Watts Aerco Benchmark OMM-0124 Installation And Start-Up Manual
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Watts Aerco Benchmark OMM-0124 Installation And Start-Up Manual

Natural gas, propane gas and dual fuel fired modulating & condensing boilers
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Installation and Startup Manual
Benchmark
Natural Gas, Propane Gas and Dual Fuel
Fired Modulating & Condensing Boilers
Models 5000 and 6000
Other documents for this product include:
OMM-0124, GF-208 Operation-Service Manual
TAG-0019, GF-2070 Boiler Application Guide
TAG-0022, GF-2050 Vent-Combustion Air Guide
TAG-0047, GF-2030 Benchmark Gas Guide
TAG-0048, GF-2060 Benchmark Power Guide
Applies to serial numbers:
N-19-0001 and above
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
OMM-0123_E • GF-207 • 12/17/2019
Boilers
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Summary of Contents for Watts Aerco Benchmark OMM-0124

  • Page 1 Installation and Startup Manual Benchmark Boilers ® Natural Gas, Propane Gas and Dual Fuel Fired Modulating & Condensing Boilers Models 5000 and 6000 Other documents for this product include: OMM-0124, GF-208 Operation-Service Manual TAG-0019, GF-2070 Boiler Application Guide TAG-0022, GF-2050 Vent-Combustion Air Guide TAG-0047, GF-2030 Benchmark Gas Guide TAG-0048, GF-2060 Benchmark Power Guide Applies to serial numbers:...

  • Page 2: Table Of Contents

    Benchmark 5000-6000 Boiler Installation & Startup 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: INSTALLATION ................
  • Page 3 Benchmark 5000-6000 Boiler Installation & Startup Manual CONTENTS 3.1 INTRODUCTION ........................... 37 3.2 START SEQUENCE ..........................37 3.3 START/STOP LEVELS ......................... 42 3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT ..............42 3.4.1 Benchmark 5000 Air/Fuel Valve Position and Energy Input ............42 3.4.2 Benchmark 6000 Air/Fuel Valve Position and Energy Input ............
  • Page 4 Benchmark 5000-6000 Boiler Installation & Startup Manual CONTENTS 6.3.3 OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor ................................. 81 6.3.4 OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor ..... 83 6.3.5 OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma Setpoint Drive ..

  • Page 5: Foreword

    Benchmark 5000-6000 Boiler Installation & Startup Manual FORWARD FOREWORD AERCO Benchmark (BMK) 5000 MBH (1465 kW) and 6000 MBH (1758 kW) natural gas and dual fuel propane/natural gas fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns.
  • Page 6 Benchmark 5000-6000 Boiler Installation & Startup Manual FORWARD AERCO Technical Terminology TERMINOLOGY MEANING A (Amp) Ampere AERCO Control System, AERCO’s boiler management systems ADDR Address AGND Analog Ground ALRM Alarm ANSI American National Standards Institute, ASME American Society of Mechanical Engineers Auxiliary Building Automation System, often used interchangeably with EMS (see below)
  • Page 7 Benchmark 5000-6000 Boiler Installation & Startup Manual FORWARD AERCO Technical Terminology TERMINOLOGY MEANING 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 the C-More Controller INTLK (INTL’K) Interlock Input/Output...
  • Page 8 Benchmark 5000-6000 Boiler Installation & Startup Manual FORWARD AERCO Technical Terminology TERMINOLOGY MEANING P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater Poly Vinyl Chloride, a common synthetic plastic Pulse Width Modulation REF (Ref) Reference RES.

  • Page 9: Safety Precautions

    Benchmark 5000-6000 Boiler Installation & Startup 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 5000-6000 Boiler Installation & Startup Manual SECTION 1: SAFETY PRECAUTIONS 1.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off, close the manual gas 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 5000-6000 Boiler Installation & Startup 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 5000-6000 Boiler Installation & Startup 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: Installation

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION SECTION 2: INSTALLATION 2.1 INTRODUCTION This section provides the descriptions and procedures necessary to unpack, inspect and install the AERCO 5000 and 6000 Benchmark boilers. 2.2 RECEIVING THE UNIT Each Benchmark boiler is shipped as a single crated unit. The shipping weight for the BMK 5000 and 6000 models is approximately 3500 pounds (1588 kg).

  • Page 14: Site Preparation

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION Figure 2-1: Benchmark 5000/6000 Mounted on Shipping Skid 2.4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark boiler includes access to: • One of the following AC Input Power: o 208 VAC, Three-Phase, 60 Hz @ 30 Amps o 460 VAC, Three-Phase, 60 Hz @ 20 Amps o 575 VAC, Three-Phase, 60 Hz @ 20 Amps...
  • Page 15 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION NOTE: Benchmark 5000 and 6000 units may be installed with zero side clearances in pairs only. The perimeter clearances still apply (see Figure 2-2 and the drawings in Appendix A: Dimensional Drawings).

  • Page 16: Setting The Unit

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION WARNING! Keep the unit area clear and free from all combustible materials and flammable vapors or liquids FOR MASSACHUSETTS ONLY: For Massachusetts installations, the unit must be installed by a plumber or gas-fitter licensed within the Commonwealth of Massachusetts.

  • Page 17: Lifting Provisions

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.4.3 LIFTING PROVISIONS Two (2) lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2- 4. The location of the lifting tabs is marked on the shrink-wrap coving the unit for shipping. Remove the four (4) lag screws securing the unit to the shipping skid, and, if still in place, remove the front Top Panel.
  • Page 18 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION When connecting the hot water outlet and cold water inlet to building piping, first make sure the mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the mating surfaces and then Loctite 567 as pipe dope.

  • Page 19: Pressure Relief Valve Installation

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.6 PRESSURE RELIEF VALVE INSTALLATION Depending on the pressure required, Benchmark 5000 and 6000 boilers are supplied with an ASME rated Pressure Relief Valves. The pressure relief valve supplied with the boiler must be installed to meet code and safety requirements.

  • Page 20: Condensate Drain And Piping

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION CORRECT LOCATION Typically located 6” to 18” (15 to 46 cm) from the boiler outlet connection 2-7: Pressure/Temperature Gauge Installation Location Figure 2.8 CONDENSATE DRAIN and PIPING The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore, the installation must have provisions for suitable condensate drainage or collection.
  • Page 21 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION • The trap must be removable for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port. While observing the above guidelines, install the condensate trap as follows: Condensate Drain Installation Instructions 1.

  • Page 22: Gas Supply Piping

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.9 GAS SUPPLY PIPING AERCO’s Benchmark Gas Components and Supply Design Guide, TAG-0047 (GF-2030) must be consulted prior to designing or installing any gas supply piping. WARNING! NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.
  • Page 23 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION • The external natural gas regulator must be capable of regulating 300,000 – 6,000,000 BTU/Hr (88 – 1758 kW) of natural gas while maintaining a minimum gas pressure of 14” W.C. (3.49 kPa) to the unit. •...

  • Page 24: Ac Electrical Power Wiring

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION PROPANE PRESSURE REGULATOR MINIMUM 10 PIPE DIAMETERS IN LENGTH DRIP LEG NATURAL GAS PRESSURE REGULATOR 2” MANUAL GAS SHUT-OFF VALVE NATURAL GAS SUPPLY DRIP LEG Figure 2-10b: Manual Gas Shut-Off Valve Location – Dual Fuel Shown 2.10 AC ELECTRICAL POWER WIRING For electrical power requirements and wiring diagrams for Benchmark Platinum 5000 and –...
  • Page 25 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION POWER BOX FRONT COVER FRONT UPPER-RIGHT CORNER OF UNIT Figure 2-11: Power Box with Closed Cover WIRE CONDUITS POWER BREAKER TRANSFORMER 24V POWER SUPPLY 12V POWER SUPPLY TERMINAL BLOCKS FUSE BLOCKS (2) Figure 2-12: Power Box Internal Components (Cover Removed) The Power Box contains terminal blocks as shown in Figure 2-12.

  • Page 26: Field Control Wiring

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.11 FIELD CONTROL WIRING Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the C-More Controller used with all Benchmark units does allow for some additional control and monitoring features.

  • Page 27: Outdoor Air & Air Sensor Common

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION Outdoor Air Remote Intl’k OUT Air Sensor Common Remote Intl’k IN Air Temp Sensor Sensor – NOT USED Not Used Delayed Intl’k OUT Spark Signal + Delayed Intl’k IN Spark Signal – Not Used Sensor + Not Used...

  • Page 28: Air Temp Sensor

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.11.2 AIR TEMP SENSOR The AIR TEMP SENSOR terminal is used to monitor the air inlet temperature sensor (P/N 123449). This input is always enabled and is a “view only” input in the AIR TEMP setting in the Operating menu (see Section 2.4: OPERATING Menu, item 4, of the Benchmark 5000 –...

  • Page 29: Shield (Shld & Shld)

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION (b) If the valve fails with the Valve Stuck Closed fault, the “Valve Stuck Closed” message will be displayed and the unit will shut down. NOTE: If the Valve Feedback option is used, Shorting Jumper MUST be inserted on JP2 on the I/O Board (see Figure 2-14, above).

  • Page 30: Fault Relay (Nc, Com, & No)

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION NOTE: Both the Delayed Interlock and Remote Interlock must be in the closed position for the unit to fire. 2.11.12.1 Remote Interlock In (OUT & IN) The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit if desired.

  • Page 31: Flue Gas Vent Installation

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.12 FLUE GAS VENT INSTALLATION AERCO’s Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification.

  • Page 32: Combustion Air

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.13 COMBUSTION AIR The Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) MUST be consulted before any flue or inlet air venting is designed or installed. Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes.
  • Page 33 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION POWER BOX PUMP RELAY Figure 2-15: Pump Relay Location (Orange) – N/O The Benchmark pump relay (SPDT) contact is rated for: (Yellow) - COM 10 A Resistive @ 277 VAC/28 VDC Pump Relay Terminals 1/3 HP N/O @ 120/240 VAC 1/6 HP N/C @ 120/240 VAC...

  • Page 34: Sequencing Isolation Valve Installation

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION 2.15 SEQUENCING ISOLATION VALVE INSTALLATION All Benchmark units are pre-wired with a connection for an optional motorized external sequencing isolation valve (P/N 92084-TAB). This valve is an integral component of AERCO’s on-board Boiler Sequencing Technology (BST) solution.
  • Page 35 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION Sequencing Isolation Valve Installation Instructions 1. Install the sequencing isolation valve in the boiler’s hot water outlet pipe (Figure 2-18). SEQUENCING ISOLATION VALVE HOT WATER OUTLET Figure 2-18: Sequencing Isolation Valve Installed 2.
  • Page 36 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 2: INSTALLATION (This page intentionally blank) OMM-0123_E • GF-207 • 12/17/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 36 of 95...

  • Page 37: Start Sequence

    Benchmark 5000-6000 Boiler Installation & Startup 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 C- More Controller, which is mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • Page 38 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE When there is a demand for heat, the following events will occur: Start Sequence 1. The DEMAND LED status indicator will light. 2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed.
  • Page 39 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE Start Sequence 4. Next, the blower proof switch on the Air/Fuel Valve (Figure 3-3) closes. The display will show PURGING and indicate the elapsed time of the purge cycle in seconds. BLOCKED INLET SWITCH BLOWER...
  • Page 40 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE Start Sequence 6. Once the spark cleaning period is finished and ignition relay 1 (R1) closes, power is supplied to the SSOVs and the following events occur in 7 seconds: a.
  • Page 41 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE BMK 5000 & 6000 Function Timing Chart For Proved Pilot Control System Operating State C-More Pre-purge PFEP MFEP Standby T = 0 T = 30 T = 37 T = 44 Component PFEP MFEP...

  • Page 42: Start/Stop Levels

    Benchmark 5000-6000 Boiler Installation & Startup 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: BMK 5000/6000 Start/Stop Levels for Natural Gas Start Level: Stop Level:...

  • Page 43: Benchmark 6000 Air/Fuel Valve Position And Energy Input

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE 3.4.2 Benchmark 6000 Air/Fuel Valve Position and Energy Input BMK 6000 Air/Fuel Valve Position and Energy Input Air Fuel Valve Boiler Energy Input Position % of Full (% Full Open) BTU/Hr Capacity 18% (Stop Level)

  • Page 44: Boiler Energy Input Charts

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE 3.5 Boiler Energy Input Charts Boiler Energy Input BMK 5000 5,000,000 4,000,000 3,000,000 2,000,000 Input Rate 1,000,000 Air/Fuel Valve Position (% Open) Figure 3-5: Relationship Between BMK 5000 Air/Fuel Valve Position and Energy Input Boiler Energy Input BMK 6000 Figure 3-6: Relationship Between BMK 6000 Air/Fuel Valve Position and Energy...
  • Page 45 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE Figure 3-7: Burner Ignition Sequence Flow Chart OMM-0123_E • GF-207 • 12/17/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 45 of 95...
  • Page 46 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 3: START SEQUENCE (This page intentionally blank) OMM-0123_E • GF-207 • 12/17/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 46 of 95...

  • Page 47: Initial Start-Up

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP SECTION 4: INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark boiler consists of the following: • Complete the installation (Section 2: Installation, above) •...

  • Page 48: Tools & Instruments For Combustion Calibration

    Benchmark 5000-6000 Boiler Installation & Startup 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 49: Accessing The Analyzer Probe Port

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration (in Section 4.5.1 and/or 4.5.2, below), install the 16” W.C. (4.0 kPa) manometer(s) as described in the following steps: Gas Supply Manometer Installation Instructions 1.

  • Page 50: Pilot Ignition

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.3 PILOT 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 51: Combustion Calibration

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.5 COMBUSTION CALIBRATION The Benchmark boiler was combustion calibrated with either standard combustion (NO emissions of <20 ppm) or Ultra-Low NO <9 ppm) at the factory prior to shipping, depending on which was ordered.
  • Page 52 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP NATURAL GAS Combustion Calibration Instructions 8. Ensure that the leak detection ball valve downstream of the SSOV is open and the manometer is attached and functioning properly. 9. Set the ON/OFF switch to the ON position. 10.
  • Page 53 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP NATURAL GAS Combustion Calibration Instructions 20. Compare the measured oxygen level to the oxygen range shown in Table 4-2. Also, ensure that the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the values shown in Table 4-2.
  • Page 54 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP NATURAL GAS Combustion Calibration Instructions 29. Repeat steps 21 through 25 for valve positions shown in Table 4-3a and 4-3b. The O NOx and CO should stay within the ranges shown in the Tables. TABLE 4-3a: NATURAL GAS Final Valve Positions: BMK 5000 Standard NO Ultra-Low NO...

  • Page 55: Propane Gas Combustion Calibration

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.5.2 PROPANE GAS COMBUSTION CALIBRATION These instructions apply only to units running PROPANE gas. Instructions for doing combustion calibration on a unit running Natural Gas appear in the previous section, 4.5.1. PROPANE Combustion Calibration Instructions 1.
  • Page 56 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP PROPANE Combustion Calibration Instructions 16. Press the Down▼ arrow key until SET Valve Position appears on the display, then press CHANGE. 17. Press the Up ▲ arrow key until the SET Valve Position reads 100%, then press ENTER. 18.
  • Page 57 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP PROPANE Combustion Calibration Instructions NOTE: Remaining combustion calibration steps are performed using the Combustion Cal menu in the C-More Controller. The combustion calibration control functions will be used to adjust the oxygen level (%) at valve position percentages described in the steps below.

  • Page 58: Reassembly

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.6 REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation. Reassembly Instructions 1. Set the ON/OFF switch in the OFF position. 2.

  • Page 59: Switchover From Natural Gas To Propane

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.7.1 Switchover from NATURAL GAS to PROPANE Switchover from NATURAL GAS to PROPANE Instructions 1. Set the ON/OFF switch on the C-More Controller to the OFF position. 2. Close the external Natural Gas supply valves. 3.

  • Page 60: Switchover From Propane To Natural Gas

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.7.2 Switchover from PROPANE to NATURAL GAS Switchover from PROPANE NATURAL GAS Instructions 1. Set the ON/OFF switch on the C-More Controller to the OFF position. 2. Close the external Propane Gas supply valves. 3.

  • Page 61: Over-Temperature Limit Switches

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP 4.8 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 62 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 4: INITIAL START-UP TABLE 4-6: Over-Temperature Alarm Switch Controls and Display CONTROL/DISPLAY MEANING FUNCTION Displays current water temperature or setpoint. LED Display TEMP status Resets the unit after an alarm condition. RESET Button Increases the displayed temperature.

  • Page 63: Safety Device Testing

    Benchmark 5000-6000 Boiler Installation & Startup 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 64 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions 7. Open the external gas supply ball valve upstream of the unit. 8. Place the unit in MANUAL mode and adjust the Air/Fuel Valve position (% open) to 100%. 9.

  • Page 65: High Gas Pressure Test

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.3 HIGH GAS PRESSURE TEST To simulate a high gas pressure fault perform the following steps: HIGH Gas Pressure Test Instructions 1. Shut off the external gas supply by closing the external gas supply ball valve. 2.
  • Page 66 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions 12. Press the CLEAR button on the Control Panel to clear the fault. 13. Upon test completion, remove the manometer, and turn the NATURAL GAS High Gas Pressure Switch port screw clockwise until port is closed.

  • Page 67: Low Water Level Fault Test

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: LOW Water Fault Test Instructions 1. Set the ON/OFF switch to the OFF position. 2.

  • Page 68: Water Temperature Fault Test

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the automatic Over-Temperature switch. This switch is accessible from the front of the unit as shown in Figure 5-4, below. Water Temperature Fault Test Instructions 1.

  • Page 69: Interlock Tests

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2-14) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.

  • Page 70: Flame Fault Test

    Benchmark 5000-6000 Boiler Installation & Startup 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 71: Blower Proof Switch Test

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.8.1 Blower Proof Switch Test Complete the test below to check the operation of the Blower Proof switch shown in Figure 5-5. Blower Proof Switch Test Instructions 1. Set the Controller’s On/Off switch to Off. 2.

  • Page 72: Blocked Inlet Switch Test

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.8.2 Blocked Inlet Switch Test This test will be run in simulated fire mode, with the Blocked Inlet switch isolated from the rest of the control circuitry. Blocked Inlet Switch Test Instructions 1.

  • Page 73: Ssov Proof Of Closure Switch Check

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.9 SSOV PROOF OF CLOSURE SWITCH CHECK The SSOV, shown in Figure 5-8, contains the Proof of Closure switch. The Proof of Closure switch circuit is checked as follows: SSOV Proof Of Closure Switch Check Instructions 1.

  • Page 74: Purge Switch Open During Purge

    Benchmark 5000-6000 Boiler Installation & Startup 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 75: Ignition Switch Open During Ignition

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING TO BLOWER PURGE STEPPER POSITION MOTOR SWITCH DIAL IGNITION POSITION SWITCH AIR IN Figure 5-10: Air/Fuel Valve Purge and Ignition Switch Locations 5.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve.

  • Page 76: Safety Pressure Relief Valve Test

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 5: SAFETY DEVICE TESTING 5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. OMM-0123_E • GF-207 • 12/17/2019 Technical Support •...

  • Page 77: Boiler Sequencing Technology

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.1 INTRODUCTION The Boiler Sequencing Technology system (BST) is built into the C-More Controller. BST is an integrated 8 boiler control system. It has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 8 boilers while achieving maximum operational efficiency.

  • Page 78: Installation Notes

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.1.1 Installation Notes If you are installing a BST system that also includes a ProtoNode SSD (Client-Client Device), you must adhere to the procedure listed below. Failure to complete these steps can result in the failure of the BST system.

  • Page 79: Bst Implementation Instruction

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3 BST Implementation Instruction 6.3.1 OPTION 1 - Constant Setpoint With Direct Wired Header Sensor OPTION 1 - Constant Setpoint With Direct Wired Header Sensor Instructions Step 1: Direct Wired Header Sensor Wiring On the MANAGER Unit, Connect the Header Temperature Sensor (P/N 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled Header Temp sensor in the I/O Box.

  • Page 80: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.2 OPTION 2 - Constant Setpoint With Modbus Wired Header Sensor OPTION 2 - Constant Setpoint With Modbus Wired Header Sensor Instructions Step 1: MODbus Header Sensor Wiring Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler...

  • Page 81: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.3 OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor Instructions NOTE: Both Header Sensor AND Outdoor Sensor must be wired.
  • Page 82 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor Instructions Step 3 - Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration menu and set the BST Menu item to Enabled. 2.

  • Page 83: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.4 OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor Instructions NOTE: Both Header Sensor AND Outdoor Sensor must be wired.
  • Page 84 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor Instructions NOTES: • Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD”...

  • Page 85: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.5 OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma Setpoint Drive OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma Setpoint Drive Instructions NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired.
  • Page 86 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma Setpoint Drive Instructions Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration menu and set the BST Menu item to Enabled. 2.

  • Page 87: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.6 OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive Instructions NOTE: Both Header Sensor AND Outdoor Sensor must be wired.
  • Page 88 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive Instructions NOTES: • Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD”...

  • Page 89: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.7 OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma Setpoint Drive OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma Setpoint Drive Instructions NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired.
  • Page 90 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma Setpoint Drive Instructions Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration menu and set the BST Menu item to Enabled. 2.

  • Page 91: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY 6.3.8 OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive Instructions NOTE: Both Header Sensor AND ProtoNode SSD Device must be wired.
  • Page 92 Benchmark 5000-6000 Boiler Installation & Startup Manual SECTION 6: BOILER SEQUENCING TECHNOLOGY OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive Instructions Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration menu and set the BST Menu item to Enabled. 2.

  • Page 93: Appendix A: Dimensional And Clearance Drawings

    Benchmark 5000-6000 Boiler Installation & Startup Manual APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS Appendix A: Dimensional and Clearance Drawings Drawing Number: AP-A-1047 rev A OMM-0123_E • GF-207 • 12/17/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 93 of 95...
  • Page 94 Benchmark 5000-6000 Boiler Installation & Startup Manual APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number: SD-A-919 rev F OMM-0123_E • GF-207 • 12/17/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 94 of 95...
  • Page 95 Benchmark 5000-6000 Boiler Installation & Startup Manual Change Log: Date Description Changed By Rev D: DIR 18-55: Changed Air Inlet Temp Sensor part number from 61024 to 123449 in Section 2.11.2. (Reference PIR 1542) DIR 18-61: Updated Blower Proof Switch Test, Section 5.8.1. DIR-19-04: Added additional requirements to Section 1.2: Emergency Shutdown.

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