDOOR TEMP SENSOR

I/O BOARD STRIP J3

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.4 Option 4 Outdoor Reset: Modbus Header Sensor & Modbus

Outdoor Sensor

OPTION 4 Instructions: Outdoor Reset, Modbus Header Sensor & Modbus Outdoor Sensor

NOTE:

Both Header Sensor AND Outdoor Sensor must be wired. See the Edge Controller Manual and (OMM-0139, GF-213) for more information.

Step 1: HEADER SENSOR WIRING – ANY BOILER

1. Connect the Modbus Transmitter (P/N 65169) terminal P in B to the I/O Board strip J3, terminal 13 (BST RS485+) and Pin A to terminal 15 (BST RS485–) on any of the Boiler units using Shielded pair 18 - 22 AWG cable.

2. Using Shielded pair 18 - 22 AWG cable, connect the Header Temperature Sensor (P/N

24410) to pins 2 and 3 of the Modbus Transmitter.

3. Install a jumper wire between pins 1 and 2 of the Modbus Transmitter.

NOTES:

• Polarity must be observed for the RS485 connections.

• Ground the shield to any Shield terminal on the I/O Board, suc h as Term inal 3 or 8.

• The Header Sensor must be installed between 2 and 10 feet (0.61 and 3.1m)

downstream of the LAST boiler in the plant’s supply water header.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 2: OUTDOOR SENSOR WIRING

1. If you have not already done so, complete step 1 of the instructions above to connect the Modbus Transmitter to the I/O Board.

2. Connect the Outdoor Temperature Sensor (P/N 61048) to Pins 5 and 6 of the Modbus Transmitter using a Shielded pair 18 - 22 AWG cable.

3. Install a jumper wire between Pins 4 and 5 on the Modbus Transmitter.

(P/N 61048)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 89 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Unit Mode

BST Manager

Hdr Temp Sensor

Network

Sensor Comm Address

240

Hdr Temp Point

Application

Space Heating

SH Operating Mode

Outdoor Reset

Outdoor Temp Sensor

Outdoor Sensor

Sensor Comm Address

240

Outdoor Temp Point

Plant Setpoint

Header temperature required for the cascade

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 4 Instructions: Outdoor Reset, Modbus Header Sensor & Modbus Outdoor Sensor

NOTES:

• Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD” terminal in the I/O the Box.

• When mounting the Outdoor sensor, it must be located on the North side of the building where an average outside air temperature is expected. The sensor must be shielded from direct sunlight as well as impingement by the elements. The outdoor sensor may be wired up to 200 feet (61m) from the boiler.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 3 – OPTION 4 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

 Advanced Setup  BST Cascade  Application Configuration:

• Set the Unit Address parameter to the communication address of the unit.

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade Configuration

Application Configuration

Cascade Comm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 90 of 146

Benchmark Platinum-Edge: Operation-Service Manual

HEADER TEMP SENSOR (P/N 24410)

5 Supply Header-

3 Shield

I/O BOARD STRIP J3

4 Supply Header+

Remote Signal + Remote Signal –

8 Shield

I/O BOARD STRIP J3

6 Remote Analog In +

7 Remote Analog In –

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.5 Option 5 Remote Setpoint: Direct Wired Header Sensor & 4-

20ma Setpoint Drive

OPTION 5 Instructions: Remote Setpoint, Direct Wired Header Sensor, 4-20ma Setpoint Drive

NOTE:

Both Header Sensor and 4-20ma Direct Drive must be wired. See the Edge Controller Manual (OMM-0139, GF-213) for more information.

Step 1: HEADER SENSOR WIRING – MANAGER Un it

1. On the Manager unit, connect the Header Temperature Sensor (P/N 24410) to the I/O board terminal strip J3, terminals 4 (Supply Header +) and 5 (Supply Header -).

2. Connect the shield to any Shield ter m inal, such as terminal 3 or 8 on strip J3.

NOTES:

• The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m) downstream of the LAST boiler in the plant’s supply water header.

• Shielded pair 18 - 22 AWG cable is recommended for header sensor wiring. There is no polarity to be observed. The ground for the shie ld is at the Shield terminal on the I/O the board. The sensor end of the shield must be left free and ungrounded.

Step 2: DIRECT WIRED 0-20mA or 4-20mA WIRING – MANAGER Unit

1. Connect the 4-20mA or 0-20mA terminals from the Direct Drive source to the I/O Board strip J3, terminals 6 (Remote Analog In +) and 7 (Remote Analog In –) on the Manager.

2. Connect the shield to any Shield terminal on the I/O Board, such as terminal 3 or 8.

NOTES:

• Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be observed.

• The ground for the shield is at the driver signal source.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 91 of 146

Continued on next page

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Configuration

Unit Mode

BST Manager

Hdr Temp Sensor

Header Temp

Application

Space Heating

SH Operating Mode

Rmt Setpt Analog

BST Remote Signal

4-20mA/1-5V *

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 5 Instructions: Remote Setpoint, Direct Wired Header Sensor, 4-20ma Setpoint Drive

Step 3: OPTION 5 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

• Set the Unit Address parameter to the communication address of the unit.

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade

 Advanced Setup  BST Cascade  Application Configuration:

Application Configuration

Cascade Comm

* Be sure that the SW 1-4 DIP s witch on Controller’s Interface Board is set ap propriate ly (On = Cur rent,

Off = Voltage.)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 92 of 146

Benchmark Platinum-Edge: Operation-Service Manual

MODBUS TRANSMITTER

15 BST RS485–

HEADER TEMP SENSOR (P/N 24410)

13 BST RS485+

3 Shield

I/O BOARD STRIP J3

15 BST RS485–

13 BST RS485+

3 Shield

MODBUS TRANSMITTER

OUTDOOR TEMP SENSOR

61048)

I/O BOARD STRIP J3

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.6 Option 6 Remote Setpoint: Direct Wired Header Sensor &

Modbus Setpoint Drive

OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Sensor, Modbus Setpoint Drive

NOTE:

Both Header Sensor and Outdoor Sensor must be wired. See the Edge Controller Manual for more information.

Step 1: HEADER SENSOR WIRING – ANY BOILER

1. Connect the Modbus Transmitter (P/N 65169) terminal P in B to the I/O Board strip J3, terminal 13 (BST RS485+) and Pin A to terminal 15 (BST RS485–) on any of the Boiler units using Shielded pair 18 - 22 AWG cable.

2. Connect the shield to any Shield terminal, such as terminal 3 or 8 on strip J3.

3. Connect the Header Temperature Sensor (P/N 24410) to pins 2 and 3 of the Modbus Transmitter using Shielded pair 18 - 22 AWG cable.

4. Install a jumper wire between pins 1 and 2 of the Modbus Transmitter.

NOTES:

• Polarity must be observed for the RS485 connections.

• Ground the shield to any Shield terminal on the I/O Board (such as Terminal 3 or 8).

• The Header Sensor must be installed between 2 and 10 feet (0.61 and 3.1m)

downstream of the LAST boiler in the plant’s supply water header.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 2: OUTDOOR SENSOR WIRING

1. If you have not already done so, complete the instructions above to connect the Modbus Transmitter to the I/O Board.

2. Connect the Outdoor Temperature Sensor (P/N 61048) to Pins 3 and 6 of the Modbus Transmitter using Shielded pair 18 - 22 AWG cable.

3. Install a jumper wire between Pins 4 and 5 of the Modbus Transmitter.

(P/N

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 93 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Unit Mode

BST Manager

Hdr Temp Sensor

Header Temp

Application

Space Heating

SH Operating Mode

Rmt Setpt Netwrk

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Sensor, Modbus Setpoint Drive

NOTES:

• Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD” terminal in the I/O the Box.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 3 – OPTION 6 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

• Set the Unit Address parameter to the communication address of the unit.

On the Manager only:

 Advanced Setup  BST Cascade  Application Configuration:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade Configuration

Application Configuration

Cascade Comm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 94 of 146

Benchmark Platinum-Edge: Operation-Service Manual

MODBUS TRANSMITTER

15 BST RS485–

HEADER TEMP SENSOR (P/N 24410)

13 BST RS485+

3 Shield

I/O BOARD STRIP J3

Remote Signal + Remote Signal –

8 Shield

I/O BOARD STRIP J3

6 Remote Analog In +

7 Remote Analog In –

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.7 Option 7 Remote Setpoint: Modbus Header Sensor & 4-20ma

Setpoint Drive

OPTION 7 Instructions: Remote Setpoint, Modbus Header Sensor & 4-20ma Setpoint Drive

NOTE:

Both Header Sensor and 4-20ma Direct Drive must be wired. See the Edge Controller Manual (OMM-0139, GF-213) for more information.

Step 1: MODBUS HEADER SENSOR WIRING – ANY BOILER

2. Connect the shield to any Shield ter m inal, such as terminal 3 or 8 on strip J3.

2. Connect the Header Temperature Sensor (P/N 24410) t o pins 2 and 3 of the Modbus Transmitter units using Shielded pair 18 - 22 AWG cable.

3. Install a jumper wire between pins 1 and 2 of the Modbus Transmitter.

NOTES:

• Polarity must be observed for the RS485 connections.

• Ground the shield to any Shield terminal on the I/O Board (such as Terminal 3).

• The Header Sensor must be installed between 2 and 10 feet (0.61 and 3.1m)

downstream of the LAST boiler in the plant’s supply water header.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 2: DIRECT WIRED 0-20mA OR 4-20mA WIRING – MANAGER

3. Connect the 4-20mA or 0-20mA terminals from the Direct Drive source to the I/O Board strip J3, terminal 6 (Remote Analog In +) and terminal 7 (Remote Analog In –) on the Manager.

4. Connect the shield to any Shield terminal on the I/O Board, such as terminal 3 or 8.

NOTES:

• Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be observed.

• The ground for the shield is at the driver signal source.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 95 of 146

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Unit Mode

BST Manager

Hdr Temp Sensor

Network

Sensor Comm Address

240

Hdr Temp Point

Application

Space Heating

SH Operating Mode

Rmt Setpt Analog

BST Remote Signal

4-20mA/1-5V *

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 7 Instructions: Remote Setpoint, Modbus Header Sensor & 4-20ma Setpoint Drive

Step 3: OPTION 7 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

• Set the Unit Address parameter to the communication address of the unit.

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade Configuration

 Advanced Setup  BST Cascade  Application Configuration:

Application Configuration

Cascade Comm

* Be sure that the SW1-4 DIP switch on Controller’s Interface Board is set ap propriate ly (On = C urrent,

Off = Voltage.)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 96 of 146

Benchmark Platinum-Edge: Operation-Service Manual

MODBUS TRANSMITTER

15 BST RS485–

HEADER TEMP SENSOR (P/N 24410)

13 BST RS485+

3 Shield

I/O BOARD STRIP J3

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

7.3.8 Option 8 Remote Setpoint: MODBUS Header Sensor & MODBUS

Setpoint Drive

OPTION 8 Instructions: Remote Setpoint, Modbus Header Sensor & Modbus Setpoint Drive

Step 1: MODBUS HEADER SENSOR WIRING – ANY BOILER

2. Connect the shield to any Shield ter m inal, such as terminal 3 or 8 on strip J3.

2. Connect the Header Temperature Sensor (P/N 24410) to pins 2 and 3 of the Modbus Transmitter using Shielded pair 18 - 22 AWG cable.

3. Install a jumper wire between pins 1 and 2 of the Modbus Transmitter.

NOTES:

• Polarity must be observed for the RS485 connections.

• Ground the shield to any Shield terminal on the I/O Board (such as Terminal 3).

• The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)

downstream of the LAST boiler in the plant’s supply water header.

• There is no polarity to be observed. The ground for the shield is at the power supply ground. The sensor end of the shield must be left free and ungrounded.

Step 3: OPTION 8 CONFIGURATION

On All Boiler:

1. Go to: Main Menu  Advanced Setup  BST Cascade  Cascade Configuration:

• Set the Unit Mode parameter to BST Client.

2. Go to: Main Menu

• Set the Unit Address parameter to the communication address of the unit.

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 97 of 146

 Advanced Setup  BST Cascade  Application Configuration:

Continued on next page

Benchmark Platinum-Edge: Operation-Service Manual

Menu/Screen Name

Parameters

Values

Unit Mode

BST Manager

Hdr Temp Sensor

Network

Sensor Comm Address

240

Hdr Temp Point

Configuration

Application

Space Heating

SH Operating Mode

Rmt Setpt Netwrk

Min address

The minimum unit address in the cascade

Max address

The maximum unit address in the cascade

Cascade Baud Rate

The baud rate for the cascade.

SECTION 7 – BOILER SEQUENCING TECHNOLOGY

OPTION 8 Instructions: Remote Setpoint, Modbus Header Sensor & Modbus Setpoint Drive

On the Manager only:

1. Go to Main Menu  Advanced Setup  BST Cascade, set the Parameters to the Values in each menu in the table below.

Cascade Configuration

Application

Cascade Comm

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 98 of 146

Benchmark Platinum-Edge: Operation-Service Manual

LABOR

TIME

Igniter-Injector (BMK 750 – 3000 only)

Inspect, replace

if necessary

Pilot Ignition Rod (BMK 5000 & 6000 only)

Inspect, replace

if necessary

Inspect, replace

if necessary

8.5

O2 Sensor

Inspect

Inspect/Clean

15 mins.

4.4

Combustion Calibration

Check

1 hr.

See ASME

CSD-1 Chart

8.7

Inspect, Clean &

Gaskets

Inspect, Clean

Gaskets

8.9

Air Filter

Clean

Replace

15 mins.

Refractory Replacement (BMK 5000-6000 only)

8.13

TABLE 8-2a: 12 Month Maintenance Kits

SECTION 8 – MAINTENANCE

SECTION 8: MAINTENANCE

8.1 MAINTENANCE SCHEDULE

All Benchmark boilers require regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 8-1. For a complete inspection check list see ASME CSD-1 chart.

WARNING!

Prior to servicing, ensure that the following guidelines are strictly observed:

• Follow all Lockout/Tagout protocols in effect at the site.

• Disconnect the AC power 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.

TABLE 8-1: Maintenance Schedule

SEC

8.2

8.3

8.4

8.6

8.8

8.10

* Only performed after initial 6 month period after initial startup.

Flame Detector Inspect

Testing of Safety Devices Burner Inspect 2 hrs.

Condensate Drain Trap Inspect

Periodic Testing Routine verification of functionality, various schedule

ITEM 6 MOS . * 12 MOS. 24 MOS.

Inspect Inspect

Replace

Repair if needed

Replace 15 mins. Replace 15 mins. Replace 15 mins.

45 mins.

& Replace

30 mins.

In order to perform the maintenance tasks specified in Table 8-1, the following maintenance kits are available from AERCO. All kits included a Technical Instruction Document (TID) with instructions for performing the maintenance.

Model Kit#

750 - 3000

6000

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 99 of 146

58025-01 58025-11

Parts Serviced/Replaced

Ignitor, Flame Rod, Condensate trap O rings Pilot Burner, Flame Rod & Condensate trap

Doc Name

TID-0131 TID-0095

Benchmark Platinum-Edge: Operation-Service Manual

TABLE 8-2b: 24 Month Maintenance Kits

Doc Name

58025-19

Burner & Blower gaskets, LWCO, air filter cleaner

cleaning kit

LEAN O2 SENSOR

STAGED IGNITION SOLENOID

IGNITER-INJECTOR

INDEXING (CLOCKING) WASHERS (0-3 as required)

FLAME

GAS LINE

GAS INJECTOR

SECTION 8 – MAINTENANCE

Model Kit# Parts Serviced/Replaced – Includes all 12 Month Parts

750/1000

58025-08

Burner & Blower gaskets, LWCO, air filter replacement

TID-0100

58025-17 Burner & Blower gaskets, LWCO, air filter cleaner 58025-13 Burner & Blower gaskets, LWCO, air filter replacement

1500/2000

TID-0113

58025-10 Burner & Blower gaskets, LWCO, air filter replacement

2500/3000

5000

6000

58025-18 58025-12 58025-14

58025-15 58025-16

Burner gaskets, LWCO, air filter cleaner LWCO, air pump filter, Burner & Blower gaskets, air filter LWCO, air pump filter, air filter LWCO, air pump filter, Burner & Blower gaskets, air filter

LWCO, air pump filter, air filter cleaning kit

TID-0102

TID-0096

8.2 IGNITER-INJECTOR – BMK 750 - 3000

The ignitor-injector should be inspected annually and replaced at least every 24 months of operation, sooner if there is evidence of substantial erosion or carbon build-up. Parts and instructions are included in 12 Month Maintenance Kit P/N 58025-01 and all BMK 750 – 3000 24 Month Maintenance Kits.

The igniter-injector may be hot, therefore care should be exercised to avoid burns. It is easier to remove the igniter-injector from the unit after the unit has cooled to room temperature. To inspect/replace the Igniter:

Note that during installation, use the number of indexing (clocking) washers necessary that, when tight, the gas injection tube is positioned as shown in Figure 8-1d.

CONNECTION

DETECTOR

& GASKET

TUBE

& WASHER

Figure 8-1a: Igniter-Injector & Flame Detector (BMK 750/1000)

OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 100 of 146

Watts Aerco BMK 750, Aerco BMK 2500, Aerco BMK 3000, Aerco BMK 5000, Aerco BMK 6000 Operation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

FOREWORD

SECTION 1: SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

1.2 EMERGENCY SHUTDOWN

1.3 PROLONGED SHUTDOWN

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS

SECTION 2: EDGE CONTROLLER OPERATION

2.1 INTRODUCTION

2.2 Login and Password Entry

SECTION 3: START SEQUENCE

3.1 INTRODUCTION

3.2 START SEQUENCE

3.3 START/STOP LEVELS

3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT

3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input

3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input

3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input

3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input

3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input

3.4.6 Benchmark 5000 Air/Fuel Valve Position and Energy Input

3.4.7 Benchmark 6000 Air/Fuel Valve Position and Energy Input

SECTION 4: INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION

4.2.1 Required Tools & Instrumentation

4.2.2 Installing Gas Supply Manometer

4.2.3 Accessing the Analyzer Probe Port

4.3 FUEL TYPES and COMBUSTION CALIBRATION

4.4 COMBUSTION CALIBRATION

4.4.1 NATURAL GAS Manual Combustion Calibration

4.4.2 PROPANE GAS COMBUSTION CALIBRATION

4.5 REASSEMBLY

4.6 DUAL FUEL SWITCHOVER

4.7 OVER-TEMPERATURE LIMIT SWITCHES

4.7.1 Adjusting the Automatic Reset Limit Switch Temperature

4.7.2 Resetting the Manual Reset Limit Switch

4.7.3 Changing the Readout Between Fahrenheit and Celsius

SECTION 5: SAFETY DEVICE TESTING

5.1 TESTING OF SAFETY DEVICES

5.2 LOW GAS PRESSURE TEST

5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500

5.2.2 LOW GAS PRESSURE TEST: BMK 3000 – 6000 Only

5.3 HIGH GAS PRESSURE TEST

5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500

5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 – 6000 Only

5.4 LOW WATER LEVEL FAULT TEST

5.5 WATER TEMPERATURE FAULT TEST

5.6 INTERLOCK TESTS

5.6.1 Remote Interlock Test

5.6.2 Delayed Interlock Test

5.7 FLAME FAULT TEST

5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES

5.8.1 Blower Proof Switch Test

5.8.2 Blocked Inlet Switch Test

5.9 SSOV PROOF OF CLOSURE SWITCH CHECK

5.10 PURGE SWITCH OPEN DURING PURGE

5.11 IGNITION SWITCH OPEN DURING IGNITION

5.12 SAFETY PRESSURE RELIEF VALVE TEST

SECTION 6: STANDALONE MODES OF OPERATION

6.1 OUTDOOR RESET MODE

6.1.1 Outdoor Air Temperature Sensor Installation

6.1.2 Outdoor Reset Mode Startup

6.2 CONSTANT SETPOINT MODE

6.3 REMOTE SETPOINT MODE

6.4 DIRECT DRIVE MODES

6.5 AERCO CONTROL SYSTEM (ACS)

6.6 COMBINATION CONTROL SYSTEM (CCS)

6.6.1 Combination Control System Field Wiring

6.6.2 Combination Control System Setup and Startup

SECTION 7: BOILER SEQUENCING TECHNOLOGY

7.1 INTRODUCTION

7.1.1 Installation Notes

7.2 BST QUICK START CHART

7.3 BST Implementation Instruction

7.3.1 Option 1 Constant Setpoint: Direct Wired Header Sensor