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
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-20-1800 and above – BMK750 – 5000N
N-20-0125 and above – BMK5000 & 6000
Disclaimer
The information contained in this manual is subject to change without notice
from AERCO International, Inc. AERCO makes no warranty of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or
consequential damages occurring in connection with the furnishing,
performance, or use of these materials.
• GF-218 •
OMM-0145_D
11/2/2020
®
Boilers
[i] Controller
Heating and Hot Water Solutions
AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913
USA: T: (845) 580-8000 • Toll Free: (800) 526-0288 • AERCO.com
Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST
© 2020 AERCO

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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 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.
  • Page 3 Benchmark with Edge [I]: Operation-Maintenance Manual CONTENTS 5.2 LOW GAS PRESSURE TEST ......................74 5.2.1 Low Gas Pressure Test: BMK750 – 2500 ......................74 5.2.2 Low Gas Pressure Test: BMK3000 – 6000 Only....................76 5.3 HIGH GAS PRESSURE TEST ......................80 5.3.1 High Gas Pressure Test: BMK750 –...
  • Page 4 Benchmark with Edge [I]: Operation-Maintenance Manual CONTENTS 8.4 O SENSOR 135 8.4.1 Air Eductor Air Pump Maintenance – BMK5000 & 6000 ................136 8.5 SAFETY DEVICE TESTING ....................... 137 8.6 BURNER INSPECTION ........................137 8.7 CONDENSATE DRAIN TRAP ......................140 8.8 AIR FILTER CLEANING AND 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 Please consult the Benchmark Venting and Combustion Air Design Guide (TAG-0022, GF- 2050) for a list of allowable and preferred vent materials. 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 with Edge [I]: Operation-Maintenance Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING 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) I.D.
  • Page 8 Benchmark with Edge [I]: Operation-Maintenance Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING 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 Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref) Reference...

  • 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 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_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 30 of 213...

  • 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 HIGH GAS PRESSURE SWITCH SSOV MANUAL LOW GAS AIR/FUEL SHUT-OFF PRESSURE VALVE VALVE SWITCH Figure 3-1c: BMK2500/3000: SSOV Location (P/N 22190 shown) NATURAL GAS INLET HIGH GAS PRESSURE SWITCH...
  • Page 34 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Start Sequence HIGH GAS PRESSURE SWITCH TO AIR/FUEL VALVE DOWNSTREAM SSOV WITH P.O.C. MANUAL SHUT- OFF VALVE UPSTREAM SSOV LOW GAS PRESSURE SWITCH GAS INLET Figure 3-1e: BMK5000-6000: SSOV Location (P/N 22330-1 shown) 3.
  • 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. Benchmark 750/1000 Air/Fuel Valve Position and Energy Input 3.4.1 TABLE 3-2a: BMK750/1000 Air/Fuel Valve Position –...

  • Page 41: Benchmark 1500 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 1500 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)

  • Page 42: Benchmark 2000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 2000 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)

  • Page 43: Benchmark 2500 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 2500 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: Benchmark 3000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 3000 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)

  • Page 45: Benchmark 4000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 4000 Air/Fuel Valve Position and Energy Input 3.4.6 TABLE 3-7a: 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...

  • Page 46: Benchmark 5000N Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 5000N Air/Fuel Valve Position and Energy Input 3.4.7 TABLE 3-8a: BMK5000N Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 256,000 6.5%...

  • Page 47: Benchmark 5000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 5000 Air/Fuel Valve Position and Energy Input 3.4.8 TABLE 3-9a: BMK5000 Air/Fuel Valve Position and Energy Input AIR/FUEL VALVE ENERGY INPUT BOILER ENERGY INPUT POSITION (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 18% (Stop Level) 400,000...

  • Page 48: Benchmark 6000 Air/Fuel Valve Position And Energy Input

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 3 - START SEQUENCE Benchmark 6000 Air/Fuel Valve Position and Energy Input 3.4.9 TABLE 3-10a: BMK6000 Air/Fuel Valve Position and Energy Input AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 18% (Stop Level) 385,000...

  • 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 Gas Supply Manometer Installation Instructions BMK5000 - 6000 1.

  • Page 54: Accessing The Analyzer Probe Port

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

  • Page 55: Benchmark 5000 & 6000 Pilot Flame Ignition

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 4.3 BENCHMARK 5000 & 6000 PILOT FLAME IGNITION Benchmark 5000 and 6000 boilers are equipped with an interrupted pilot ignition system. The pilot is ignited by a spark discharge within the Pilot Burner inside the combustion chamber. The input. of the Pilot flame is approximately 18,000 BTU/hr.

  • Page 56: Natural Gas Manual Combustion Calibration

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP IT IS IMPORTANT TO PERFORM THE COMBUSTION CALIBRATION PROCEDURE BELOW TO PROVIDE OPTIMUM PERFORMANCE AND KEEP READJUSTMENTS TO A MINIMUM. BRASS HEX HEAD (Remove to access Gas Pressure Adjustment Screw). TAC SCREW Figure 4-3: Gas Pressure Adjustment Screw and TAC Screw Location WARNING:...
  • Page 57 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP Figure 4-4: First Manual Combustion Calibration Screen 7. Connect the gas pressure manometer to the upstream side of the gas train’s SSOV (see Section 4.2.2) and connect the Combustion Analyzer and Multimeter (per Section 4.2.3) and ensure that the heating loop is capable of dissipating sufficient heat at full fire.
  • Page 58 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions FINE VALVE POSITION CONTROLS PRE-SET CALIBRATION STEPS Figure 4-6: Manual Combustion Calibration Screens 12. Set the Controller’s Enable/Disable switch to Enable. 13. Change the valve position to 30%, press the Go button, then verify that the unit has ignited and is operating as expected.
  • Page 59 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 60 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions 22. On Benchmark 3000 - 6000 units only, record the manifold (downstream) gas pressure at 100%. This value will be used in Section 5.2.2: Low Pressure Gas Test, and Section 5.3.2: High Pressure Gas Test.
  • Page 61 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions TABLE 4-3c: NATURAL GAS Final Valve Positions: BMK1500/2000 Duel Fuel BMK1500 BMK2000 Valve % ≤20 ppm 6.0% ± 0.2% 6.5% ± 0.2% <100 ppm ≤20 ppm 6.3% ±...
  • Page 62 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: BMK4000/5000N Dual Fuel Standard NO Ultra-Low NO Valve Position ≤20 ppm ≤9 ppm 5.5% ± 0.2% 6.0% ±...

  • Page 63: Propane Gas Combustion Calibration

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE GAS Combustion Calibration 4.5.2 These instructions apply only to units running PROPANE gas. PROPANE Combustion Calibration Instructions 1. Set the Edge [i] Controller’s Enable/Disable switch to Disable. 2. Open the water supply and return valves to the unit and ensure that the system pumps are running.
  • Page 64 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 11. The main Manual Combustion Calibration screen appears. It provides two methods to ramp the unit’s valve position up or down: • Method 1: Toggle through the pre-set calibration points till you reach the desired valve position, then press Go to go to that point (left image below).
  • Page 65 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE 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 66 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 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 67 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions Valve Position Oxygen (O Nitrogen Oxide (NOx) Carbon Monoxide (CO) BMK2500 5.4% ± 0.2% <100 ppm <150 ppm 5.6% ± 0.2% <100 ppm <150 ppm 6.0% ±...

  • Page 68: Reassembly

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions BMK6000 5.5% ± 0.5% <100 ppm <150 ppm 5.5% ± 0.5% <100 ppm <150 ppm 5.5% ± 0.5% <100 ppm <150 ppm 5.5% ± 0.5% <100 ppm <150 ppm 6.0% ±...

  • Page 69: Dual Fuel Switchover

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP 4.7 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 70 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 4 – INITIAL START-UP The adjustable Temperature Limit switch is manually adjustable from 32ºF - 212ºF (0ºC – 100ºC). This switch allows the boiler to restart, once the temperature drops below the selected temperature setting on the dial.

  • Page 71: 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 4.8.1 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 72 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 73: 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 74: 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 75 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH SSOV (P/N 22140-1 shown) GAS INLET 1/4” NPT PLUG Install manometer here for LOW gas LOW GAS PRESSURE pressure fault test.

  • Page 76: Low Gas Pressure Test: Bmk3000 - 6000 Only

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING NATURAL GAS INLET HIGH GAS PRESSURE SWITCH SSOV (P/N 22190 shown) LOW GAS MANUAL AIR/FUEL PRESSURE SHUT-OFF VALVE SWITCH VALVE 1/4” NPT PLUG Install manometer here for LOW gas pressure fault test.
  • Page 77 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 6000 Only →____ x 0.5 + 6.0 = ______ min gas pressure FM Natural Gas pressure LGP * Natural Gas pressure →____ x 0.5 + 0.9 = ______ min gas pressure BMK5000 →____ x 0.5 + 3.7 = ______ min gas pressure Propane Gas pressure...
  • Page 78 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 6000 Only NATURAL HIGH GAS GAS INLET PRESSURE SWITCH SSOV MANUAL SHUT- AIR/FUEL VALVE OFF VALVE LOW GAS PRESSURE SWITCH LOW Gas Pressure Port Install manometer here for Low Gas Pressure test (P/N 22373-3 shown)
  • Page 79 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 HIGH GAS PRESSURE SWITCH Low Gas Pressure Test Port Install manometer here (P/N 22330-1 shown) LOW GAS PRESSURE SWITCH Figure 5-2c: BMK6000 LOW and HIGH Gas Pressure Test Components...

  • Page 80: 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 81 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK750 – 2500 TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH SSOV 1/4” NTP PLUG (Install manometer here (P/N 22140-1 shown) for High Gas Pressure Test) GAS INLET...

  • Page 82: 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 GAS INLET HIGH GAS PRESSURE 1/4” NPT PLUG SWITCH (install manometer here for HIGH GAS PRESSURE FAULT TEST) SSOV HIGH GAS BALL VALVE LOW GAS...
  • Page 83 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY Open the external gas supply ball valve upstream of the unit. Main Menu → Diagnostics → Manual Mode On the Controller, go to: and then enable the Manual Mode control.
  • Page 84 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY NATURAL GAS INLET HIGH GAS PRESSURE PORT Install manometer here for High Gas Pressure test SSOV AIR/FUEL MANUAL VALVE SHUT-OFF VALVE LOW GAS...
  • Page 85 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY AIR/FUEL VALVE MANUAL SHUT- OFF VALVE HIGH Gas Pressure Port Install manometer here for High Gas Pressure test DOWNSTREAM SSOV WITH POC SWITCH (P/N 22330-1 shown)

  • Page 86: 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 87: 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 88: 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 89: 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 90: 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 91: 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 92 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 93: 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 94: 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 95: 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 96 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 97: 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 98 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 5 – SAFETY DEVICE TESTING (This page intentionally blank) OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 98 of 213...

  • Page 99: Section 6. Standalone Modes Of Operation

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 100: Outdoor Reset Mode Startup

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 101: Constant Setpoint Mode

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 102: Direct Drive Modes

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 103: Aerco Control System (Acs)

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 104: Combination Control System Field Wiring

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 105 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE 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 106 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 6 – STANDALONE MODES OF OPERATION (This page intentionally blank) OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 106 of 213...

  • Page 107: 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 108: 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 109: 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 in the Benchmark 750-6000 with Edge [i]: Install- Startup Manual (OMM-0144, GF-217).
  • Page 110 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 1 Instructions: Constant Setpoint with Direct Wired Header Temp Sensor SD-A-1010 rev C OPTION 1 Step 3: CONFIGURATION On All Boilers: Main Menu → Advanced Setup → BST Cascade → Cascade Configuration 1.

  • Page 111: 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 OPTION 2 Step 1: MODBUS HEADER TEMP SENSOR WIRING – ANY BOILER Using the Modbus Transmitter gives the plant the ability to use the Backup manager feature.
  • Page 112 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 2 Instructions: Constant Setpoint with Modbus Wired Header Temp Sensor SD-A-1012 rev C Step 3: CONFIGURATION On All Boilers: Main Menu → Advanced Setup → BST Cascade → Cascade Configuration 1.
  • Page 113 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 1. Go to Cascade, set the Parameters to the Values in each menu in the table below.

  • Page 114: 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 115 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Temp Sensor & Outdoor Sensor OPTION 3 Step 3 –DAISY CHAIN WIRING BETWEEN BOILERS 1. Connect the boilers in a daisy chain, as shown below. SD-A-1010 rev C OPTION 3 Step 4 –CONFIGURATION On All Boilers:...
  • Page 116 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Temp Sensor & Outdoor Sensor On the BST Manager only: Main Menu → Advanced Setup → BST 1. Go to Cascade, set the Parameters to the Values in each menu in the table below.

  • Page 117: 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 118 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 NOTES: • Polarity must be observed for the RS485 connections. • Ground the shield at any SHLD terminal in the I/O the Board. •...
  • Page 119 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 OPTION 4 Step 4 –CONFIGURATION Using the Modbus Transmitter gives the plant the ability to use the Backup manager feature.

  • Page 120: 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 121 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 SD-A-1010 rev C OPTION 5 Step 4: OPTION 5 CONFIGURATION On All Boilers: Main Menu → Advanced Setup → BST Cascade → Cascade Configuration Go to: and set the Unit Mode parameter to BST Client.

  • Page 122: Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive (Via Protonode)

    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 (via ProtoNode) OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, Modbus Setpoint Drive via ProtoNode NOTE: Both Header Temp Sensor and Outdoor Sensor must be wired.
  • Page 123 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 via ProtoNode OPTION 6 Step 3 – DAISY CHAIN WIRING BETWEEN BOILERS 1. Connect the boilers in a daisy chain, as shown below. SD-A-1011 rev E NOTES: •...
  • Page 124 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 via ProtoNode OPTION 6 Step 4 – CONFIGURATION On All Boilers: Main Menu → Advanced Setup → BST Cascade → Cascade Configuration Go to: set the Unit Mode parameter to BST Client.

  • Page 125: 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 126 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 OPTION 7 Step 3: CONNECT BOILERS IN DAISY CHAIN Connect the boilers in a daisy chain, as shown below. SD-A-1012 rev C OPTION 7 Step 4: OPTION 7 CONFIGURATION Using the Modbus Transmitter gives the plant the ability to use the Backup manager...
  • Page 127 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 On the BST Manager only: Main Menu → Advanced Setup → BST 1. Go to Cascade, set the Parameters to the Values in each menu in the table below.

  • Page 128: Option 8 Remote Setpoint: Modbus Header Temp Sensor & Modbus Setpoint Drive Via Protonode

    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 via ProtoNode OPTION 8 Instructions: Remote Setpoint, Modbus Header Temp Sensor & Modbus Setpoint Drive HEADER TEMP SENSOR WIRING –...
  • Page 129 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 8 Instructions: Remote Setpoint, Modbus Header Temp Sensor & Modbus Setpoint Drive SD-A-1013 rev D OPTION 8 Step 4: CONFIGURATION On All Boilers: Main Menu → Advanced Setup → BST Cascade → Cascade 1.
  • Page 130 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 gives the plant the ability to use the Backup manager feature. This allows any of the client units to become a Backup manager if the manager unit is not communicating.

  • Page 131: 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 132: Igniter-Injector - Bmk750 - 5000N

    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 133 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 (BMK1500/2000) BLOWER PLENUM SENSOR FLAME DETECTOR IGNITOR-INJECTOR ASSEMBLY FLAME OBSERVATION PORT BURNER Figure 8-1c: Igniter-Injector &...

  • Page 134: Pilot Ignition Rod - Bmk5000 & 6000

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE Pilot Ignition Rod – BMK5000 & 6000 8.2.1 The Benchmark 5000 and 6000 Pilot Burner (P/N 66026) is mounted to the Burner’s front plate. It should be inspected every 12 months and replaced every 24 months, or if damaged or warped.

  • Page 135: O 2 Sensor

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.4 O SENSOR The Lean Oxygen Sensor (P/N 61026) should be cleaned and inspected every 12 months. It is not included in any of the 12- or 24-month maintenance kits. On BMK750 –...

  • Page 136: Air Eductor Air Pump Maintenance - Bmk5000 & 6000

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE Lean O Sensor Maintenance Instructions 4. Next, loosen and remove the O sensor and crush washer from the burner plate using a 15/16" open-end wrench. 5. Thoroughly inspect the O sensor.

  • Page 137: Safety Device Testing

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1, require that these tests be performed on a scheduled basis.
  • Page 138 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE BLOWER GASKET (P/N 81184) 3/8”-16 HEX NUTS (8 each) BURNER PLATE A/F VALVE PLENUM 1/2” NUTS & BOLTS (4 ea.) AIR FILTER (P/N 59138) Figure 8-5b: BMK1500/2000 Burner Assembly Mounting Details BLOWER GASKET BLOWER PLENUM (P/N 81157)
  • Page 139 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE BURNER GASKETS (2) (P/N 81159) 3/8” HEX NUTS/WASHERS (8 EA.) BLOWER TO AIR-FUEL VALVE O-RING (P/N 88016) AIR/FUEL VALVE BURNER BLOWER FLANGE BLOWER Figure 8-5d: Burner Assembly Exploded View – BMK5000 & 6000 OMM-0145_D •...

  • Page 140: Condensate Drain Trap

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.7 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 141: Air Filter Cleaning And Replacement

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.8 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 142: Shutting Boiler Down For Extended Period

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.10 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 143 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 144: Returning The Boiler To Service After Shutdown

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.11 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 145 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE TABLE 8-3: Recommended Periodic Testing ITEM FREQUENCY ACTION BY REMARKS Check for leakage in accordance with the SSOV SSOV Leakage test Annually Service Tech manufacturer’s (Siemens) recommendations. Close manual gas shutoff valve and check Flame failure Weekly Operator...

  • Page 146: Recommended Spares

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 8 – MAINTENANCE 8.13 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 147: 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 148 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 149 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 150 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 151 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 152 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 153 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 154 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 155 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Check “Heartbeat” LED DS1 and verify it is Defective IGST Board. blinking ON & OFF every second. If not, replace IGST Board. Defective Purge switch.
  • Page 156 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action FLAME Check open/close indicator window of Safety SSOV not fully closed. Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator.
  • Page 157 Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective Air/Fuel Valve Replace stepper motor. stepper motor. Defective Power Supply Board Check DS1 & DS2 LEDs on Power Supply or fuse.

  • Page 158: Additional Faults Without Specific Fault Messages

    Benchmark with Edge [I]: Operation-Maintenance Manual SECTION 9 – TROUBLESHOOTING 9.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 9-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 9-2: Boiler Troubleshooting with No Fault Message Displayed Observed Probable Causes Corrective Action...

  • Page 159: Appendix A: Wiring Schematics

    Benchmark with Edge [I]: Operation-Maintenance Manual APPENDIX A: WIRING SCHEMATICS Benchmark 750/1000 – Drawing Number: 68038 rev H Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 159 of 213...
  • Page 160 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 750/1000 – Drawing Number: 68038 rev H Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 160 of 213...
  • Page 161 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 750/1000 – Drawing Number: 68080 rev B Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 161 of 213...

  • Page 162: A-2: Benchmark 2500 - 3000 Schematics

    Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 750/1000 – Drawing Number: 68080 rev B Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 162 of 213...
  • Page 163 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 750 – 1000 – Drawing Number: 68090 rev B Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 163 of 213...
  • Page 164 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 750 – 1000 – Drawing Number: 68090 rev B Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 164 of 213...
  • Page 165 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68050 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 165 of 213...

  • Page 166: A-3: Benchmark 4000 - 5000N Schematics

    Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68050 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 166 of 213...
  • Page 167 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68071 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 167 of 213...
  • Page 168 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68071 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 168 of 213...
  • Page 169 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68064 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 169 of 213...
  • Page 170 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68064 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 170 of 213...
  • Page 171 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68068 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 171 of 213...
  • Page 172 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68068 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 172 of 213...
  • Page 173 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68088 rev C Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 173 of 213...
  • Page 174 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 1500 – 2000 – Drawing Number: 68088 rev C Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 174 of 213...
  • Page 175 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68041 rev G Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 175 of 213...
  • Page 176 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68041 rev G Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 176 of 213...
  • Page 177 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68040 rev G Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 177 of 213...
  • Page 178 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68040 rev G Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 178 of 213...
  • Page 179 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68063 rev C Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 179 of 213...
  • Page 180 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68063 rev C Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 180 of 213...
  • Page 181 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68062 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 181 of 213...
  • Page 182 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68062 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 182 of 213...
  • Page 183 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68044 rev E Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 183 of 213...
  • Page 184 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68044 rev E Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 184 of 213...
  • Page 185 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68045 rev E Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 185 of 213...
  • Page 186 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68045 rev E Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 186 of 213...
  • Page 187 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68046 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 187 of 213...
  • Page 188 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68046 rev E Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 188 of 213...
  • Page 189 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68047 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 189 of 213...
  • Page 190 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68047 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 190 of 213...
  • Page 191 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68074 rev A Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 191 of 213...
  • Page 192 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 2500 – 3000 – Drawing Number: 68074 rev A Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 192 of 213...
  • Page 193 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 4000/5000N Drawing Number: 68102 rev B Sheet 1 of 4 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 193 of 213...
  • Page 194 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 4000/5000N Drawing Number: 68102 rev B Sheet 2 of 4 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 194 of 213...
  • Page 195 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 4000/5000N Drawing Number: 68102 rev B Sheet 3 of 4 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 195 of 213...
  • Page 196 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 4000/5000N Drawing Number: 68102 rev B Sheet 4 of 4 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 196 of 213...
  • Page 197 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68043 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 197 of 213...
  • Page 198 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68043 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 198 of 213...
  • Page 199 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68048 rev D Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 199 of 213...
  • Page 200 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68048 rev D Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 200 of 213...
  • Page 201 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68052 rev C Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 201 of 213...
  • Page 202 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68052 rev C Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 202 of 213...
  • Page 203 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68053 rev C Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 203 of 213...
  • Page 204 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68053 rev C Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 204 of 213...
  • Page 205 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68076 rev C Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 205 of 213...
  • Page 206 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68076 rev C Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 206 of 213...
  • Page 207 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68077 rev B Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 207 of 213...
  • Page 208 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68077 rev B Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 208 of 213...
  • Page 209 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68098 rev A Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 209 of 213...
  • Page 210 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68098 rev A Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 210 of 213...
  • Page 211 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68099 rev A Sheet 1 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 211 of 213...
  • Page 212 Benchmark with Edge [I]: Operation-Maintenance Manual Benchmark 5000/6000 Drawing Number: 68099 rev A Sheet 2 of 2 OMM-0145_D • GF-218 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 11/2/2020 Page 212 of 213...

  • Page 213: Technical Support • (800) 526-0288 • Mon-Fri, 8 Am - 5 Pm Est

    Benchmark with Edge [I]: Operation-Maintenance Manual Change Log: Date Description Changed By Rev B: Added Appendix A: Wiring Schematics Replaced gas train graphics in Section 3.2, 5.2 and 5.3. Linley Corrected location of Outdoor Air and Air Temp Sensor terminal Thobourne &...

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