Watts AERCO Benchmark BMK750 Operation And Service Manual
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Watts AERCO Benchmark BMK750 Operation And Service Manual

With edge (i) controller
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Operations and Service Manual
Benchmark
with Edge [i] Controller
Natural Gas, Propane Gas and Dual
Fuel Modulating & Condensing Boilers
Models 750 through 6000
Other documents for this product include:
OMM-0144, GF-217 Installation and Startup Manual
OMM-0146, GF-219 Reference Manual
TAG-0019, GF-2070 Boiler Application Design Guide
TAG-0022, GF-2050 Vent-Combustion Air Design Guide
TAG-0047, GF-2030 Benchmark Gas Guide
TAG-0048, GF-2060 Benchmark Power Design Guide
Applies to serial numbers:
G-19-0001 and above – BMK750 – 4000
N-19-0001 and above – BMK5000 & 6000
• GF-218 •
OMM-0145_A99
®
Boilers
9/18/2019

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Summary of Contents for Watts AERCO Benchmark BMK750

  • Page 1 Operations and Service Manual ® Benchmark Boilers with Edge [i] Controller Natural Gas, Propane Gas and Dual Fuel Modulating & Condensing Boilers Models 750 through 6000 Other documents for this product include: OMM-0144, GF-217 Installation and Startup Manual OMM-0146, GF-219 Reference Manual TAG-0019, GF-2070 Boiler Application Design Guide TAG-0022, GF-2050 Vent-Combustion Air Design Guide TAG-0047, GF-2030 Benchmark Gas Guide...

  • Page 2: Table Of Contents

    Benchmark with Edge [I]: Operation-Maintenance Manual CONTENTS Table of Contents TABLE OF CONTENTS ................... 2 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 –...
  • Page 3 Benchmark with Edge [I]: Operation-Maintenance Manual CONTENTS 5.2 LOW GAS PRESSURE TEST ......................72 5.2.1 LOW GAS PRESSURE TEST: BMK750 – 2500 ....................72 5.2.2 LOW GAS PRESSURE TEST: BMK3000 – 6000 Only ..................74 5.3 HIGH GAS PRESSURE TEST ......................78 5.3.1 HIGH GAS PRESSURE TEST: BMK750 –...
  • Page 4 Benchmark with Edge [I]: Operation-Maintenance Manual CONTENTS 8.5.1 Air Eductor Air Pump Maintenance – BMK5000 & 6000 ................130 8.6 SAFETY DEVICE TESTING ....................... 131 8.7 BURNER INSPECTION ........................131 8.8 CONDENSATE DRAIN TRAP ......................134 8.9 AIR FILTER CLEANING AND REPLACEMENT ................135 8.10 REFRACTORY REPLACEMENT –...

  • Page 5: Foreword

    Benchmark with Edge [I]: Operation-Maintenance 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 with Edge [I]: Operation-Maintenance Manual FORWARD 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 AERCO Control System, AERCO’s boiler management systems ADDR Address AGND...
  • Page 7 Benchmark with Edge [I]: Operation-Maintenance Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Ground Header Hexadecimal Number (0 – 9, A – F) Horse Power Heat Exchanger Hertz (Cycles Per Second) I.D. Inside Diameter Ignition IGST Board Ignition/Stepper Board, contained in Edge [i] Controller INTLK (INTL’K) Interlock Input/Output...
  • Page 8 Benchmark with Edge [I]: Operation-Maintenance Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref) Reference RES. Resistive RS232 A standard for serial, full-duplex (FDX) transmission of data based on (or EIA-232)

  • Page 9: Section 1. Safety Precautions

    Benchmark with Edge [I]: Operation-Maintenance 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 with Edge [I]: Operation-Maintenance 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 with Edge [I]: Operation-Maintenance 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 with Edge [I]: Operation-Maintenance 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 [I] Controller Operation

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION SECTION 2. EDGE [I] CONTROLLER OPERATION 2.1 INTRODUCTION This section provides a brief outline of how to gain access to Benchmark Boiler’s Edge [i] Controller functionality. Full instructions for using the Edge [i] Controller to setup, configure and operate a Benchmark Boiler are included in the Edge [i] Controller Manual, OMM-0141, GF-213- The Edge [i] Controller is shown below.

  • Page 14: Login And Password Entry

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION 2.2 Login and Password Entry The Edge [i] Controller has multiple levels of password protection. Level Password Description The default. Many parameters are visible but “Read Only.” No password Allows routine maintenance to be performed. Appropriate for AERCO Trained Technicians (ATT).

  • Page 15: Menu Structure

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION 2.3 MENU STRUCTURE The Main Menu give you access to all Edge [i] Controller user functionality. There are four major divisions within the menu structure. Figure 3.3: The Edge [i] Controller Main Menu Unit Status Menu 2.3.1 The Unit Status menu contains the following sections and parameters.

  • Page 16: Calibration Menu

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Units Firing Read Only The number of units firing in the BST cascade. Main Menu → Isolation Valve Status – BST Manager Only The number of isolation valves designated as “always Min # Valves Open Read Only open.”...

  • Page 17: Diagnostics Menu

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Specify Auto Calibrate time of day (Calibration Time Numeric Entry Frequency = Daily). Main Menu → Calibration → Input/Output → Analog Inputs Analog Name Select Select: Flow or Remote Analog In. Offset Numeric Entry A correction value to selected input, if needed.
  • Page 18 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION → → Main Menu Diagnostics Front Panel 2.3.3.2 Main Menu → Diagnostics → Front Panel Touchscreen Display Test On/Off Starts the Touchscreen Display Test. Touchscreen Test On/Off Starts the Touchscreen Test. Status Light Test On/Off Starts the Status Light Test.
  • Page 19 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION The Controller’s Engineering software version. Engineering Version Read Only The Controller’s graphic version. Graphic Data Version Read Only The Controller’s display version. Display Version Read Only I/O Board Version Read Only The I/O board version.

  • Page 20: Advanced Setup Menu

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION → → Main Menu Diagnostics Input/Output Summary 2.3.3.7 Main Menu → Diagnostics → Input/Output Summary This screen is a read-only display of the following unit and/or BST cascade parameters: Air Inlet: Supply Header: Exhaust: Return Header:...
  • Page 21 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Choose the vent material: PVC, cPVC, Polypro, Stainless Vent Type Select Steel. Depending on exhaust temperature and value of Vent Type, Exhaust Safety Enable/Disable triggers an exhaust temperature warning, reduced fire rate or unit shutoff.
  • Page 22 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Select unit’s application: SH, DHW or Other. Unit Application Select Unit SH Operating Mode Unit DHW Operating Mode Toggle Choose either Constant or Remote Setpoint. Unit Other Operating Mode Unit SH Setpoint Sets the unit’s setpoint (Unit Operating Mode = Constant Unit DHW Setpoint Numeric Entry...
  • Page 23 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION The threshold outside temperature above which the Warm Weather Shtdwn Numeric Entry Client/Manager unit shuts down (Outdoor Air Temp Sens = Network, Direct or BAS). Allows BST Manger functionality to be transferred Auto-Manager Transfer Toggle Manager...
  • Page 24 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION The number of Modbus Comm errors allowed Error Threshold Numeric Entry Client/Manager before invoking a Modbus comm fault (1 to 9). Comm Error 1-8 Read Only Client/Manager The number of comm errors on ports 1 - 8. The number of comm errors on ports 9 –...
  • Page 25 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Main Menu → Advanced Setup → BST Cascade → Operating Controls → Temperature Control Generates a fire rate based on the error that exists between the SH Proportional Band setpoint temperature and the actual outlet temperature. If the Numeric Entry DHW Proportional Band difference is less than the value of these parameters, the fire...
  • Page 26 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Specify the address of the Lag unit (0 to 16, Lead/Lag Setting Lag Unit Numeric Entry = Select Lead Lag). → → Main Menu Advanced Setup Com & Failsafe 2.3.4.3 Main Menu → Advanced Setup → Comm & Network → onAER To enable onAER, select the communication method: onAER Mode Select...
  • Page 27 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Specifies the time that this action advances the output; it Derivative Band Numeric Entry responds to the rate of change of the setpoint error (0.00 to 2.00 min.). Warm-up Prop Band Numeric Entry These three parameters eliminate Temperature Overshoots during the “Warmup”...
  • Page 28 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION When the Outlet Temperature exceeds the Temperature Hi Limit by 5 to 15°F, the effective Fire Rate will be GOV Limit-5 – GOV Limit-15 Numeric Entry reduced by the value entered in GOV Limit-5 through GOV Limit-15 (0 –...
  • Page 29 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION Defines a Shutoff delay, during which time the unit remains at minimum fire rate after the unit has sequenced to Off Delay Numeric Entry shutoff. It is activated only when Off Delay Threshold is reached (0 to 9999 secs).
  • Page 30 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 2: OPERATION (This page intentionally blank) OMM-0145_A99 • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 9/18/2019 Page 30 of 157...

  • Page 31: Section 3. Start Sequence

    Benchmark with Edge [I]: Operation-Maintenance 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 [i] Controller. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • Page 32 Benchmark with Edge [I]: Operation-Maintenance 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 [i] Controller’s ignition sequence screen walks you through the ignition screens and demonstrates (or highlights) which switches are not met.
  • Page 33 Benchmark with Edge [I]: Operation-Maintenance 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: BMK2500: SSOV Location (P/N 22318 shown) NATURAL GAS INLET AIR/FUEL SSOV VALVE MANUAL LOW GAS SHUT-OFF VALVE...
  • Page 34 Benchmark with Edge [I]: Operation-Maintenance 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 - BMK6000: 10.5” W.C., 2.6 kPa - BMK6000: 8.5”...
  • Page 35 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Start Sequence TO BLOWER STEPPER MOTOR PURGE VALVE POSITION DIAL AT 100% AIR IN Figure 3-2b: BMK1500 – 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 36 Benchmark with Edge [I]: Operation-Maintenance 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: BMK1500 – 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 37 Benchmark with Edge [I]: Operation-Maintenance 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 38 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE BMK5000 & 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...

  • Page 39: Start/Stop Levels

    Benchmark with Edge [I]: Operation-Maintenance 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 40: Start/Stop Levels - Air/Fuel & Energy Input

    Benchmark with Edge [I]: Operation-Maintenance 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. BMK750/1000 Air/Fuel Valve Position and Energy Input 3.4.1 TABLE 3-2a: BMK750/1000 Air/Fuel Valve Position –...

  • Page 41: Bmk1500 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE BMK1500 Air/Fuel Valve Position and Energy Input 3.4.2 TABLE 3-3a: BMK1500 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 42: Bmk2000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE BMK2000 Air/Fuel Valve Position and Energy Input 3.4.3 TABLE 3-4a: BMK2000 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 43: Bmk2500 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE BMK2500 Air/Fuel Valve Position and Energy Input 3.4.4 TABLE 3-5a: BMK2500 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 44: Bmk3000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE BMK3000 Air/Fuel Valve Position and Energy Input 3.4.5 TABLE 3-6a: BMK3000 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 45: Benchmark4000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark4000 Air/Fuel Valve Position and Energy Input 3.4.6 TABLE 3-6a: BMK4000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 23% (Stop Level) 228,180 5.7%...

  • Page 46: Benchmark5000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark5000 Air/Fuel Valve Position and Energy Input 3.4.7 BMK5000 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 47: Benchmark6000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark6000 Air/Fuel Valve Position and Energy Input 3.4.8 BMK6000 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 48 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE (This page intentionally blank) OMM-0145_A99 • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 9/18/2019 Page 48 of 157...

  • Page 49: Section 4. Initial Start-Up

    Benchmark with Edge [I]: Operation-Maintenance 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 750-6000 with Edge [i]: Install-Startup Manual (OMM-0144, GF-217), including gas supply piping, vent installation and condensate drain piping.

  • Page 50: Tools & Instruments For Combustion Calibration

    Benchmark with Edge [I]: Operation-Maintenance 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 51 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP TO AIR/FUEL VALVE MANUAL SHUT- OFF VALVE SSOV 1/4” NTP PLUG (Install manometer here for 1/4” NTP PLUG downstream combustion calibration reading ) (Install manometer here for upstream combustion calibration reading ) LEAK DETECTION BALL VALVE LEAK DETECTION BALL VALVE...
  • Page 52 Benchmark with Edge [I]: Operation-Maintenance 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-...
  • Page 53 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP HIGH GAS PRESSURE SWITCH NATURAL LEAK DETECTION GAS INLET BALL VALVE SSOV MANUAL SHUT- OFF VALVE TO AIR/FUEL VALVE LOW GAS PRESSURE SWITCH LEAK DETECTION BALL VALVE Figure 4-1e: Port Location for Combustion Calibration – BMK4000 TO AIR/FUEL VALVE MANUAL...

  • Page 54: Accessing The Analyzer Probe Port

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP Accessing the Analyzer Probe Port 4.2.3 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: Analyzer Probe Port Access Instructions 1.

  • Page 55: Fuel Types And Combustion Calibration

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 4.3 FUEL TYPES and COMBUSTION CALIBRATION All BMK 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.

  • Page 56: Natural Gas Manual Combustion Calibration

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration 4.4.1 These instructions apply only to units running NATURAL GAS. NATURAL GAS Manual Combustion Calibration Instructions 1. Ensure the Edge [i] Controller’s Enable/Disable switch is set to Disable. 2.
  • Page 57 Benchmark with Edge [I]: Operation-Maintenance 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 58 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions 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.
  • Page 59 Benchmark with Edge [I]: Operation-Maintenance 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 60 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions BMK2000 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 61: Propane Gas Combustion Calibration

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions TABLE 4-3g: NATURAL GAS Final Valve Positions: BMK6000, Single & DF Valve Position Standard NO Ultra-Low NO Single Dual Fuel Fuel ≤9 ppm 5.5% ±...
  • Page 62 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions 7. Verify that the incoming gas pressure to the unit is within the allowable range (see the Benchmark Gas Supply Design Guide (TAG-0047, GF-2030). 9. Once you have completed the previous step, move the manometer (or use a secondary one) to the downstream side of the SSOV and press Next to continue.
  • Page 63 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions TABLE 4-4: PROPANE Gas Pressure Range @ 100% Fire Rate Model Nominal Gas Pressure 3.9” W.C. ± 0.2” W.C. (0.97 kPa ± 0.05 kPa) BMK750P 7.6”...
  • Page 64 Benchmark with Edge [I]: Operation-Maintenance Manual 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 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 65 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions BMK2500 5.4% ± 0.2% <100 ppm <150 ppm 5.6% ± 0.2% <100 ppm <150 ppm 6.0% ± 0.2% <100 ppm <100 ppm 5.8% ± 0.2% <100 ppm <100 ppm 6.0% ±...

  • Page 66: Reassembly

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 4.5 REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation. Reassembly Instructions 1. Set the Enable/Disable switch in the Disable position. 2.

  • Page 67: Dual Fuel Switchover

    Benchmark with Edge [I]: Operation-Maintenance 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 SWITCH Figure 4-10: Dual Fuel Switch Switchover from NATURAL GAS to PROPANE Instructions 1.

  • Page 68: Over-Temperature Limit Switches

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 4.7 OVER-TEMPERATURE LIMIT SWITCHES The unit contains three (3) types of over-temperature limit controls. These controls consist of a Manual Reset button, a rotary adjustable Temperature Limit switch and a digital Over- Temperature Alarm button.

  • Page 69: Digital Alarm Switch Checks And Adjustments

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP DIGITAL OVER-TEMPERATURE LIMIT CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH (AUTO-REST) RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 4-11c: BMK5000-6000 Over-Temperature Limit Switch Location Digital Alarm Switch Checks and Adjustments 4.7.1 The Over-Temperature Alarm switch settings can be checked or adjusted using the controls and display on the front panel of the switch illustrated and described in Figure 4-12 and...
  • Page 70 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP Over-Temp Alarm Switch Check and Adjustment Instructions 5. Once the desired over-temperature alarm setting (210ºF) is displayed, press the SET button to store the setting in memory. 6. To calibrate the offset (P1), press and hold the SET button on the Over-Temperature Alarm switch for 8 seconds.

  • Page 71: Section 5. Safety Device Testing

    Benchmark with Edge [I]: Operation-Maintenance 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 72: Low Gas Pressure Test

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING 5.2 LOW GAS PRESSURE TEST Complete the instructions in Section 5.2.1 for BMK750 – 2500 units, or in Section 5.2.2 for BMK3000 – 6000 units, which have different Low and High Gas Pressure switches. LOW GAS PRESSURE TEST: BMK750 –...
  • Page 73 Benchmark with Edge [I]: Operation-Maintenance 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 74: Low Gas Pressure Test: Bmk3000 - 6000 Only

    Benchmark with Edge [I]: Operation-Maintenance 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.
  • Page 75 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 6000 Only Remove the cover from the Low Gas Pressure switch and set the dial indicator to 2 (the minimum). Open the external gas supply ball valve upstream of the unit. Main Menu →...
  • Page 76 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 6000 Only HIGH GAS PRESSURE SWITCH NATURAL GAS INLET SSOV MANUAL SHUT- OFF VALVE TO AIR/FUEL VALVE LOW GAS PRESSURE (P/N 22373-3 shown) SWITCH LOW Gas Pressure Port...
  • Page 77 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 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 78: High Gas Pressure Test

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING 5.3 HIGH GAS PRESSURE TEST Complete the instructions in Section 5.3.1 for BMK750 – 2500 units, or in Section 5.3.2 for BMK3000 – 6000 units, which have different High Gas Pressure switches. HIGH GAS PRESSURE TEST: BMK750 –...
  • Page 79 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK750 – 2500 TO AIR/FUEL MANUAL SHUT-OFF VALVE VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH (P/N 22322 shown) SSOV GAS INLET 1/4”...

  • Page 80: High Gas Pressure Test: Bmk3000 - 6000 Only

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK750 – 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 81 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY Main Menu → Diagnostics → Manual Mode On the Controller, go to: and then enable the Manual Mode control. Use the + (Plus) and –...
  • Page 82 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY HIGH Gas Pressure Port Install manometer here HIGH GAS for High Gas Pressure PRESSURE NATURAL test SWITCH GAS INLET SSOV MANUAL SHUT- OFF VALVE...
  • Page 83 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY NATURAL GAS HIGH GAS PRESSURE SWITCH - BMK6000 – 10.5” W.C., 2.6 kPa - BMK5000 – 11.0” W.C., 2.7 kPa NATURAL GAS HIGH Gas Pressure Port Install manometer here for High...

  • Page 84: Low Water Level Fault Test

    Benchmark with Edge [I]: Operation-Maintenance 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 Set the Controller’s Enable/Disable switch to Disable. Close the water shut-off valves in the supply and return piping to the unit.

  • Page 85: Water Temperature Fault Test

    Benchmark with Edge [I]: Operation-Maintenance 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. Allow the unit to stabilize at its setpoint. 2.

  • Page 86: Interlock Tests

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING Water Temperature Fault Test Instructions The unit should start once the adjustable Temperature Limit switch setting is above the actual outlet water temperature. OVER TEMPERATURE LIMIT DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH...

  • Page 87: Delayed Interlock Test

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING Delayed Interlock Test 5.6.2 Delayed Interlock Test Instructions 1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals. Main Menu → Diagnostics → Manual 2.

  • Page 88: Flame Fault Test

    Benchmark with Edge [I]: Operation-Maintenance 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 89: Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches

    Benchmark with Edge [I]: Operation-Maintenance 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.
  • Page 90 Benchmark with Edge [I]: Operation-Maintenance 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 – BMK5000 & 6000 Blower Proof Switch Test Instructions 1.

  • Page 91: Blocked Inlet Switch Test

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING Blocked Inlet Switch Test 5.8.2 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 Set the Controller’s Enable/Disable switch to Disable.

  • Page 92: Ssov Proof Of Closure Switch Check

    Benchmark with Edge [I]: Operation-Maintenance 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 Set the Controller’s Enable/Disable switch to Disable.

  • Page 93: Purge Switch Open During Purge

    Benchmark with Edge [I]: Operation-Maintenance 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 94 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING Purge Switch Open During Purge Check Instructions Purge Position Switch Ignition Position Switch TO BLOWER AIR IN Figure 5-11a: Air/Fuel Purge and Ignition Locations – BMK750/1000 TO BLOWER Ignition Position Switch VALVE...

  • Page 95: Ignition Switch Open During Ignition

    Benchmark with Edge [I]: Operation-Maintenance 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 – BMK5000 & 6000 5.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve.
  • Page 96 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING (This page intentionally blank) OMM-0145_A99 • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 9/18/2019 Page 96 of 157...

  • Page 97: Section 6. Standalone Modes Of Operation

    Benchmark with Edge [I]: Operation-Maintenance 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. Main Menu →...

  • Page 98: Outdoor Reset Mode Startup

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – MODES OF OPERATION Outdoor Reset Mode Startup 6.1.2 Startup in the Outdoor Reset mode is accomplished as follows: NOTE: It is required to have an outdoor sensor for the Outdoor reset. A header sensor or boiler supply sensor can be used depending on the plant configuration.

  • Page 99: Constant Setpoint Mode

    Benchmark with Edge [I]: Operation-Maintenance 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 100: Direct Drive Modes

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – MODES OF OPERATION To set the unit to Remote Setpoint mode: Remote Setpoint Mode Setup Instructions Main Menu →Advanced Setup → Unit →Application Configuration. 1. Go to 2. Press SH Operating Mode and choose Remote Setpt. 3.

  • Page 101: Aerco Control System (Acs)

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – MODES OF OPERATION Direct Drive Mode Setup Instructions 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. 6.5 AERCO CONTROL SYSTEM (ACS) NOTE: ACS is for installations with between 17 and 32 boilers.

  • Page 102: Combination Control System Field Wiring

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – MODES OF OPERATION 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.
  • Page 103 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – MODES OF OPERATION Combination Control System Setup Instructions 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.
  • Page 104 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – MODES OF OPERATION (This page intentionally blank) OMM-0145_A99 • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 9/18/2019 Page 104 of 157...

  • Page 105: Section 7. Boiler Sequencing Technology

    Benchmark with Edge [I]: Operation-Maintenance 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 [i] 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 106: Installation Notes

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Installation Notes 7.1.1 A ProtoNode is needed for all Protocols on BMK with EDGE[i] Controllers, including BACnet, Modbus. If your installation includes a ProtoNode SSD (Client-Client Device), you must adhere to the procedure listed below.

  • Page 107: Bst Implementation Instruction

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3 BST Implementation Instruction There are 8 BST implementation options, described below. The instructions for each refer to I/O board connections described in Section 2.11.1 in the Benchmark 750-6000 with Edge [i]: Install- Startup Manual (OMM-0144, GF-217).
  • Page 108 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 1 Instructions: Constant Setpoint with Direct Wired Header Temp Sensor Main Menu → Advanced Setup → BST Cascade → Application Configuration: 2. Go to: • Set the Unit Address parameter to the communication address of the unit. On the BST Manager only: Main Menu →...

  • Page 109: Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor 7.3.2 OPTION 2 Instructions: Constant Setpoint with Modbus Wired Header Temp Sensor Step 1: MODBUS HEADER TEMP SENSOR WIRING – ANY BOILER Using the Modbus Transmitter provides gives the plant the ability to use the Backup manager feature.
  • Page 110 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 2 Instructions: Constant Setpoint with Modbus Wired Header Temp Sensor On the BST Manager only: Main Menu → Advanced Setup → BST Cascade, 1. Go to set the Parameters to the Values in each menu in the table below.

  • Page 111: Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Sensor

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired 7.3.3 Outdoor Sensor OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Temp Sensor & Outdoor Sensor NOTE: Both Header Temp Sensor and Outdoor Sensor must be wired.
  • Page 112 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Temp Sensor & Outdoor Sensor Step 3 – OPTION 3 CONFIGURATION On All Boiler: Main Menu → Advanced Setup → BST Cascade → Cascade 1.

  • Page 113: Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor 7.3.4 Temp Sensor OPTION 4 Instructions: Outdoor Reset, Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor NOTE: Both Header Temp Sensor and Outdoor Sensor must be wired.
  • Page 114 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 4 Instructions: Outdoor Reset, Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor OUTDOOR TEMP SENSOR I/O BOARD MODBUS TRANSMITTER NOTES: • Polarity must be observed for the RS485 connections. •...
  • Page 115 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 4 Instructions: Outdoor Reset, Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor Outdoor Temp Sensor Network Sensor Comm Address Outdoor Temp Point Plant Setpoint Header temperature required for the cascade Min address The minimum unit address in the cascade Cascade Comm...

  • Page 116: Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20Ma Setpoint Drive

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20ma 7.3.5 Setpoint Drive OPTION 5 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, 4-20ma Setpoint Drive NOTE: Both Header Temp Sensor and 4-20ma Direct Drive must be wired.
  • Page 117 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 5 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, 4-20ma Setpoint Drive Step 3: OPTION 5 CONFIGURATION On All Boiler: Main Menu → Advanced Setup → BST Cascade → Cascade 1.

  • Page 118: Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus 7.3.6 Setpoint Drive OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, Modbus Setpoint Drive NOTE: Both Header Temp Sensor and Outdoor Sensor must be wired.
  • Page 119 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, Modbus Setpoint Drive NOTES: • Polarity must be observed for the RS485 connections. • Connect the shield to any SHLD terminal on the I/O Board. •...

  • Page 120: Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4-20Ma Setpoint Drive

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4-20ma 7.3.7 Setpoint Drive OPTION 7 Instructions: Remote Setpoint, Modbus Header Temp Sensor & 4-20ma Setpoint Drive NOTE: Both Header Temp Sensor and 4-20ma Direct Drive must be wired. See the Edge [i] Controller Manual (OMM-0141, GF-213-B) for more information.
  • Page 121 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 7 Instructions: Remote Setpoint, Modbus Header Temp Sensor & 4-20ma Setpoint Drive Step 3: OPTION 7 CONFIGURATION Using the Modbus Transmitter provides gives the plant the ability to use the Backup manager feature.

  • Page 122: Option 8 Remote Setpoint: Modbus Header Temp Sensor & Modbus Setpoint Drive

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY Option 8 Remote Setpoint: Modbus Header Temp Sensor & MODBUS 7.3.8 Setpoint Drive OPTION 8 Instructions: Remote Setpoint, Modbus Header Temp Sensor & Modbus Setpoint Drive HEADER TEMP SENSOR WIRING – ANY BOILER Step 1: MODBUS 1.
  • Page 123 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 8 Instructions: Remote Setpoint, Modbus Header Temp Sensor & Modbus Setpoint Drive Using the Modbus Transmitter provides gives the plant the ability to use the Backup manager feature. This allows the any of the client units to become a Backup manager if the manager unit is not communicating.
  • Page 124 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY (This page intentionally blank) OMM-0145_A99 • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 9/18/2019 Page 124 of 157...

  • Page 125: Section 8. Maintenance

    Benchmark with Edge [I]: Operation-Maintenance 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 126: Igniter-Injector - Bmk750 - 4000

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE TABLE 8-2b: 24 Month Maintenance Kits Parts Serviced/Replaced – Includes all 12 Month Parts Model Kit# Doc Name 58025-08 Burner & Blower gaskets, LWCO, air filter replacement 750/1000 TID-0100 58025-17 Burner &...
  • Page 127 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE IGNITER- INJECTOR BLOWER ASSEMBLY PLENUM SENSOR FLAME DETECTOR BURNER FLAME OBSERVATION PORT Figure 8-1b: Igniter-Injector & Flame Detector (BMK1500/3000) BLOWER PLENUM SENSOR FLAME DETECTOR IGNITOR-INJECTOR ASSEMBLY FLAME OBSERVATION PORT BURNER Figure 8-1c: Igniter-Injector &...

  • Page 128: Pilot Ignition Rod - Bmk5000 & 6000

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.3 PILOT IGNITION ROD – BMK5000 & 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 129: O 2 Sensor

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE removing the flame detector. Be sure to use the current model flame detector, included in the maintenance kit; some older flame detectors are shaped differently and may not function properly. This part and instructions are included in both 12 Month Maintenance Kit P/N 58025-01 (BMK750 –3000) and P/N 58025-11 (BMK5000 &...

  • Page 130: Air Eductor Air Pump Maintenance - Bmk5000 & 6000

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE Lean O Sensor Maintenance Instructions 1. Set the Edge [i] Controller’s Enable/Disable switch 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 131: Safety Device Testing

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE Air Pump Maintenance and Troubleshooting Instructions Sensor Cover to the unit’s back panel. 3. Reattach the O GAS SUCTION LINE TO EXHAUST MANIFOLD AIR FILTER COVER BRACKET (Hangs on opening in back panel) Figure 8-4: Air Eductor Assembly –...
  • Page 132 Benchmark with Edge [I]: Operation-Maintenance 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 – BMK750/1000 BLOWER GASKET (P/N 81184) 3/8”-16...
  • Page 133 Benchmark with Edge [I]: Operation-Maintenance 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 134: Condensate Drain Trap

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.8 CONDENSATE DRAIN TRAP All Benchmark boilers contain a condensate trap (P/N 24441), located external to the unit, attached to the exhaust manifold’s drain at the rear of the unit. This trap must be inspected for leaks and blockages, cleaned to ensure that the float is free to move, and condensate flows normally, and the O-Ring (P/N 84017 included in all 24 Month Maintenance Kits) replaced if it is worn or damaged.

  • Page 135: Air Filter Cleaning And Replacement

    Benchmark with Edge [I]: Operation-Maintenance 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 136: Rear Refractory Replacement

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE Rear Refractory Replacement 8.10.1 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 137 Benchmark with Edge [I]: Operation-Maintenance 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 138: Front Refractory Replacement

    Benchmark with Edge [I]: Operation-Maintenance 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 139: Shutting Boiler Down For Extended Period

    Benchmark with Edge [I]: Operation-Maintenance 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 140 Benchmark with Edge [I]: Operation-Maintenance 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 are functioning properly. Check for scratches in the finish which will allow corrosion or rust to form Rotate wheel a minimum of 10 full revolutions to...

  • Page 141: Returning The Boiler To Service After Shutdown

    Benchmark with Edge [I]: Operation-Maintenance 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 142: Recommended Periodic Testing

    Benchmark with Edge [I]: Operation-Maintenance 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 143 Benchmark with Edge [I]: Operation-Maintenance 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: Edge [i] Controller Operation in Operating controls Annually Operator...

  • Page 144: Recommended Spares

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.14 RECOMMENDED SPARES NOTE: Refer to the parts list illustrations in the Benchmark 750-6000 With Edge [I]: Install- Startup Manual (OMM-0144, GF-217) for the locations of the parts listed below. For a list of 12- and 24-Month Maintenance Kits, see Section 8.1: Maintenance Schedule.

  • Page 145: Section 9. Troubleshooting

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING SECTION 9. TROUBLESHOOTING 9.1 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 146 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blower stopped running due to Check combustion blower for signs of thermal or current overload. excessive heat or high current drain that may trip thermal or current overload devices.
  • Page 147 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blower not running or running Start the unit. If the blower does not run check too slow. the blower solid state relay for input and output voltage.
  • Page 148 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Delayed Interlock Jumper not Check to insure jumper is properly installed properly installed or missing. across the Delayed Interlock terminals in the I/O Box.
  • Page 149 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Worn Flame Detector or Remove and inspect the Flame Detector for cracked ceramic. signs of wear or cracked ceramic. Replace if necessary.
  • Page 150 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action TEMP Check PID settings (Advanced Setup → Incorrect PID settings. SWITCH Performance → Temperature Control, first 3 OPEN items). If the settings have been changed, record the current readings then reset to default values.
  • Page 151 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Switch wired incorrectly. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). If the switch is wired correctly, replace the switch.
  • Page 152 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action OUT OF Incorrect power supply Check transformer wiring, in AC Power Box, PHASE transformer wiring. against the power box transformer wiring diagram to ensure it is wired correctly.
  • Page 153 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective Power Supply Board Check DS1 & DS2 LEDs on Power Supply or fuse. Board. If they are not steady ON, replace Power Supply Board.
  • Page 154 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Check DIP switch on PMC board to ensure it is Edge [i] Controller signal type selection switches not set for set correctly for the type of signal being sent.

  • Page 155: Additional Faults Without Specific Fault Messages

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Incorrectly wired switch. Ensure that the SSOV Proof of Closure switch is correctly wired. Air/Fuel Valve unplugged. Check that the Air/Fuel Valve is connected to the Edge [i] Controller.
  • Page 156 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING downstream SSOV Actuator). DAMPING ORIFICE BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 9-1: SSOV Actuator with Gas Pressure Adjustment (SKP25) OMM-0145_A99 • GF-218 • Technical Support •...
  • Page 157 Benchmark with Edge [I]: Operation-Maintenance Manual Change Log: Date Description Changed By 9/18/2019 Rev A: Initial release (internal reference DIR 19-50 and 19-46) © AERCO International, Inc., 2019 OMM-0145_A99 • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 9/18/2019 Page 157 of 157...

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