Watts Aerco Benchmark Series Operation And Service Manual
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Watts Aerco Benchmark Series Operation And Service Manual

Platinum boilers with edge controller
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Operation and Service Manual
Benchmark
With Edge Controller
Natural Gas, Propane Gas and Dual Fuel
Modulating & Condensing Boilers
Models 750 through 6000
Other documents for this product include:
OMM-0136, GF-210 210 Installation and Startup Manual
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 – BMK 750 – 3000
N-19-0100 and above – BMK 5000 & 6000
• GF-211 • 7/16/2019
OMM-0137_D
®
Platinum Boilers

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Summary of Contents for Watts Aerco Benchmark Series

  • Page 1 Operation and Service Manual ® Benchmark Platinum Boilers With Edge Controller Natural Gas, Propane Gas and Dual Fuel Modulating & Condensing Boilers Models 750 through 6000 Other documents for this product include: OMM-0136, GF-210 210 Installation and Startup Manual 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...

  • Page 2: Table Of Contents

    Benchmark Platinum-Edge: Operation-Service Manual CONTENTS Table of Contents FOREWORD ...................... 5 SECTION 1: SAFETY PRECAUTIONS ..............9 1.1 WARNINGS & CAUTIONS ........................9 1.2 EMERGENCY SHUTDOWN ......................... 10 1.3 PROLONGED SHUTDOWN ......................... 10 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ............... 11 SECTION 2: EDGE CONTROLLER OPERATION ..........
  • Page 3 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 ............................
  • Page 4 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 ..................

  • Page 5: Foreword

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 6 Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 7 Benchmark Platinum-Edge: Operation-Service Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Energy Management System; often used interchangeably with BAS Factory Mutual. Used to define boiler gas trains. GF-xxxx Gas Fired (an AERCO document numbering system) Ground Header Hexadecimal Number (0 – 9, A – F) Horse Power Heat Exchanger Hertz (Cycles Per Second)
  • Page 8 Benchmark Platinum-Edge: Operation-Service Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) Point-to-Point (usually over RS232 networks) P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref)

  • Page 9: Section 1: Safety Precautions

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS 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.

  • Page 10: Emergency Shutdown

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 11: Important - For Massachusetts Installations

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS Requirements For Massachusetts Installations Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements: • Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
  • Page 12 Benchmark Platinum-Edge: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS Requirements For Massachusetts Installations 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 observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

  • Page 13: Section 2: Edge Controller Operation

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 14: Login And Password Entry

    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 No password The default. Many parameters are visible but “Read Only.” Allows routine maintenance to be performed. Appropriate for AERCO Trained technicians (ATT).

  • Page 15: Section 3: Start Sequence

    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.
  • Page 16 Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 17 Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence NATURAL GAS INLET SSOV AIR/FUEL LOW GAS VALVE MANUAL PRESSURE SHUT-OFF SWITCH VALVE Figure 3-1c: BMK 2500: SSOV Location (P/N 22318 shown) NATURAL GAS INLET AIR/FUEL SSOV VALVE MANUAL LOW GAS SHUT-OFF VALVE PRESSURE...
  • Page 18 Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence UPSTREAM DOWNSTREAM SSOV SSOV WITH TO AIR/FUEL VALVE MANUAL SHUT- OFF VALVE GAS INLET HIGH GAS UPSTREAM LOW GAS PRESSURE SWITCH PRESSURE SWITCH - BMK 6000: 10.5” W.C., 2.6 kPa - BMK 6000: 8.5”...
  • Page 19 Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN 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.
  • Page 20 Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence AIR/FUEL VALVE OUTLET TO BLOWER BLOWER PROOF SWITCH AIR/FUEL VALVE INLET FROM GAS TRAIN 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: he Air/Fuel Valve rotates to the low-fire (Ignition) position and closes the ignition switch.
  • Page 21 Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence TO BLOWER STEPPER MOTOR IGNITION VALVE POSITION DIAL AT 25% to 35% AIR IN 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.
  • Page 22 Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE BMK 5000 & 6000 Function Timing Chart For Proved Pilot Control System Operating State Pre-purge PFEP MFEP Standby T = 0 T = 30 T = 37 T = 44 Component PFEP MFEP C-More Controller...

  • Page 23: Start/Stop Levels

    Benchmark Platinum-Edge: Operation-Service Manual 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: TABLE 3-1a: Start/Stop Levels –...

  • Page 24: Start/Stop Levels - Air/Fuel & Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual 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 TABLE 3-2a: BMK 750/1000 Air/Fuel Valve Position –...

  • Page 25: Bmk 1500 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input TABLE 3-3a: BMK 1500 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 16% (Stop Level) 75,000 (22.3 kW) 5.0%...

  • Page 26: Bmk 2000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input TABLE 3-4a: BMK 2000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 18% (Stop Level) 100,000 (29.3 kW) 5.7%...

  • Page 27: Bmk 2500 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input TABLE 3-5a: BMK 2500 Air/Fuel Valve Position – NATURAL GAS, Single Fuel AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 16% (Stop Level)

  • Page 28: Bmk 3000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input TABLE 3-6a: BMK 3000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 14% (Stop Level) 200,000 (58.6 kW) 6.7%...

  • Page 29: Benchmark 5000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.6 Benchmark 5000 Air/Fuel Valve Position and Energy Input BMK 5000 Air/Fuel Valve Position and Energy Input Air Fuel Valve Boiler Energy Input Position % of Full (% Full Open) BTU/Hr Capacity 18% (Stop Level) 400,000...

  • Page 30: Benchmark 6000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.7 Benchmark 6000 Air/Fuel Valve Position and Energy Input BMK 6000 Air/Fuel Valve Position and Energy Input Air Fuel Valve Boiler Energy Input Position % of Full (% Full Open) BTU/Hr Capacity 18% (Stop Level) 385,000...

  • Page 31: Section 4: Initial Start-Up

    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.

  • Page 32: Tools & Instruments For Combustion Calibration

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 33 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP TO AIR/FUEL VALVE MANUAL SHUT- OFF VALVE SSOV 1/4” NTP PLUG (Install manometer here for downstream combustion 1/4” NTP PLUG calibration reading ) (Install manometer here for upstream combustion calibration reading ) LEAK DETECTION BALL VALVE LEAK DETECTION BALL VALVE NATURAL GAS INLET...
  • Page 34 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS INLET HIGH GAS PRESSURE SWITCH 1/4” NPT PLUG (Install manometer here for downstream combustion calibration SSOV reading) LEAK DETECTION LOW GAS BALL VALVE PRESSURE SWITCH AIR/FUEL VALVE LEAK DETECTION BALL VALVE MANUAL SHUT- OFF VALVE...

  • Page 35: Accessing The Analyzer Probe Port

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP TO AIR/FUEL VALVE MANUAL DOWNSTREAM SHUT-OFF UPSTREAM LEAK SSOV WITH POC VALVE DETECTION BALL VALVE GAS PORT (Install manometer here for Alternative location for upstream combustion calibration manometer if hose reading) barb is preferred LOW GAS PRESSURE SWITCH...

  • Page 36: Fuel Types And Combustion Calibration

    Benchmark Platinum-Edge: Operation-Service Manual 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).

  • Page 37: Natural Gas Manual Combustion Calibration

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP 4.4.1 NATURAL GAS Manual Combustion Calibration These instructions apply only to units running NATURAL GAS. NATURAL GAS Manual Combustion Calibration Instructions 1. Ensure the Edge Controller’s Enable/Disable switch is set to Disable. 2.
  • Page 38 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions 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).
  • Page 39 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions 17. Compare the combustion analyzer’s oxygen (O ) reading to the O value in the Reading 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 sensor match the value from the combustion analyzer.
  • Page 40 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions 23. Once the O 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.
  • Page 41 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions BMK 2000 Dual Fuel Units ≤20 ppm 6.5% ± 0.2% <100 ppm ≤20 ppm 6.5% ± 0.2% <100 ppm ≤20 ppm 6.5% ± 0.2% <50 ppm ≤20 ppm 6.5% ±...

  • Page 42: Propane Gas Combustion Calibration

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions ≤9 ppm 5.5% ± 0.5% <20 ppm 6.0% ± 1.0% <50 ppm ≤9 ppm 6.0% ± 1.0% <20 ppm 6.5% ± 1.5% <50 ppm 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).
  • Page 43 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions 10. For the NOx requirement choose None. 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: •...
  • Page 44 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions TABLE 4-4: PROPANE Gas Pressure Range @ 100% Fire Rate Model Nominal Gas Pressure BMK 750P 3.9” W.C. ± 0.2” W.C. (0.97 kPa ± 0.05 kPa) BMK 1000P 7.6”...
  • Page 45 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions 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 4-4, above, or Table 4- 6, below, increase the O level up to 1% higher than the Target value.
  • Page 46 Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions Valve Position Oxygen (O Nitrogen oxide (NOx) Carbon Monoxide (CO) BMK 2000 <100 ppm 6.5% ± 0.2% <150 ppm <100 ppm <150 ppm 6.5% ± 0.2% <100 ppm <150 ppm 6.5% ±...

  • Page 47: Reassembly

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions 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).

  • Page 48: Dual Fuel Switchover

    Benchmark Platinum-Edge: Operation-Service Manual 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. FUEL SELECTOR I/O BOARD SWITCH and cover Figure 4-10: Dual Fuel Switch Switchover from NATURAL GAS to PROPANE Instructions...

  • Page 49: Over-Temperature Limit Switches

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 50: Resetting The Manual Reset Limit Switch

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 4 – INITIAL START-UP Temperature Adjustment Instructions INCREASE TEMPERATURE DECREASE 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 the temperature has fallen at least 10 degrees below the limit.

  • Page 51: Section 5: Safety Device Testing

    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 combustion- related safety devices before, during and after the start sequence.

  • Page 52: Low Gas Pressure Test

    Benchmark Platinum-Edge: Operation-Service Manual 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 –...
  • Page 53 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING TO AIR/FUEL VALVE (P/N 22322 shown) MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH SSOV GAS INLET 1/4” NPT PLUG Install manometer LOW GAS PRESSURE here for LOW gas LEAK DETECTION BALL VALVE pressure fault test.

  • Page 54: Low Gas Pressure Test: Bmk 3000 - 6000 Only

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING NATURAL HIGH GAS PRESSURE GAS INLET SWITCH (P/N 22190 shown) SSOV LOW GAS PRESSURE AIR/FUEL VALVE SWITCH MANUAL SHUT-OFF VALVE 1/4” NPT PLUG Install manometer here for LOW gas pressure fault test. LOW GAS BALL VALVE Figure 5-1c: BMK 2500 LOW Gas Pressure Test Components 5.2.2 LOW GAS PRESSURE TEST: BMK 3000 –...
  • Page 55 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK 3000 – 6000 Only 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.
  • Page 56 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK 3000 – 6000 Only MANUAL SHUT-OFF VALVE AIR/FUEL VALVE NATURAL GAS Low Gas Pressure Test Port Install manometer here Alternative location PROPANE Low Gas Pressure Test Port Install manometer here Dual Fuel gas train showing both Natural Gas and...

  • Page 57: High Gas Pressure Test

    Benchmark Platinum-Edge: Operation-Service Manual 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 –...
  • Page 58 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 750 – 2500 14. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4" NPT plug removed in step 2. TO AIR/FUEL MANUAL SHUT-OFF VALVE...

  • Page 59: High Gas Pressure Test: Bmk 3000 - 6000 Only

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 750 – 2500 NATURAL HIGH GAS PRESSURE GAS INLET 1/4” NPT SWITCH PLUG (install manometer here for HIGH SSOV PRESSURE FAULT TEST) HIGH GAS LOW GAS BALL VALVE PRESSURE...
  • Page 60 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 3000 – 6000 ONLY 6. Open the external gas supply ball valve upstream of the unit. 7. On the Controller, go to: Main Menu  Diagnostics  Manual Run and then enable the Manual Mode control.
  • Page 61 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK 3000 – 6000 ONLY Alternative location for manometer if hose barb is preferred NATURAL GAS HIGH GAS PRESSURE SWITCH - BMK 6000 – 10.5” W.C., 2.6 kPa - BMK 5000 –...

  • Page 62: Low Water Level Fault Test

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: LOW Water Fault Test Instructions 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.

  • Page 63: Water Temperature Fault Test

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the Automatic Reset Over- Temperature switch. Water Temperature Fault Test Instructions 1. Start the unit in the normal operating mode and allow the unit to stabilize at its setpoint. 2.

  • Page 64: Interlock Tests

    Benchmark Platinum-Edge: Operation-Service Manual 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).

  • Page 65: Flame Fault Test

    Benchmark Platinum-Edge: Operation-Service Manual 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: Flame Fault Test Instructions 1.

  • Page 66: Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches

    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 Proof switch and Blocked Inlet switch shown in Figure 5-6a, 5-6b and 5-6c. 5.8.1 Blower Proof Switch Test BLOWER PROOF...
  • Page 67 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING BLOCKED INLET SWITCH BLOWER PROOF SWITCH HEX SCREWS HOLDING WYE DUCT TO A/F VALVE MANUAL SHUT- (1 OF 3) OFF VALVE Figure 5-6c: Blower Proof & Blocked Inlet Switch Locations – BMK 5000 & 6000 Blower Proof Switch Test Instructions 1.

  • Page 68: Blocked Inlet Switch Test

    Benchmark Platinum-Edge: Operation-Service Manual 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. Blocked Inlet Switch Test Instructions 1.

  • Page 69: Ssov Proof Of Closure Switch Check

    Benchmark Platinum-Edge: Operation-Service Manual 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: SSOV Proof Of Closure Switch Check Instructions 1.

  • Page 70: Purge Switch Open During Purge

    Benchmark Platinum-Edge: Operation-Service Manual 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: Purge Switch Open During Purge Check Instructions 1.
  • Page 71 Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING Purge Switch Open During Purge Check Instructions Ignition Position Switch Purge Position Switch TO BLOWER AIR IN Figure 5-11a: Air/Fuel Purge and Ignition Locations – BMK 750/1000 TO BLOWER Ignition Position Switch VALVE POSITION DIAL...

  • Page 72: Ignition Switch Open During Ignition

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING Purge Switch Open During Purge Check Instructions TO BLOWER PURGE POSITION SWITCH DIAL IGNITION POSITION SWITCH AIR IN 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.

  • Page 73: Section 6: Standalone Modes Of Operation

    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.

  • Page 74: Outdoor Reset Mode Startup

    Benchmark Platinum-Edge: Operation-Service Manual 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. Outdoor Reset Mode Setup Instructions 1.

  • Page 75: Constant Setpoint Mode

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 76: Direct Drive Modes

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – MODES OF OPERATION To set the unit to Remote Setpoint mode: Remote Setpoint Mode Setup Instructions 1. As a prerequisite, verify that the unit is not a BST Client or Manager. Go to: Main Menu  Advanced Setup ...

  • Page 77: Aerco Control System (Acs)

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – MODES OF OPERATION Direct Drive Mode Setup Instructions 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. •...

  • Page 78: Combination Control System (Ccs)

    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 space- heating and domestic hot water needs.

  • Page 79: Combination Control System Field Wiring

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 80 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...

  • Page 81: Section 7: Boiler Sequencing Technology

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 82: Installation Notes

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 83: Bst Implementation Instruction

    Benchmark Platinum-Edge: Operation-Service Manual 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).
  • Page 84 Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 85: Option 2 Constant Setpoint: Modbus Wired Header Sensor

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 86 Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 87: Option 3 Outdoor Reset: Direct Wired Header Sensor & Direct Wired Outdoor Sensor

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 88 Benchmark Platinum-Edge: Operation-Service Manual 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: •...

  • Page 89: Option 4 Outdoor Reset: Modbus Header Sensor & Modbus Outdoor Sensor

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 90 Benchmark Platinum-Edge: Operation-Service Manual 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. •...

  • Page 91: Option 5 Remote Setpoint: Direct Wired Header Sensor & 4-20Ma Setpoint Drive

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 92 Benchmark Platinum-Edge: Operation-Service Manual 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: •...

  • Page 93: Option 6 Remote Setpoint: Direct Wired Header Sensor & Modbus Setpoint Drive

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 94 Benchmark Platinum-Edge: Operation-Service Manual 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. •...

  • Page 95: Option 7 Remote Setpoint: Modbus Header Sensor & 4-20Ma Setpoint Drive

    Benchmark Platinum-Edge: Operation-Service Manual 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.
  • Page 96 Benchmark Platinum-Edge: Operation-Service Manual 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: •...

  • Page 97: Option 8 Remote Setpoint: Modbus Header Sensor & Modbus Setpoint Drive

    Benchmark Platinum-Edge: Operation-Service Manual 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: HEADER SENSOR WIRING – ANY BOILER MODBUS 1.
  • Page 98 Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 99: Section 8: Maintenance

    Benchmark Platinum-Edge: Operation-Service Manual 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.

  • Page 100: Igniter-Injector - Bmk 750 - 3000

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE TABLE 8-2b: 24 Month Maintenance Kits Model Kit# Parts Serviced/Replaced – Includes all 12 Month Parts Doc Name 58025-08 Burner & Blower gaskets, LWCO, air filter replacement 750/1000 TID-0100 58025-17 Burner & Blower gaskets, LWCO, air filter cleaner 58025-13 Burner &...
  • Page 101 Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE IGNITER- INJECTOR BLOWER ASSEMBLY PLENUM SENSOR FLAME DETECTOR BURNER FLAME OBSERVATION PORT Figure 8-1b: Igniter-Injector & Flame Detector (BMK 1500/3000) BLOWER PLENUM SENSOR FLAME DETECTOR IGNITOR-INJECTOR ASSEMBLY FLAME OBSERVATION PORT BURNER Figure 8-1c: Igniter-Injector & Flame Detector (BMK 2500/3000) O2 SENSOR POSITION INJECTOR TUBE...

  • Page 102: Pilot Ignition Rod - Bmk 5000 & 6000

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.3 PILOT IGNITION ROD – BMK 5000 & 6000 The Pilot Burner (P/N 29700) is located on the right-front of the Burner Plate. It contains an ignition cable, the Pilot gas line connected to the bushing. The Pilot Burner Rod (P/N 66100), should be inspected every 12 months and replaced if damaged or warped.

  • Page 103: Osensor

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE The flame detector should be inspected every 12 months and replaced every 24 months, or sooner if damaged or warped. Note, it may be hot; allow the unit to cool sufficiently before removing the flame detector.

  • Page 104: Air Eductor Air Pump Maintenance - Bmk 5000 & 6000

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE Lean O Sensor Maintenance Instructions 1. Set the ON/OFF switch on the Edge Controller to the OFF position. 2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

  • Page 105: Safety Device Testing

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE Air Pump Maintenance and Troubleshooting Instructions 3. Reattach the O Sensor Cover to the unit’s back panel. GAS SUCTION LINE TO EXHAUST MANIFOLD AIR FILTER COVER BRACKET (Hangs on opening in back panel) Figure 8-4: Air Eductor Assembly –...
  • Page 106 Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE AIR/FUEL VALVE BLOWER GAS TRAIN CONNECTS HERE SENSOR PIPE FLANGE GASKET (P/N 81155) FLAME DETECTOR BLOWER GASKET (P/N 81064) BURNER PLATE BURNER GASKET (P/N 81143) BURNER Figure 8-5a: Burner Assembly Exploded View – BMK 750/1000 BLOWER GASKET (P/N 81184) 3/8”-16...
  • Page 107 Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE BLOWER GASKET BLOWER PLENUM (P/N 81157) IGNITER- BLOWER INJECTOR ASSEMBLY A/F VALVE PLENUM BURNER PLATE AIR/FUEL VALVE 3/8”-16 HEX NUTS 5/8” NUTS (8 each) & BOLTS (4 each) AIR FILTER (P/N 88014) Figure 8-5c: Burner Assembly Mounting Details –...

  • Page 108: Condensate Drain Trap

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.8 CONDENSATE DRAIN TRAP All Benchmark Platinum boilers contain a condensate trap (P/N 24441), located external to the unit and attached to the drain connection from the exhaust manifold at the rear of the unit. It must be inspected for leaks and blockages and cleaned to ensure that condensate flows normally.

  • Page 109: Air Filter Cleaning And Replacement

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.9 AIR FILTER CLEANING and REPLACEMENT The boiler’s air filter should be maintained as follows: Cleaned every 12 months. Replaced after 24 months if it shows any signs of deterioration. However, if it is still in good condition, you can order a 24 Month Maintenance kit that includes an air filter cleaning kit in place of a new filter.

  • Page 110: Rear Refractory Replacement

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.10.1 Rear Refractory Replacement Rear Refractory Replacement Instructions 1. Turn off gas and electrical power to the unit. In addition, turn off any other units sharing the exhaust flue. 2. Disconnect the flue from the exhaust manifold of the boiler being serviced and remove flue sections up to the top of the unit enclosure.
  • Page 111 Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE Rear Refractory Replacement Instructions SENSOR COVER LOCATION (cover removed) SPRING LATCH AIR EDUCTOR Access the rear panel nuts (behind arrows) are on the RIGHT REAR PANEL rail & base inside the unit, accessible after removing the side panel on each side.

  • Page 112: Front Refractory Replacement

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE Rear Refractory Replacement Instructions 15. The combustion chamber can now be viewed and inspected with a full view of the Burner assembly and rear tubesheet. A borescope can be used to inspect the front tubesheet as well as under the expansion joints.

  • Page 113: Shutting Boiler Down For Extended Period

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD If the boiler is to be taken out of service for an extended period of time (one year or more), the following instructions must be followed. Shutting Boiler Down For An Extended Period Instructions 1.
  • Page 114 Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE Benchmark 5000/6000 Long Term Blower Storage Instructions Example Storage / Maintenance Schedule Log Item Action Dates Checked Re-inspect units to insure any protective devices used functioning properly. Check scratches in the finish which will allow corrosion or rust to form Rotate wheel a minimum of 10 full revolutions to keep the motor bearing grease from separating...

  • Page 115: Returning The Boiler To Service After Shutdown

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN After a prolonged shutdown (one year or more), the following procedures must be followed: Placing The Boiler Back In Service After A Prolonged Shutdown Instructions 1.

  • Page 116: Recommended Periodic Testing

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.13 RECOMMENDED PERIODIC TESTING WARNING! Periodic testing of all boiler controls and safety devices is required to ensure they continue to operate as designed. Precautions must be taken while tests are being performed to protect against bodily injury and property damage.
  • Page 117 Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE TABLE 8-3: Recommended Periodic Testing ITEM FREQUENCY ACTION BY REMARKS High water temp. See Section 5.5: Water Temperature Fault Test Annually Service Tech safety control test in this guide. See Section 2.2: Edge Controller Description in Operating controls Annually Operator...

  • Page 118: Recommended Spares

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 8 – MAINTENANCE 8.14 RECOMMENDED SPARES NOTE: Refer to the parts list illustrations in the Benchmark Platinum-Edge: REFERENCE Manual (GF-212) for the locations of the parts listed below. For a list of 12 and 24 Month Maintenance Kits, see Section 8.1: Maintenance Schedule. TABLE 8-4: Recommended Emergency Spare Parts DESCRIPTION BMK 750/1000...

  • Page 119: Section 9: Aertrim Operation

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION SECTION 9: AERTRIM OPERATION 9.1 AERtrim INTRODUCTION Advanced combustion control systems need to maintain precise air/fuel ratios to maximize efficiency. Gas and oil-fired boilers often deviate from the ideal air-fuel ratio due to environmental variations such as humidity, atmospheric pressure, filter dust loading, delivered gas energy content and other factors.

  • Page 120: Operation Details

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION AERtrim Activation Instructions 1. Record the following information from the unit you wish to activate. To do this, go to the Main Menu  Advanced Setup  Performance  AERtrim  AERtrim Settings and scroll down until you see the following parameters: •...
  • Page 121 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION Figure 9-3 graphically shows the functional logic of the AERtrim system and how the blower voltage (BV), O Limits, and air/fuel ratio interact during an AERtrim operation. The limits are fixed presets within the controller. The target range is adjustable within these limits to allow the user to select the optimal air/fuel ratio for a particular boiler or application.

  • Page 122: Aertrim O 2 Sensor Auto Calibration

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION 9.4 AERtrim O SENSOR AUTO CALIBRATION AERtrim includes an automatic O sensor calibration feature, which helps maintain oxygen sensor readout accuracy. When sensor calibration occurs, the controller starts the O Cal Purge for 40 seconds (55 seconds on the BMK 6000) in order to remove residual combustion fumes.

  • Page 123: Aertrim Menu Values And Defaults

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION 9.5 AERtrim MENU VALUES and DEFAULTS The AERtrim menus are in: Main Menu  Advanced Setup  Performance  AERtrim AERtrim Settings and are described the Edge Controller Manual (GF-213), Section 6.6.1. BMK 750 AERtrim Values Minimum Maximum...
  • Page 124 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK 1000 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 5.5% Target 5.5% 5.5% (must be between O 5.5% Upper & O 5.5% Lower) 100%...
  • Page 125 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK 1500 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 5.5% Target 6.5% 6.5% (must be between O 6.5% Upper & O 6.0% Lower) 100%...
  • Page 126 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK 2000 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 6.5% Target 6.0% 6.0% (must be between O 5.5% Upper & O 5.5% Lower) 100%...
  • Page 127 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK 2500 AERtrim Values Minimum Maximum Default MENU ITEM Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 5.5% Target 6.5% 7.0% (must be between O 6.0% Upper & O 6.0% Lower) 100%...
  • Page 128 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK 3000 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 6.5% Target 7.3% 7.5% (must be between 7.0% Upper & 5.5% Lower) 100% 5.0%...

  • Page 129: Aertrim Maintenance And Troubleshooting

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION 9.6 AERtrim MAINTENANCE and TROUBLESHOOTING The AERtrim system, which maximizes blower efficiency, depends on the O sensor. The AERtrim system needs only minimal maintenance. It is recommended that you inspect the oxygen sensor for accuracy every 12 months by comparing it to a sensor reading from a properly calibrated flue analyzer.
  • Page 130 Benchmark Platinum-Edge: Operation-Service Manual SECTION 9 – AERTRIM OPERATION The Edge Controller does not display a message when O levels are within the target range. However, if O levels fall outside the target range, one of the messages listed in Table 9-2 will be displayed in the Auto Calibration Status parameter on the Main Menu ...

  • Page 131: Section 10: Troubleshooting

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 10 – TROUBLESHOOTING SECTION 10: TROUBLESHOOTING 10.1 INTRODUCTION This section is intended to aid service/maintenance personnel in isolating the cause of a fault in your Benchmark boiler. The troubleshooting procedures below are presented in tabular form on the following pages.
  • Page 132 Benchmark Platinum-Edge: Operation-Service Manual SECTION 10 – TROUBLESHOOTING (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 132 of 146...
  • Page 133 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blower stopped running due to thermal or Check combustion blower for signs of excessive heat or high current current overload. drain that may trip thermal or current overload devices. Blocked Blower inlet or inlet air filter.
  • Page 134 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blower not running or running too slow. Start the unit. If the blower does not run check the blower solid state relay for input and output voltage. If the relay is OK, check the blower.
  • Page 135 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Delayed Interlock Jumper not properly installed Check to insure jumper is properly installed across the Delayed or missing. Interlock terminals in the I/O Box. DELAYED Device proving switch hooked to interlocks is If there are 2 external wires on these terminals, check to see if an...
  • Page 136 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective SSOV. While externally arcing the spark igniter, observe the open/close indicator in the Safety Shut-Off Valve to ensure it is opening. If the valve does not open, check for 120VAC at the valve input terminals.
  • Page 137 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective SSOV Actuator. If gas supply pressure downstream of SSOV Actuator cannot be lowered to the range specified in Table 4-1 (Natural Gas) or Table 4- 4 (Propane) in Section 4.4: Combustion Calibration of this guide;...
  • Page 138 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Air/Fuel Valve not rotating. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration.
  • Page 139 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Interlock jumper not installed or removed. Check for a jumper properly installed across the interlock terminals in the I/O box. Energy Management System does not have unit If there are two external wires on these terminals check any Energy INTERLOCK enabled.
  • Page 140 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action A/F Valve rotated open to purge and did not Start the unit. The Air/Fuel Valve should rotate to the purge (open) rotate to ignition position. position, then back to ignition position (towards closed) during the ignition cycle.
  • Page 141 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Loose or broken wiring. Inspect Outdoor Temperature sensor for loose or broken wiring. OUTDOOR Defective Sensor. Check resistance of sensor to determine if it is within specification. TEMP SENSOR FAULT Incorrect Sensor.
  • Page 142 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action SSOV relay failed on IGST board. Press CLEAR button and restart unit. If fault persists, replace Ignition/Stepper (IGST) Board. Floating Neutral. The Neutral and Earth Ground are not connected at the source and SSOV RELAY therefore there is a voltage measured between the two.

  • Page 143: Additional Faults Without Specific Fault Messages

    Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING 10.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 10-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 10-2: Boiler Troubleshooting With No Fault Message Displayed Observed Incident Probable Causes Corrective Action...
  • Page 144 Benchmark Platinum-Edge: Operation-Service Manual SECTION 6 – TROUBLESHOOTING DAMPING ORIFICE BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 10-1: SSOV Actuator With Gas Pressure Adjustment (SKP25) OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 144 of 146...

  • Page 145: Notes

    Benchmark Platinum-Edge: Operation-Service Manual CHANGE LOG NOTES: OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 145 of 146...
  • Page 146 Benchmark Platinum-Edge: Operation-Service Manual CHANGE LOG Change Log: Date Description Changed By Rev C: 07/02/2018 Chris Blair DIR 18-65: Updated Tables 4-3 in Section 4.4.1 and Tables 4-6 in Section 4.4.2. Rev D: DIR 18-61: Updated Blower Proof Switch Test, Section 5.8.1. DIR 19-01: Corrected Table 4-3b, Oxygen values in Standard and Low NOx columns, 16%-18% row.

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