Watts AERCO Benchmark OMM-0136 Operation And Service Manual
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Watts AERCO Benchmark OMM-0136 Operation And Service Manual

Natural gas, propane gas and dual fuel modulating & condensing boilers
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Operation and Service Manual
Benchmark
with Edge [ii] Controller
Natural Gas, Propane Gas and Dual Fuel
Modulating & Condensing Boilers
Models 750 through 6000
Other documents for this product include:
OMM-0136, GF-210 210 Installation and Startup Manual
OMM-0138, GF-212 Reference Manual
OMM-0139, GF-213 Edge Controller Manual
TAG-0019, GF-2070 Boiler Application Guide
TAG-0022, GF-2050 Vent-Combustion Air Guide
TAG-0047, GF-2030 Benchmark Gas Guide
TAG-0048, GF-2060 Benchmark Power Guide
Applies to serial numbers:
G-19-0300 and above – BMK750 – 4000
N-19-0100 and above – BMK5000 & 6000
OMM-0137_E • GF-211 • 12/13/2019
®
Platinum Boilers

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Summary of Contents for Watts AERCO Benchmark OMM-0136

  • Page 1 Operation and Service Manual ® Benchmark Platinum Boilers with Edge [ii] Controller Natural Gas, Propane Gas and Dual Fuel Modulating & Condensing Boilers Models 750 through 6000 Other documents for this product include: OMM-0136, GF-210 210 Installation and Startup Manual OMM-0138, GF-212 Reference Manual OMM-0139, GF-213 Edge Controller Manual TAG-0019, GF-2070 Boiler Application Guide...

  • Page 2: Table Of Contents

    Benchmark Platinum-Edge [II]: Operation-Service Manual CONTENTS Table of Contents TABLE OF CONTENTS ................... 2 FOREWORD ...................... 5 SECTION 1: SAFETY PRECAUTIONS ..............9 1.1 WARNINGS & CAUTIONS ........................9 1.2 EMERGENCY SHUTDOWN ......................... 10 1.3 PROLONGED SHUTDOWN ......................... 10 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ............... 11 SECTION 2: EDGE CONTROLLER OPERATION ..........
  • Page 3 Benchmark Platinum-Edge [II]: Operation-Service Manual CONTENTS 5.2.2 LOW GAS PRESSURE TEST: BMK3000 – 6000 Only ..................58 5.3 HIGH GAS PRESSURE TEST ......................62 5.3.1 HIGH GAS PRESSURE TEST: BMK750 – 2500 ....................62 5.3.2 HIGH GAS PRESSURE TEST: BMK3000 – 6000 Only ..................64 5.4 LOW WATER LEVEL FAULT TEST .....................
  • Page 4 Benchmark Platinum-Edge [II]: Operation-Service Manual CONTENTS 8.6 SAFETY DEVICE TESTING ....................... 111 8.7 BURNER INSPECTION ........................111 8.8 CONDENSATE DRAIN TRAP ......................114 8.9 AIR FILTER CLEANING AND REPLACEMENT ................115 8.10 REFRACTORY REPLACEMENT – BMK5000 & 6000 ONLY ................115 8.10.1 Rear Refractory Replacement ........................

  • Page 5: Foreword

    Benchmark Platinum-Edge [II]: Operation-Service Manual FORWARD FOREWORD The AERCO Benchmark (BMK) 750 through 6000 natural gas and propane fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
  • Page 6 Benchmark Platinum-Edge [II]: Operation-Service Manual FORWARD o Horizontal Discharge These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In addition, the BMK750 & 1000 models are also approved for PVC and CPVC, vent systems (excluding the state of Massachusetts). The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration.
  • Page 7 Benchmark Platinum-Edge [II]: Operation-Service Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING A control system developed by AERCO and currently used in all Edge Controller Benchmark Platinum boilers. Energy Management System; often used interchangeably with BAS Factory Mutual. Used to define boiler gas trains. GF-xxxx Gas Fired (an AERCO document numbering system) Ground...
  • Page 8 Benchmark Platinum-Edge [II]: Operation-Service Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING PMC Board Primary Micro-Controller (PMC) board, contained in the Edge Part Number Proof of Closure Parts per Million Pounds per Square Inch (1 PSI = 6.89 kPa) Point-to-Point (usually over RS232 networks) P&T Pressure and Temperature ProtoNode...

  • Page 9: Section 1: Safety Precautions

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS SECTION 1: SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.

  • Page 10: Emergency Shutdown

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS 1.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off, close the manual shutoff valve (Figure 1- 1) located external to the unit. NOTE: The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

  • Page 11: Important - For Massachusetts Installations

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS Requirements for Massachusetts Installations Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements: • Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
  • Page 12 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 1: SAFETY PRECAUTIONS Requirements for Massachusetts Installations 4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

  • Page 13: Section 2: Edge Controller Operation

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 2: OPERATION SECTION 2: EDGE CONTROLLER OPERATION 2.1 INTRODUCTION This section provides a brief outline of how to gain access to Benchmark Boiler’s Edge Controller functionality. Full instructions for using the Edge Controller to setup, configure and operate a Benchmark Boiler are included in the Edge Controller Manual.

  • Page 14: Login And Password Entry

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 2: OPERATION 2.2 Login and Password Entry The Edge 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: Section 3: Start Sequence

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE SECTION 3: START SEQUENCE 3.1 INTRODUCTION The information in this section provides a guide to starting the Benchmark Boiler using the Edge Controller. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • Page 16 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence 1. The Controller’s red DEMAND LED status indicator will light. 2. The unit checks all five pre-purge safety switches listed at the beginning of this section. The Edge Controller’s ignition sequence screen walks you through the ignition screens and demonstrates (or highlights) which switches are not met.
  • Page 17 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence NATURAL GAS INLET SSOV AIR/FUEL LOW GAS VALVE MANUAL PRESSURE SHUT-OFF SWITCH VALVE Figure 3-1c: BMK2500: SSOV Location (P/N 22318 shown) NATURAL GAS INLET AIR/FUEL SSOV VALVE MANUAL LOW GAS SHUT-OFF VALVE PRESSURE...
  • Page 18 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence UPSTREAM DOWNSTREAM SSOV SSOV WITH TO AIR/FUEL VALVE MANUAL SHUT- OFF VALVE GAS INLET HIGH GAS UPSTREAM LOW GAS PRESSURE SWITCH PRESSURE SWITCH - BMK6000: 10.5” W.C., 2.6 kPa - BMK6000: 8.5”...
  • Page 19 Benchmark Platinum-Edge [II]: Operation-Service 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 20 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence Figure 3-4a: BMK750 & 1000 Blower Proof Switch 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.
  • Page 21 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE Start Sequence TO BLOWER STEPPER MOTOR IGNITION VALVE POSITION DIAL AT 25% to 35% AIR IN Figure 3-5: Air/Fuel Valve in Ignition Position 7. Up to 4 seconds are allowed for ignition to be detected. The ignition circuit is turned off one second after flame is detected.
  • Page 22 Benchmark Platinum-Edge [II]: Operation-Service 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 C-More Controller...

  • Page 23: Start/Stop Levels

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.3 START/STOP LEVELS The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows: TABLE 3-1a: Start/Stop Levels –...

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

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT The Tables below show the relationship between the energy input and Air/Fuel Valve position for the BMK models covered in this document. 3.4.1 BMK750/1000 Air/Fuel Valve Position and Energy Input TABLE 3-2a: BMK750/1000 Air/Fuel Valve Position –...

  • Page 25: Bmk1500 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.2 BMK1500 Air/Fuel Valve Position and Energy Input TABLE 3-3a: BMK1500 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 16% (Stop Level) 75,000 (22.3 kW) 5.0%...

  • Page 26: Bmk2000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.3 BMK2000 Air/Fuel Valve Position and Energy Input TABLE 3-4a: BMK2000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR) (% OF FULL CAPACITY) 18% (Stop Level) 100,000 (29.3 kW) 5.7%...

  • Page 27: Bmk2500 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.4 BMK2500 Air/Fuel Valve Position and Energy Input 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) 167,000 (48.9 kW)

  • Page 28: Bmk3000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.5 BMK3000 Air/Fuel Valve Position and Energy Input TABLE 3-6a: BMK3000 Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR.) (% OF FULL CAPACITY) 14% (Stop Level) 200,000 (58.6 kW) 6.7%...

  • Page 29: Bmk4000 Air/Fuel Valve Position And Energy Input

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

  • Page 30: Benchmark 5000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.7 Benchmark 5000 Air/Fuel Valve Position and Energy Input BMK5000 Air/Fuel Valve Position and Energy Input Air Fuel Valve Boiler Energy Input Position % of Full (% Full Open) BTU/Hr Capacity 18% (Stop Level) 400,000...

  • Page 31: Benchmark 6000 Air/Fuel Valve Position And Energy Input

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE 3.4.8 Benchmark 6000 Air/Fuel Valve Position and Energy Input BMK6000 Air/Fuel Valve Position and Energy Input Air Fuel Valve Boiler Energy Input Position % of Full (% Full Open) BTU/Hr Capacity 18% (Stop Level) 385,000...
  • Page 32 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 3 - START SEQUENCE (This page intentionally blank) OMM-0137_E • GF-211 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 12/13/2019 Page 32 of 153...

  • Page 33: Section 4: Initial Start-Up

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP SECTION 4: INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The following are the prerequisites for the initial start-up of the Benchmark boiler: • Complete the installation per the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210), including gas supply piping, vent installation and condensate drain piping.

  • Page 34: Tools & Instruments For Combustion Calibration

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP 4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION To properly perform combustion calibration, the proper instruments and tools must be used and correctly attached to the unit. The following sections outline the necessary tools and instrumentation as well as their installation.
  • Page 35 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP TO AIR/FUEL VALVE MANUAL SHUT- OFF VALVE SSOV 1/4” NTP PLUG (Install manometer here for 1/4” NTP PLUG downstream combustion calibration reading) (Install manometer here for upstream combustion calibration reading) LEAK DETECTION BALL VALVE LEAK DETECTION BALL VALVE NATURAL GAS INLET...
  • Page 36 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS INLET HIGH GAS PRESSURE SWITCH 1/4” NPT PLUG (Install manometer here for downstream combustion calibration SSOV reading) LEAK DETECTION LOW GAS BALL VALVE PRESSURE SWITCH AIR/FUEL VALVE LEAK DETECTION BALL VALVE MANUAL SHUT- OFF VALVE...
  • Page 37 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP DOWNSTREAM HIGH GAS SSOV WITH POC PRESSURE SWITCH SWITCH TO AIR/FUEL VALVE LOW GAS MANUAL PRESSURE SWITCH SHUT-OFF VALVE UPSTREAM LEAK DETECTION BALL VALVE Figure 4-1e: Port Location for Combustion Calibration – BMK4000 TO AIR/FUEL VALVE MANUAL...

  • Page 38: Accessing The Analyzer Probe Port

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP 4.2.3 Accessing the Analyzer Probe Port Benchmark units contain a 1/4” NPT port on the side of the exhaust manifold, as shown in Figure 4-2. Prepare the port for the combustion analyzer probe as follows: Analyzer Probe Port Access Instructions 1.

  • Page 39: Natural Gas Manual Combustion Calibration

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation. 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...
  • Page 40 Benchmark Platinum-Edge [II]: Operation-Service 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 then 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 41 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions PRE-SET CALIBRATION CONTROLS FINE VALVE POSITION CONTROLS PRESET CALIBRATION POINTS METHOD FINE VP STEP METHOD Figure 4-6: Manual Combustion Calibration Screens 12. Set the Controller’s Enable/Disable switch to Enable. 13.
  • Page 42 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions 17. Compare the combustion analyzer’s oxygen (O ) reading to the O value in the Reading column (Figure 4-6). If they differ, go to the Main Menu → Calibration → Input/Output → O2 Sensor screen and adjust the O2 Offset parameter, up to ±3%, to make the on-board sensor match the value from the combustion analyzer.
  • Page 43 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions • Enter the Flame Strength, NOx and CO readings from the Combustion Analyzer and multi-meter in the Manual Combustion Calibration screen’s Reading column. • Enter the same values, plus the O value, on the Combustion Calibration Data Sheet provided with the unit.
  • Page 44 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions BMK2000 Dual Fuel Units ≤20 ppm 6.5% ± 0.2% <100 ppm ≤20 ppm 6.5% ± 0.2% <100 ppm ≤20 ppm 6.5% ± 0.2% <50 ppm ≤20 ppm 6.5% ±...

  • Page 45: Propane Gas Combustion Calibration

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP NATURAL GAS Manual Combustion Calibration Instructions TABLE 4-3g: NATURAL GAS Final Valve Positions: BMK6000, Single & DF Valve Position Standard NO Ultra-Low NO Single Dual Fuel Fuel ≤9 ppm 5.5% ± 0.5% <20 ppm 6.0% ±...
  • Page 46 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP Figure 4-7: First Manual Combustion Calibration Screen 7. Connect the gas pressure manometer to the upstream side of the gas train’s SSOV, as shown in Section 4.2.2 and connect the Combustion Analyzer and Multimeter, as shown in Section 4.2.3, and ensure that the heating loop is capable of dissipating sufficient heat at full fire.
  • Page 47 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions PRE-SET CALIBRATION CONTROLS VALVE POSITION CONTROLS PRESET CALIBRATION POINTS METHOD FINE VP STEP METHOD Figure 4-9: Manual Combustion Calibration Screens 12. Set the Controller’s Enable/Disable switch to Enable. 13.
  • Page 48 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions value in the Target and Reading columns. If they don’t match, adjust the 18. Compare the O value in both columns match; use either the + or – controls, or Blower Voltage until the O press on the field and type the value directly.
  • Page 49 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions • BMK5000DF & 6000DF: 85% 25. Repeat step 17, 18 and 21 at that valve position and the rest of the valve positions in Table Table 4-6a and 4-6b, depending on model. The O , NOx and CO should stay within the ranges shown in these tables.

  • Page 50: Reassembly

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP PROPANE Combustion Calibration Instructions TABLE 4-6b: PROPANE Final Valve Positions: BMK5000 & 6000 Valve Position Nitrogen Oxide Carbon Oxygen (O Monoxide (CO) Single-Fuel Dual-Fuel BMK5000 5.5% ± 0.5% <100 ppm <150 ppm 5.5% ±...
  • Page 51 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP Reassembly Instructions 6. Replace all previously removed sheet metal enclosures on the unit. This concludes reassembly of the unit after combustion calibration. OMM-0137_E • GF-211 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 12/13/2019 Page 51 of 153...

  • Page 52: Dual Fuel Switchover

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP 4.6 DUAL FUEL SWITCHOVER All Benchmark Dual Fuel models contain a fuel selector switch, located to the right of the I/O board, behind the front panel. FUEL SELECTOR I/O BOARD SWITCH and cover Figure 4-10: Dual Fuel Switch...

  • Page 53: Over-Temperature Limit Switches

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP 4.7 OVER-TEMPERATURE LIMIT SWITCHES The unit contains two configurable over-temperature limit controls, positioned behind the unit’s front panel, under the Edge Controller: • Automatic Reset: If the unit’s operating temperature exceeds the limit set on the switch, the unit goes into an alarm mode and shuts the unit down.

  • Page 54: Resetting The Manual Reset Limit Switch

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 4 – INITIAL START-UP Temperature Adjustment Instructions INCREASE TEMPERATURE DECREASE TEMPERATURE Figure 4-12: Auto-Reset Over-Temperature Limit Switch 4.7.2 Resetting the Manual Reset Limit Switch Perform the following steps to rest the Manual Reset Limit Switch after it has gone into Alarm mode, and after the temperature has fallen at least 10 degrees below the limit.

  • Page 55: Section 5: Safety Device Testing

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING SECTION 5: SAFETY DEVICE TESTING 5.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion- related safety devices before, during and after the start sequence.

  • Page 56: Low Gas Pressure Test

    Benchmark Platinum-Edge [II]: Operation-Service 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. 5.2.1 LOW GAS PRESSURE TEST: BMK750 –...
  • Page 57 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING TO AIR/FUEL VALVE (P/N 22322 shown) MANUAL SHUT-OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH SSOV GAS INLET 1/4” NPT PLUG Install manometer LOW GAS PRESSURE here for LOW gas LEAK DETECTION BALL VALVE pressure fault test.

  • Page 58: Low Gas Pressure Test: Bmk3000 - 6000 Only

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING NATURAL HIGH GAS PRESSURE GAS INLET SWITCH (P/N 22190 shown) SSOV LOW GAS PRESSURE AIR/FUEL VALVE SWITCH MANUAL SHUT-OFF VALVE 1/4” NPT PLUG Install manometer here for LOW gas pressure fault test.
  • Page 59 Benchmark Platinum-Edge [II]: Operation-Service 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 BMK5000 & →____ x 0.5 + 3.7 = ______ min gas pressure 6000 Propane Gas pressure 6.
  • Page 60 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 6000 Only Figure 5-2a: LOW and HIGH Gas Pressure Test Components – BMK3000 Shown HIGH GAS PRESSURE NATURAL SWITCH GAS INLET SSOV MANUAL SHUT- OFF VALVE TO AIR/FUEL...
  • Page 61 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING LOW Gas Pressure Test Instructions: BMK3000 – 6000 Only MANUAL SHUT-OFF VALVE AIR/FUEL VALVE NATURAL GAS Low Gas Pressure Test Port Install manometer here Alternative location PROPANE Low Gas Pressure Test Port Install manometer here Dual Fuel gas train showing both Natural Gas and...

  • Page 62: High Gas Pressure Test

    Benchmark Platinum-Edge [II]: Operation-Service 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. 5.3.1 HIGH GAS PRESSURE TEST: BMK750 –...
  • Page 63 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK750 – 2500 14. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4" NPT plug removed in step 2. TO AIR/FUEL MANUAL SHUT-OFF VALVE...

  • Page 64: High Gas Pressure Test: Bmk3000 - 6000 Only

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK750 – 2500 NATURAL HIGH GAS PRESSURE GAS INLET 1/4” NPT SWITCH PLUG (install manometer here for HIGH SSOV PRESSURE FAULT TEST) HIGH GAS LOW GAS BALL VALVE PRESSURE...
  • Page 65 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY 7. On the Controller, go to: Main Menu → Diagnostics → Manual Run and then enable the Manual Mode control. 8.
  • Page 66 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY HIGH Gas Pressure Port Install manometer here HIGH GAS for High Gas Pressure PRESSURE test NATURAL SWITCH GAS INLET LEAK DETECTION BALL VALVE MANUAL SHUT- OFF VALVE...
  • Page 67 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING HIGH Gas Pressure Test Instructions: BMK3000 – 6000 ONLY Alternative location for manometer if hose NATURAL GAS HIGH GAS barb is preferred PRESSURE SWITCH - BMK6000 – 10.5” W.C., 2.6 kPa - BMK5000 –...

  • Page 68: Low Water Level Fault Test

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: LOW Water Fault Test Instructions 1. Set the Controller’s Enable/Disable switch to Disable. 2.

  • Page 69: Water Temperature Fault Test

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

  • Page 70: Interlock Tests

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.6 INTERLOCK TESTS The unit is equipped with three interlock circuits, called the Remote Interlock, and Delayed Interlock. These circuits are connected to the I/O board’s connector strip J6, labeled Remote Interlock, Delayed Interlock 1 and Delayed Interlock 2 (see Section 2.11.1: I/O Board Connections in the Benchmark Platinum-Edge: INSTALLATION Manual (GF-210).

  • Page 71: Flame Fault Test

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.7 FLAME FAULT TEST Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: Flame Fault Test Instructions 1.

  • Page 72: Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5-6a, 5-6b and 5-6c. 5.8.1 Blower Proof Switch Test BLOWER PROOF...
  • Page 73 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING BLOCKED INLET SWITCH BLOWER PROOF SWITCH HEX SCREWS HOLDING WYE DUCT TO A/F VALVE MANUAL SHUT- (1 OF 3) OFF VALVE Figure 5-6c: Blower Proof & Blocked Inlet Switch Locations – BMK5000 & 6000 Blower Proof Switch Test Instructions 1.

  • Page 74: Blocked Inlet Switch Test

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.8.2 Blocked Inlet Switch Test This test will be run in simulated fire mode, with the Blocked Inlet switch isolated from the rest of the control circuitry. Blocked Inlet Switch Test Instructions 1.

  • Page 75: Ssov Proof Of Closure Switch Check

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.9 SSOV PROOF OF CLOSURE SWITCH CHECK The SSOV, shown in Figure 5-9, contains the Proof of Closure switch. The Proof of Closure switch circuit is checked as follows: SSOV Proof of Closure Switch Check Instructions 1.

  • Page 76: Purge Switch Open During Purge

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING 5.10 PURGE SWITCH OPEN DURING PURGE The Purge switch (and Ignition switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Purge Switch Open During Purge Check Instructions 1.
  • Page 77 Benchmark Platinum-Edge [II]: Operation-Service 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 POSITION DIAL...

  • Page 78: Ignition Switch Open During Ignition

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 5 – SAFETY DEVICE TESTING Purge Switch Open During Purge Check Instructions TO BLOWER PURGE POSITION SWITCH DIAL IGNITION POSITION SWITCH AIR IN Figure 5-11c: Air/Fuel Purge and Ignition Locations – BMK5000 & 6000 5.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve.

  • Page 79: Section 6: Standalone Modes Of Operation

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION SECTION 6: STANDALONE MODES OF OPERATION The descriptions and instructions in this chapter apply to Standalone units only; the unit cannot be a BST Client or BST Manager. For instructions on configuring BST modes of operation, see Chapter 7: Boiler Sequencing Technology, below Benchmark standalone boilers are capable of being operated in any one of six different modes.

  • Page 80: Outdoor Reset Mode Startup

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION 6.1.2 Outdoor Reset Mode Startup Startup in the Outdoor Reset mode is accomplished as follows: NOTE: 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 81: Constant Setpoint Mode

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION 6.2 CONSTANT SETPOINT MODE The Constant Setpoint mode (the default) is used when a fixed header temperature is desired. Common uses of this mode of operation include water source heat pump loops, and indirect heat exchangers for potable hot water systems or processes.

  • Page 82: Direct Drive Modes

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

  • Page 83: Aerco Control System (Acs)

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION Direct Drive Mode Setup Instructions 3. Press SH Operating Mode parameter and choose Direct Drive. 4. The Remote Signal parameter now appears. It can be set to one of the options below. •...

  • Page 84: Combination Control System (Ccs)

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION 6.6 COMBINATION CONTROL SYSTEM (CCS) NOTE: The ACS can be utilized for a Combination Control System. A Combination Control System (CCS) is one that uses multiple boilers to cover both space- heating and domestic hot water needs.

  • Page 85: Combination Control System Field Wiring

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION 6.6.1 Combination Control System Field Wiring Wiring for this system is between the ACS, the ACS Relay Box, and the terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above.
  • Page 86 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – MODES OF OPERATION (This page intentionally blank) OMM-0137_E • GF-211 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 12/13/2019 Page 86 of 153...

  • Page 87: Section 7: Boiler Sequencing Technology

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY SECTION 7: BOILER SEQUENCING TECHNOLOGY 7.1 INTRODUCTION The Boiler Sequencing Technology system (BST) is an integrated 16 boiler control system. It is built into the Edge Controller. It has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 16 boilers while achieving maximum operational efficiency.

  • Page 88: Installation Notes

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.1.1 Installation Notes A ProtoNode is needed for all protocols on BMK. If your installation 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 89: Bst Implementation Instruction

    Benchmark Platinum-Edge [II]: Operation-Service 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 on the Benchmark boilers, as described in Section 2.11.1 of Benchmark Platinum-Edge: INSTALLATION Manual (OMM-0136, GF-210).
  • Page 90 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 1 Instructions: Constant Setpoint with Direct 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 listed in the table below.

  • Page 91: Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor OPTION 2 Instructions: Constant Setpoint, Modbus Wired Header Temp Sensor Step 1: MODBUS HEADER TEMP SENSOR WIRING – ANY BOILER 1.
  • Page 92 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 2 Instructions: Constant Setpoint, Modbus Wired Header Temp Sensor Step 2: OPTION 2 CONFIGURATION On All Boilers: → → → 1. Go to: Main Menu Advanced Setup BST Cascade Cascade Configuration: •...

  • Page 93: Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Temp Sensor

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.3 Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Temp Sensor OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Temp Sensor & Outdoor Temp Sensor NOTE: Both Header Temp Sensor and Outdoor Temp Sensor must be wired.
  • Page 94 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 3 Instructions: Outdoor Reset, Direct Wired Header Temp Sensor & Outdoor Temp Sensor Step 3 – OPTION 3 CONFIGURATION On All Boiler: → → → 1. Go to: Main Menu Advanced Setup BST Cascade...

  • Page 95: Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.4 Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor OPTION 4 Instructions: Outdoor Reset, Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor NOTE: Both Header Temp Sensor and Outdoor Temp Sensor must be wired.
  • Page 96 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 4 Instructions: Outdoor Reset, Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor 3 Shield 13 BST RS485+ 15 BST RS485– OUTDOOR TEMP SENSOR (P/N 61048) I/O BOARD STRIP J3 MODBUS TRANSMITTER NOTES: •...

  • Page 97: Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20Ma Setpoint Drive

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.5 Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20ma 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. See the Edge Controller Manual (OMM-0139, GF-213) for more information.
  • Page 98 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 5 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, 4-20ma Setpoint Drive Step 3: OPTION 5 CONFIGURATION On All Boiler: → → → 1. Go to: Main Menu Advanced Setup BST Cascade Cascade...

  • Page 99: Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.6 Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, Modbus Setpoint Drive NOTE: Both Header Temp Sensor and Outdoor Temp Sensor must be wired. See the Edge Controller Manual for more information.
  • Page 100 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 6 Instructions: Remote Setpoint, Direct Wired Header Temp Sensor, Modbus Setpoint Drive NOTES: • Polarity must be observed for the RS485 connections. The ground for the shield is at the “SHLD”...

  • Page 101: Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4-20Ma Setpoint Drive

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.7 Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4- 20ma 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 Controller Manual (OMM-0139, GF-213) for more information.
  • Page 102 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 7 Instructions: Remote Setpoint, Modbus Header Temp Sensor & 4-20ma Setpoint Drive 6 Remote Analog In + Remote Signal + 7 Remote Analog In – Remote Signal – 8 Shield I/O BOARD STRIP J3 Step 3: OPTION 7 CONFIGURATION...

  • Page 103: Option 8 Remote Setpoint: Modbus Header Temp Sensor & Modbus Setpoint Drive

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY 7.3.8 Option 8 Remote Setpoint: MODBUS Header Temp Sensor & MODBUS Setpoint Drive OPTION 8 Instructions: Remote Setpoint, Modbus Header Temp Sensor & Modbus Setpoint Drive HEADER TEMP SENSOR WIRING – ANY BOILER Step 1: MODBUS 1.
  • Page 104 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 7 – BOILER SEQUENCING TECHNOLOGY OPTION 8 Instructions: Remote Setpoint, Modbus Header Temp Sensor & Modbus Setpoint Drive Step 3: OPTION 8 CONFIGURATION On All Boiler: → → → 1. Go to: Main Menu Advanced Setup BST Cascade Cascade...

  • Page 105: Section 8: Maintenance

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE SECTION 8: MAINTENANCE 8.1 MAINTENANCE SCHEDULE All Benchmark boilers require regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 8-1.

  • Page 106: Igniter-Injector - Bmk750 - 4000

    Benchmark Platinum-Edge [II]: Operation-Service 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 & Blower gaskets, LWCO, air filter cleaner 58025-13 Burner &...
  • Page 107 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE IGNITER- INJECTOR BLOWER ASSEMBLY PLENUM SENSOR FLAME DETECTOR BURNER FLAME OBSERVATION PORT Figure 8-1b: Igniter-Injector & Flame Detector (BMK1500/2000) BLOWER PLENUM SENSOR FLAME DETECTOR IGNITOR-INJECTOR ASSEMBLY FLAME OBSERVATION PORT BURNER Figure 8-1c: Igniter-Injector & Flame Detector (BMK2500 - 4000) O2 SENSOR POSITION INJECTOR TUBE...

  • Page 108: Pilot Ignition Rod - Bmk5000 & 6000

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE 8.3 PILOT IGNITION ROD – BMK5000 & 6000 The Pilot Burner (P/N 29700) is located on the right-front of the Burner Plate. It contains an ignition cable, the Pilot gas line connected to the bushing. The Pilot Burner Rod (P/N 66100), should be inspected every 12 months and replaced if damaged or warped.

  • Page 109: O 2 Sensor

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

  • Page 110: Air Eductor Air Pump Maintenance - Bmk5000 & 6000

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE Figure 8-3b: O Sensor Mounting Location – BMK5000 & 6000 Lean O Sensor Maintenance Instructions 1. Set the ON/OFF switch on the Edge Controller to the OFF position. 2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

  • Page 111: Safety Device Testing

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE Air Pump Maintenance and Troubleshooting Instructions Sensor Cover to the unit’s back panel. 3. Reattach the O GAS SUCTION LINE TO EXHAUST MANIFOLD AIR FILTER COVER BRACKET (Hangs on opening in back panel) Figure 8-4: Air Eductor Assembly –...
  • Page 112 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE AIR/FUEL VALVE BLOWER GAS TRAIN CONNECTS HERE SENSOR PIPE FLANGE GASKET (P/N 81155) FLAME DETECTOR BLOWER GASKET (P/N 81064) BURNER PLATE BURNER GASKET (P/N 81143) BURNER Figure 8-5a: Burner Assembly Exploded View – BMK750/1000 BLOWER GASKET (P/N 81184) 3/8”-16...
  • Page 113 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE BLOWER GASKET BLOWER PLENUM (P/N 81157) IGNITER- BLOWER INJECTOR ASSEMBLY A/F VALVE PLENUM BURNER PLATE AIR/FUEL VALVE 3/8”-16 HEX NUTS 5/8” NUTS (8 each) & BOLTS (4 each) AIR FILTER (P/N 88014) Figure 8-5c: Burner Assembly Mounting Details –...

  • Page 114: Condensate Drain Trap

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

  • Page 115: Air Filter Cleaning And Replacement

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

  • Page 116: Rear Refractory Replacement

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE 8.10.1 Rear Refractory Replacement Rear Refractory Replacement Instructions 1. Turn off gas and electrical power to the unit. In addition, turn off any other units sharing the exhaust flue. 2. Disconnect the flue from the exhaust manifold of the boiler being serviced and remove flue sections up to the top of the unit enclosure.
  • Page 117 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE Rear Refractory Replacement Instructions SENSOR COVER LOCATION (cover removed) SPRING LATCH AIR EDUCTOR Access the rear panel nuts (behind arrows) are on the RIGHT REAR PANEL rail & base inside the unit, accessible after removing the side panel on each side.

  • Page 118: Front Refractory Replacement

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

  • Page 119: Shutting Boiler Down For Extended Period

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE 8.11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD If the boiler is to be taken out of service for an extended period of time (one year or more), the following instructions must be followed. Shutting Boiler Down for An Extended Period Instructions 1.
  • Page 120 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE Benchmark 5000 & 6000 Long Term Blower Storage Instructions Example Storage / Maintenance Schedule Log Item Action Dates Checked Re-inspect units to insure any protective devices used 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 121: Returning The Boiler To Service After Shutdown

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

  • Page 122: Recommended Periodic Testing

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE 8.13 RECOMMENDED PERIODIC TESTING WARNING! Periodic testing of all boiler controls and safety devices is required to ensure they continue to operate as designed. Precautions must be taken while tests are being performed to protect against bodily injury and property damage.
  • Page 123 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE TABLE 8-3: Recommended Periodic Testing ITEM FREQUENCY ACTION BY REMARKS High water temp. See Section 5.5: Water Temperature Fault Test Annually Service Tech safety control test in this guide. See Section 2: Edge Controller Operation in this Operating controls Annually Operator...

  • Page 124: Recommended Spares

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 8 – MAINTENANCE 8.14 RECOMMENDED SPARES NOTE: Refer to the parts list illustrations in the Benchmark Platinum-Edge: REFERENCE Manual (GF-212) for the locations of the parts listed below. For a list of 12- and 24-Month Maintenance Kits, see Section 8.1: Maintenance Schedule. TABLE 8-4: Recommended Emergency Spare Parts DESCRIPTION 1500/2000...

  • Page 125: Section 9: Aertrim Operation

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

  • Page 126: Aertrim Activation

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION 9.2 AERtrim ACTIVATION AERtrim is activated at the factory prior to shipping all Benchmark Platinum boilers. However, if the Edge Controller is replaced for any reason, you must activate the AERtrim function by entering an activation code, as described below.
  • Page 127 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION Figure 9-2: Active O Sensor Cycle Coverage Chart Figure 9-3 graphically shows the functional logic of the AERtrim system and how the blower voltage (BV), O Limits, and air/fuel ratio interact during an AERtrim operation. The limits are fixed presets within the controller.

  • Page 128: Aertrim Osensor Auto Calibration

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION Once the system operational stability conditions are met, the AERtrim system will execute the following steps: 1. Lock the fire rate at the current position that needs adjustment to the air/fuel ratio. 2.
  • Page 129 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK750 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 5.5% Target 5.5% 5.5% (must be between 5.5% Upper & 5.5% Lower) 100% 5.0%...
  • Page 130 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION Trim Gain 0.250 Max Tries 5.5% Target 5.5% 5.5% (must be between O 5.5% Upper & O 5.5% Lower) 100% 5.0% 2.5% 5.5% 4.5% Lower Limit 2.5% 5.5% 4.5% 2.5% 5.5% 5.0% (must be at...
  • Page 131 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK1500 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 5.5% Target 6.5% 6.5% (must be between O 6.5% Upper & O 6.0% Lower) 100%...
  • Page 132 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK2000 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 6.5% Target 6.0% 6.0% (must be between O 5.5% Upper & O 5.5% Lower) 100%...
  • Page 133 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK2500 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 5.5% Target 6.5% 7.0% (must be between O 6.0% Upper & O 6.0% Lower) 100%...
  • Page 134 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK3000 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 Sec 20 Sec Trim Gain 0.250 Max Tries 6.5% Target 7.3% 7.5% (must be between 7.0% Upper & 5.5% Lower) 100% 5.0%...
  • Page 135 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION BMK 4000 AERtrim Values MENU ITEM Minimum Maximum Default Settle Time 120 sec 20 sec Trim Gain 0.250 Max Tries Target (must be between Upper & Lower) 100% Lower (must be at least 1% lower than Upper)

  • Page 136: Aertrim Maintenance And Troubleshooting

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION 9.6 AERtrim MAINTENANCE and TROUBLESHOOTING The AERtrim system, which maximizes blower efficiency, depends on the O sensor. The AERtrim system needs only minimal maintenance. It is recommended that you inspect the oxygen sensor for accuracy every 12 months by comparing it to a sensor reading from a properly calibrated flue analyzer.
  • Page 137 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION The Edge Controller does not display a message when O levels are within the target range. However, if O levels fall outside the target range, one of the messages listed in Table 9-2 will be displayed in the Auto Calibration Status parameter on the Main Menu →...
  • Page 138 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 9 – AERTRIM OPERATION (This page intentionally blank) OMM-0137_E • GF-211 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 12/13/2019 Page 138 of 153...

  • Page 139: Section 10: Troubleshooting

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 10 – TROUBLESHOOTING SECTION 10: TROUBLESHOOTING 10.1 INTRODUCTION This section is intended to aid service/maintenance personnel in isolating the cause of a fault in your Benchmark boiler. The troubleshooting procedures below are presented in tabular form on the following pages.
  • Page 140 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blower stopped running due to thermal or Check combustion blower for signs of excessive heat or high current overload. current drain that may trip thermal or current overload devices. Blocked Blower inlet or inlet air filter.
  • Page 141 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blower not running or running too slow. Start the unit. If the blower does not run check the blower solid state relay for input and output voltage. If the relay is OK, check the blower.
  • Page 142 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Combustion oscillations. Run unit to full fire. If the unit rumbles or runs rough, perform combustion calibration. Probable causes from 3 to 16 for AIRFLOW See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT FAULT DURING IGNITION applies for this DURING IGNITION.
  • Page 143 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective Ignition/Stepper (IGST) Board. If 120VAC is not present, the IGST Board in the Edge Controller may be defective. Refer fault to qualified service personnel. Defective SSOV.
  • Page 144 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective SSOV Actuator. If gas supply pressure downstream of SSOV Actuator cannot be lowered to the range specified in Table 4-1 (Natural Gas) or Table 4-4 (Propane) in Section 4.4: Combustion Calibration of this guide;...
  • Page 145 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Replace 32 Pin Ribbon cable. 32 Pin Ribbon cable defective. Air/Fuel Valve not rotating. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position.
  • Page 146 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Interlock jumper not installed or removed. Check for a jumper properly installed across the interlock terminals in the I/O box. Energy Management System does not have If there are two external wires on these terminals check any Energy INTERLOCK unit enabled.
  • Page 147 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action A/F Valve rotated open to purge and did not Start the unit. The Air/Fuel Valve should rotate to the purge (open) rotate to ignition position.
  • Page 148 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Loose or broken wiring. Inspect Outdoor Temperature sensor for loose or broken wiring. OUTDOOR TEMP Defective Sensor. Check resistance of sensor to determine if it is within specification. SENSOR FAULT Incorrect Sensor.
  • Page 149 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING TABLE 10-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action SSOV relay failed on IGST board. Press CLEAR button and restart unit. If fault persists, replace Ignition/Stepper (IGST) Board. Floating Neutral. The Neutral and Earth Ground are not connected at the source and SSOV RELAY therefore there is a voltage measured between the two.

  • Page 150: Additional Faults Without Specific Fault Messages

    Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING 10.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 10-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 10-2: Boiler Troubleshooting with No Fault Message Displayed Observed Incident Probable Causes Corrective Action...
  • Page 151 Benchmark Platinum-Edge [II]: Operation-Service Manual SECTION 6 – TROUBLESHOOTING DAMPING ORIFICE BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 10-1: SSOV Actuator with Gas Pressure Adjustment (SKP25) OMM-0137_E • GF-211 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 12/13/2019 Page 151 of 153...

  • Page 152: Notes

    Benchmark Platinum-Edge [II]: Operation-Service Manual CHANGE LOG NOTES: OMM-0137_E • GF-211 • Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST 12/13/2019 Page 152 of 153...
  • Page 153 Benchmark Platinum-Edge [II]: Operation-Service Manual CHANGE LOG Change Log: Date Description Changed By Rev D: DIR 18-61: Updated Blower Proof Switch Test, Section 5.8.1. DIR 19-01: Corrected Table 4-3b, Oxygen values in Standard and Low NOx columns, 16%-18% row. DIR 19-04: Added additional requirements to Section 1.2: Emergency Shutdown 7/16/2019 Chris Blair...

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