Watts Aerco Benchmark Series, Operation And Service Manual

Page 1: ...e 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...

Page 2: ...3 4 6 Benchmark 5000 Air Fuel Valve Position and Energy Input 29 3 4 7 Benchmark 6000 Air Fuel Valve Position and Energy Input 30 SECTION 4 INITIAL START UP 31 4 1 INITIAL START UP REQUIREMENTS 31 4...

Page 3: ...CCS 78 6 6 1 Combination Control System Field Wiring 79 6 6 2 Combination Control System Setup and Startup 79 SECTION 7 BOILER SEQUENCING TECHNOLOGY 81 7 1 INTRODUCTION 81 7 1 1 Installation Notes 82...

Page 4: ...NDED PERIOD 113 8 11 1 Benchmark 5000 6000 Long Term Blower Storage 113 8 12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN 115 8 13 RECOMMENDED PERIODIC TESTING 116 8 14 RECOMMENDED SPARES 118 SECTIO...

Page 5: ...00 14 6 kW 1 000 000 293 kW 48 300 14 15 kW 968 000 284 kW BMK 1500 75 000 22 kW 1 500 000 440 kW 64 500 18 9 kW 1 395 000 409 kW BMK 2000 100 000 29 3 kW 2 000 000 586 kW 86 000 25 2 kW 1 860 000 545...

Page 6: ...ation System often used interchangeably with EMS see below Baud Rate Symbol rate or simply the number of distinct symbol changes signaling events transmitted per second It is not equal to bits per sec...

Page 7: ...ed in Edge Controller INTLK INTL K Interlock I O Input Output I O Box Input Output I O Box currently used on Benchmark boilers IP Internet Protocol ISO International Organization for Standardization L...

Page 8: ...ansmission of data based on the RS232 Standard RS485 or EIA 485 A standard for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature S...

Page 9: ...lace for future reference WARNING Do not use matches candles flames or other sources of ignition to check for gas leaks Fluids under pressure may cause injury to personnel or damage to equipment when...

Page 10: ...nded boilers in a location other than a boiler room provide a manually operated remote shutdown switch or circuit breaker marked for easy identification at a location readily accessible in the event o...

Page 11: ...on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm...

Page 12: ...n or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the i...

Page 13: ...adjust and troubleshoot the boiler The Edge Controller s front panel consists of a touchscreen display along with a variety of indicators and buttons Figure 2 1 Edge Controller Front Panel 1 Multi Fun...

Page 14: ...d AERCO Master Technicians AMT It is distributed on an individual basis To enter a password 1 On the Edge Controller go to Main Menu Advanced Setup Access The Enter Password screen appears 2 Use the n...

Page 15: ...ull water level can seriously damage the unit and may result in injury to personnel or property damage This situation will void any warranty Initial startup of the unit must be be performed by AERCO f...

Page 16: ...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 SSOV locations are shown in Figure 3 1a...

Page 17: ...am 5 pm EST Page 17 of 146 Start Sequence Figure 3 1c BMK 2500 SSOV Location P N 22318 shown Figure 3 1d BMK 3000 SSOV Location P N 22310 shown TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS PRESSURE...

Page 18: ...r relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on the Air Fuel Valve Figure 3 2a and 3 2b will read 10...

Page 19: ...n 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 di...

Page 20: ...n Sequence screen s Spark Cleaning indicator Figure 3 3 turns grey This cycle turns on the ignition transformer to produce a spark with no gas flowing to remove moisture and carbon buildup from the sp...

Page 21: ...is indicated After 5 seconds the Unit Status screen appears 9 With the unit firing properly it will be controlled by the temperature control circuitry The boiler s fire rate or valve position dependin...

Page 22: ...ntroller Scanner Power Ignition Power SSOV Power Pilot Valve Closed Pilot Valve Open Ignition Transformer Off Ignition Transformer On UV Scanner Powered UV Scanner Ignored UV Scanner In Use Relay 1 Co...

Page 23: ...s NATURAL GAS BMK 750 BMK 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 BMK 5000 BMK 6000 Start Level 22 22 20 24 24 20 24 24 Stop Level 18 18 16 18 16 14 18 18 Ignition Position 35 35 29 29 29 29 35 50 TA...

Page 24: ...0 246 000 72 1 kW 297 000 87 0 kW 33 30 50 369 000 108 1 kW 443 000 126 9 kW 49 44 60 465 000 136 3 kW 564 000 165 3 kW 62 56 70 554 000 162 4 kW 660 000 193 4 kW 74 66 80 637 000 186 7 kW 789 000 231...

Page 25: ...op Level 75 000 22 3 kW 5 0 20 127 000 37 2 kW 8 5 30 366 000 107 2 kW 24 4 40 629 000 184 3 kW 41 9 50 822 000 240 9 kW 54 7 60 977 000 286 2 kW 65 0 70 1 119 000 327 9 kW 74 5 80 1 255 000 367 7 kW...

Page 26: ...Stop Level 100 000 29 3 kW 5 7 20 143 000 41 9 kW 11 30 388 000 113 7 kW 23 40 759 000 222 4 kW 37 50 1 069 000 313 2 kW 51 60 1 283 000 375 9 kW 61 70 1 476 000 432 5 kW 74 80 1 675 000 490 1 kW 83 9...

Page 27: ...RGY INPUT OF FULL CAPACITY 16 Stop Level 167 000 48 9 kW 6 7 30 430 000 126 0 kW 17 40 770 000 225 7 kW 31 50 1 070 000 313 6 kW 43 60 1 440 000 422 0 kW 58 70 1 815 000 531 9 kW 73 80 2 030 000 594 9...

Page 28: ...NERGY INPUT OF FULL CAPACITY 14 Stop Level 200 000 58 6 kW 6 7 30 520 000 152 kW 17 40 880 000 258 kW 29 50 1 270 000 372 kW 42 60 1 680 000 492 kW 56 70 2 100 000 615 kW 70 80 2 390 000 700 kW 80 90...

Page 29: ...U Hr of Full Capacity 0 0 0 10 0 0 18 Stop Level 400 000 117 kW 8 30 997 217 292 kW 20 40 1 667 848 489 kW 33 50 1 992 380 584 kW 40 60 2 486 881 729 kW 50 70 2 981 381 874 kW 60 80 3 780 230 1108 kW...

Page 30: ...put BTU Hr of Full Capacity 0 0 0 10 0 0 18 Stop Level 385 000 113 kW 6 20 400 000 117 kW 7 30 540 000 158 kW 9 40 770 000 226 kW 13 50 1 160 000 340 kW 19 60 1 650 000 484 kW 28 70 2 386 000 699 kW 4...

Page 31: ...structions below should be followed precisely in order to operate the unit safely and at high thermal efficiency and low flue gas emissions Initial unit start up must be performed by AERCO factory tra...

Page 32: ...n the upstream side of the SSOV to verify that the gas supply pressure is within the required range of 4 W C and 14 W C Mounted on the downstream side of the SSOV to monitor the gas pressure during th...

Page 33: ...VALVE LEAK DETECTION BALL VALVES 1 4 NPT PLUG Install manometer here for upstream combustion calibration reading HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE SSOV TO AIR FUE...

Page 34: ...anometer here for downstream combustion calibration reading HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE NATURAL GAS INLET NATURAL GAS INLET TO AIR FUEL VALVE LEAK DETECTION...

Page 35: ...2 and remove the 1 4 NPT plug from the exhaust manifold 2 If necessary adjust the stop on the combustion analyzer probe so it will extend mid way into the flue gas flow DO NOT install the probe at thi...

Page 36: ...n Section 4 6 4 4 COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated with either standard combustion NOx emissions of 20 ppm or Ultra Low NOx NOx 9 ppm on the BMK 750 to 2000 only at...

Page 37: ...a technician level password 6 The first Manual Combustion Calibration screen appears lists the three steps that must be completed before continuing Figure 4 4 First Manual Combustion Calibration Scree...

Page 38: ...of the SSOV is within the required range shown in Table 4 1 If it isn t remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Make adjustments using a fl...

Page 39: ...the Target column 20 Enter the downstream manometer s gas pressure reading in the Downstream Gas Pressure field Note this field appears only when Valve Position 100 21 Compare the measured nitrogen o...

Page 40: ...n Table 4 3a through 4 3d depending on model The O2 NOx and CO should stay within the ranges shown in these tables TABLE 4 3a NATURAL GAS BMK Final Valve Positions BMK 750 1000 750 1000 Valve Position...

Page 41: ...6 6 0 0 2 16 6 0 0 2 20 ppm 50 ppm BMK 3000 70 5 1 0 2 85 5 4 0 2 20 ppm 100 ppm 50 6 1 0 2 65 5 5 0 2 20 ppm 100 ppm 40 5 0 0 2 45 5 7 0 2 20 ppm 50 ppm 30 6 4 0 2 30 5 6 0 2 20 ppm 50 ppm 14 6 4 0 2...

Page 42: ...ration Instructions 1 Set the Edge Controller s Enable Disable switch to Disable 2 Open the water supply and return valves to the unit and ensure that the system pumps are running 3 Open the PROPANE s...

Page 43: ...TION POINTS METHOD FINE VP STEP METHOD Figure 4 9 Manual Combustion Calibration Screens 12 Set the Controller s Enable Disable switch to Enable 13 Change the valve position to 30 press the Go button t...

Page 44: ...sensor cannot be made to match the analyzer the sensor may be defective and need to be replaced 18 Compare the O2 value in the Target and Reading columns If they don t match adjust the Blower Voltage...

Page 45: ...multi meter in the Manual Combustion Calibration screen s Reading column Enter the same values plus the O2 value on the Combustion Calibration Data Sheet provided with the unit 24 Lower the Valve Pos...

Page 46: ...0 ppm 65 5 4 0 2 100 ppm 150 ppm 45 6 0 0 2 100 ppm 150 ppm 30 6 4 0 2 100 ppm 100 ppm 18 6 4 0 2 100 ppm 100 ppm TABLE 4 6b PROPANE Final Valve Positions BMK 5000 6000 Valve Position Oxygen O2 Nitrog...

Page 47: ...est valve position after making a change to the TAC screw This completes the PROPANE gas combustion calibration procedure 4 5 REASSEMBLY Once the combustion calibration adjustments are properly set th...

Page 48: ...as supply valve 3 Open the external Propane gas supply valve 4 Locate the Fuel Selector Switch see Figure 4 10 behind the front door 5 Set the Fuel Selector Switch from NAT GAS to PROPANE 6 Replace th...

Page 49: ...98 9 C and should not be changed Note the following points Both switches display the temperature to which the switch is set the temperature limit not the actual temperature it is reading Both switche...

Page 50: ...and remove the front panel to expose the Over Temperature Limit switches 2 Press the Manual Reset Limit Switch s RST Reset button 3 You can now restart the unit Figure 4 13 Manual Reset Over Temperatu...

Page 51: ...ing as designed Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTES Manual an...

Page 52: ...and the MANUAL LED will light 8 Adjust the Air Fuel Valve position between 25 and 30 using the Plus and Minus controls 9 While the unit is firing slowly close the external manual gas shut off valve up...

Page 53: ...e Test Components SSOV GAS INLET TO AIR FUEL VALVE LOW GAS PRESSURE LEAK DETECTION BALL VALVE shown closed HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE 1 4 NPT PLUG Install m...

Page 54: ...1 4 inch plug shown in Figure 5 2a and 5 2b and install a hose barb fitting in that location 4 Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 16 W C 0 4 0 kP...

Page 55: ...a reading of the inlet gas pressure If the inlet pressure is below the minimum calculated in step 5 above then increase the pressure to match the calculated minimum 12 Slowly turn the indicator dial...

Page 56: ...146 LOW Gas Pressure Test Instructions BMK 3000 6000 Only Figure 5 2b Low Gas Pressure Switch Locations Test Ports BMK 6000 MANUAL SHUT OFF VALVE TO AIR FUEL VALVE NATURAL GAS Low Gas Pressure Test Po...

Page 57: ...as pressure using the adjustment screw on the SSOV while counting the number of turns you make 10 The FAULT indicator should start flashing and the unit should shut down and display a Fault Lockout Ga...

Page 58: ...gure 5 3a BMK 750 1000 HIGH Gas Pressure Test Components Figure 5 3b BMK 1500 2000 HIGH Gas Pressure Fault Test SSOV GAS INLET TO AIR FUEL VALVE HIGH GAS PRESSURE BALL VALVE 1 4 NTP PLUG Install manom...

Page 59: ...inch plug shown in Figure 5 4a and 5 4b and install a hose barb fitting in that location 3 Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 16 W C 0 4 0 kPa ma...

Page 60: ...to decrease the manifold pressure until it is at the maximum allowed 11 Slowly turn the indicator dial on the High Gas Pressure switch until the unit shuts down due to a gas pressure fault This is th...

Page 61: ...6000 DOWNSTREAM SSOV WITH POC SWITCH NATURAL GAS HIGH Gas Pressure Port Install manometer here for High Gas Pressure test PROPANE Gas Pressure Port Install manometer here for High Gas Pressure test A...

Page 62: ...ator flashes 5 On the Controller go to Main Menu Diagnostics Manual Run 6 Enable the Manual Mode control 7 Raise the valve position above 30 using the Plus and Minus controls 8 Set the Controller s En...

Page 63: ...troller s is not configured to display outlet temperature go to the Main Menu Advanced Setup Unit Front Panel Configuration screen and set the Upper Right Display parameter to Water Outlet Figure 5 5b...

Page 64: ...controls 5 If there is a jumper across the Remote Interlock terminals remove one side of the jumper If the interlock is being controlled by an external device either open the interlock via the extern...

Page 65: ...reaching the main Burner Ignition cycle and display Flame Loss During Ign 9 Open the Manual Shutoff valve closed in step 5 and press the CLEAR soft key 10 Restart the unit and allow it to prove flame...

Page 66: ...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 Figure 5 6a Blower Proof Blocked Inlet Sw...

Page 67: ...tting indicator dial 0 3 in the Figure below COVER WITH LABEL COVER REMOVED Figure 5 7 Blower Proof Switch 4 Set the Controller s Enable Disable switch to Enable and wait for the boiler to go into the...

Page 68: ...alligator clip away from bare metal parts until step 4b Figure 5 8 Connecting the Flame Signal Generator 4 On the Controller go to Main Menu Diagnostics Manual Run and then put the unit in Manual Mode...

Page 69: ...ion between 25 and 30 using the Plus and Minus controls 4 Remove the cover from the SSOV by loosening the screw shown in Figure 5 9 Lift off the cover to access the terminal wiring connections 5 Disco...

Page 70: ...in Manual Mode 3 Set the valve position between 25 and 30 using the Plus and Minus controls 4 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it see Figure 5 10 5 Remo...

Page 71: ...rge Switch Open During Purge Check Instructions Figure 5 11a Air Fuel Purge and Ignition Locations BMK 750 1000 Figure 5 11b Air Fuel Purge and Ignition Locations BMK 1500 3000 TO BLOWER Purge Positio...

Page 72: ...Manual Run and then put the unit in Manual Mode 3 Set the valve position between 25 and 30 using the Plus and Minus controls 4 Remove the Air Fuel Valve cover Figure 5 10 above by rotating the cover c...

Page 73: ...parameters can be customized to suit the needs of the specific application 6 1 OUTDOOR RESET MODE The the Outdoor Reset mode of operation is based on outside air temperatures As the outside air temper...

Page 74: ...the total outside air temperature span which will be used for Setpoint control OAR Min Outside Temp The minimum outside temperature the system can read it is tied to the OAR Max Setpoint For example i...

Page 75: ...2 On the Controller go to Main Menu Advanced Setup Unit Application Configuration 3 Press SH Operating Mode and choose Constant Setpt 4 Press SH Setpoint and choose the desired setpoint 6 3 REMOTE SET...

Page 76: ...a remote signal which is typically sent from an Energy Management System EMS or from a Building Automation System BAS The Direct Drive mode can be driven by a current or voltage signal The default se...

Page 77: ...AERCO Control System The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible For this mode of operation an ACS Header Sensor must be installed between 2...

Page 78: ...boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the D...

Page 79: ...o setup a boiler for Combination mode Combination Control System Setup Instructions 1 As a prerequisite verify that the unit is not a BST Client or Manager Go to Main Menu Advanced Setup BST Cascade C...

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Page 81: ...ager and all other units on the network are defined as Client units The Manager monitors the system Header Temperature and also monitors all Client unit s status information efficiently controlling al...

Page 82: ...erify that it is operating proper e Once the installation is working properly as a BST system install the ProtoNode device f Make sure that the Modbus load and bias resistors are properly configured f...

Page 83: ...J3 terminals 4 Supply Header and 5 Supply Header 2 Ground the shield to any Shield terminal on the I O Board such as Terminal 3 or 8 NOTES The Header Sensor must be installed between 2 and 10 feet 0...

Page 84: ...t the Parameters to the Values in each menu listed in the table below Menu Screen Name Parameters Values Cascade Configuration Unit Mode BST Manager Hdr Temp Sensor Header Temp Application Configurati...

Page 85: ...mper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield terminal on the I O Board such as Terminal 3 or 8 The...

Page 86: ...the Values in each menu in the table below Menu Screen Name Parameters Values Cascade Configuration Unit Mode BST Manager Hdr Temp Sensor Header Temp Sensor Comm Address 240 Hdr Temp Point 14 Applicat...

Page 87: ...s recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the Shield terminal on the I O the board The sensor end of the shield must be left free and u...

Page 88: ...on Configuration Set the Unit Address parameter to the communication address of the unit On the Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu...

Page 89: ...per wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield terminal on the I O Board such as Terminal 3 or 8 The...

Page 90: ...hield must be left free and ungrounded Step 3 OPTION 4 CONFIGURATION On All Boiler 1 Go to Main Menu Advanced Setup BST Cascade Cascade Configuration Set the Unit Mode parameter to BST Client 2 Go to...

Page 91: ...n 2 and 10 feet 0 61 and 3 1m downstream of the LAST boiler in the plant s supply water header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed...

Page 92: ...the Unit Address parameter to the communication address of the unit On the Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu in the table below M...

Page 93: ...hielded pair 18 22 AWG cable 4 Install a jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield terminal o...

Page 94: ...be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 3 OPTION 6 CONFIGURATION On All Boiler 1 Go to Main Menu Advance...

Page 95: ...jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield terminal on the I O Board such as Terminal 3 The H...

Page 96: ...meter to the communication address of the unit On the Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu in the table below Menu Screen Name Parame...

Page 97: ...ter using Shielded pair 18 22 AWG cable 3 Install a jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield...

Page 98: ...n Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu in the table below Menu Screen Name Parameters Values Cascade Configuration Unit Mode BST Manager Hdr Temp Sensor Networ...

Page 99: ...jector BMK 750 3000 only Inspect Inspect replace if necessary Replace 15 mins 8 3 Pilot Ignition Rod BMK 5000 6000 only Inspect Inspect replace if necessary Replace 15 mins 8 4 Flame Detector Inspect...

Page 100: ...r Blower gaskets air filter cleaning kit 58025 16 LWCO air pump filter air filter cleaning kit 8 2 IGNITER INJECTOR BMK 750 3000 The ignitor injector should be inspected annually and replaced at least...

Page 101: ...00 3000 Figure 8 1c Igniter Injector Flame Detector BMK 2500 3000 Figure 8 1d Igniter Injector Orientation BMK 2500 3000 Shown BLOWER PLENUM IGNITER INJECTOR ASSEMBLY FLAME DETECTOR FLAME OBSERVATION...

Page 102: ...components Parts and instructions are included in 12 Month Maintenance Kit P N 58025 11 and all BMK 5000 6000 24 Month Maintenance Kits Figure 8 2a Pilot Burner Main Pilot Flame Detector Figure 8 2b P...

Page 103: ...nance Kit P N 58025 01 BMK 750 3000 and P N 58025 11 BMK 5000 6000 and all BMK 750 6000 24 Month Maintenance Kits 8 5 O2 SENSOR The Lean Oxygen Sensor P N 61026 should be cleaned and inspected every 1...

Page 104: ...enchmark Platinum 5000 and 6000 units contain an Air Eductor assembly mounted just inside the O2 Sensor Cover on the unit s back panel see Figure 8 3b above It includes an air pump which draws an air...

Page 105: ...fety Device Testing in this guide for a description and instructions for performing these tests 8 7 BURNER INSPECTION The burner assembly should be inspected every 24 months to ensure that all compone...

Page 106: ...er Assembly Exploded View BMK 750 1000 Figure 8 5b BMK 1500 2000 Burner Assembly Mounting Details AIR FUEL VALVE BURNER GASKET P N 81143 FLAME DETECTOR O2 SENSOR BLOWER GASKET P N 81064 BURNER BLOWER...

Page 107: ...ing Details BMK 2500 3000 Figure 8 5d Burner Assembly Exploded View BMK 5000 6000 BLOWER GASKET P N 81157 BLOWER PLENUM AIR FILTER P N 88014 A F VALVE PLENUM BLOWER BURNER PLATE 3 8 16 HEX NUTS 8 each...

Page 108: ...d blockages and cleaned to ensure that condensate flows normally A Condensate Trap O Ring is included all 24 Month Maintenance Kits instructions are in the Technical Instruction Documents TIDs include...

Page 109: ...tructions are included in the TID that accompanies the kit 8 10 REFRACTORY REPLACEMENT BMK 5000 6000 ONLY Low mass fiber based material insulates the front and rear end plates of the combustion chambe...

Page 110: ...each Access the nuts for removal through the side panel as shown in Figure 8 8 4 Remove the left rear panel which is held in place by 2 spring latches and 7 16 bolts inside the panel on the top rail...

Page 111: ...opposing metal tabs located on the outer edge of the fiber blanket then alternately pull on the other two opposing tabs Continue this process until the fiber refractory package can be removed from the...

Page 112: ...attern to ensure a uniform seal Torque bolts to approximately 20 ft lbs 18 To avoid exhaust leaks ensure that a uniform seal is established when reconnecting the flue system to the boiler Figure 8 10...

Page 113: ...f the heat exchanger chamber and base assembly WARNING If the temperature will ever fall below freezing failure to drain all water can cause heat exchanger tubes to crack and fail 8 11 1 Benchmark 500...

Page 114: ...e a Use a Megger each month to ensure that integrity of the winding insulation has been maintained Record the Megger readings Immediately investigate any significant drop in insulation resistance b DO...

Page 115: ...be followed Placing The Boiler Back In Service After A Prolonged Shutdown Instructions 1 Review installation requirements included in Section 2 of the Benchmark Platinum Edge INSTALLATION Manual GF 21...

Page 116: ...ifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Tech Verify factory settings Annually Service Tech Check with combustion calibration test equipment see Sec...

Page 117: ...guide High and low gas pressure interlocks Monthly Operator See Sections 5 2 Low Gas Pressure Test and 5 3 High Gas Pressure Test in this guide Air Fuel Valve purge position switch Annually Service Te...

Page 118: ...ulator Combo Used on ALL FM gas trains Downstream SSOV on DBB gas trains 64048 64048 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV on DBB gas trains 27086 1 27086 1 27086 1...

Page 119: ...ssions It does this by first measuring post combustion oxygen percentages inside the combustion chamber This data is fed through the Electronic Control Unit ECU which is connected to the Edge Controll...

Page 120: ...ed as needed NOTE For full instructions including all menu options see the Edge Controller Manual Section 6 6 1 AERtrim 9 3 OPERATION DETAILS During operation the AERtrim system will adjust the comman...

Page 121: ...at fire rate The control will then store this as the new BV calibration setting until changed manually or by another cycle of the AERtrim function NOTE When the O2 sensor is off during the 10 hour O2...

Page 122: ...l of 20 9 If the calculated offset is more than 3 O2 Warning Service Required message is displayed and the trim function is disabled Auto Calibration occurs only when the unit is in Standby mode For e...

Page 123: ...n 0 1 5 0 0 250 Max Tries 0 100 15 O2 Target must be between O2 Upper O2 Lower 18 3 8 5 5 30 3 8 5 5 45 3 8 5 5 60 3 8 5 5 80 3 8 5 5 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper...

Page 124: ...8 5 5 45 3 8 5 5 60 3 8 5 5 80 3 8 5 5 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 18 2 5 5 5 4 5 30 2 5 5 5 4 5 45 2 5 5 5 5 0 60 2 5 5 5 5 0 80 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 U...

Page 125: ...8 6 5 40 3 8 6 5 50 3 8 6 5 70 3 8 6 0 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 16 2 5 5 5 5 0 30 2 5 5 5 5 0 40 2 5 5 5 5 0 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 U...

Page 126: ...30 3 8 6 0 40 3 8 6 0 50 3 8 5 5 70 3 8 5 5 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 18 2 5 5 5 5 0 30 2 5 5 5 5 5 40 2 5 5 5 5 5 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 U...

Page 127: ...30 3 8 6 5 40 3 8 7 0 50 3 8 6 0 70 3 8 6 0 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 16 2 5 5 5 5 0 30 2 5 5 5 4 5 40 2 5 5 5 5 0 50 2 5 5 5 5 5 70 2 5 5 5 5 5 100 2 5 5 5 4 5 O2 U...

Page 128: ...30 3 8 7 3 40 3 8 7 5 50 3 8 7 0 70 3 8 5 5 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 14 2 5 5 5 5 5 30 2 5 5 5 5 5 40 2 5 5 5 5 5 50 2 5 5 5 5 5 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Up...

Page 129: ...the device may be required TABLE 9 1 AERtrim General Warnings Warning Cause Possible Solutions O2 Percentage Low O2 Levels less than 2 for more than 30 seconds auto reset when valve comes back in rang...

Page 130: ...Performance AERtrim AERtrim Status screen TABLE 9 2 AERtrim Operation Interruption Errors Error Message Cause Possible Solutions BV Hi Err Trim operation exceeds allowable blower voltage limits Check...

Page 131: ...sages are included in Section 9 6 above When a fault occurs in the unit proceed as follows to isolate and correct the fault Fault Correction Instructions 1 Observe the fault messages displayed on the...

Page 132: ...enchmark Platinum Edge Operation Service Manual SECTION 10 TROUBLESHOOTING OMM 0137_D GF 211 7 16 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 132 of 146 This page intentionally blan...

Page 133: ...stance reading or the resistance reading is greater than zero ohms replace the switch 6 Defective Blocked Inlet switch 6 Turn off unit and check the continuity of the Blocked Inlet switch If there is...

Page 134: ...ground If 24 VAC is not present refer fault to qualified service personnel 6 PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT DURING IGNITION apply for this fault 6 See CORRECTIVE ACTIONS for AIRFLOW F...

Page 135: ...Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check wiring continuity between source and unit 2 Signal is not isolated floating...

Page 136: ...re into and out of the valve is correct 3 Poor combustion calibration 3 Check combustion calibration using the procedures in Section 4 4 Combustion Calibration of this guide 4 Debris on burner 4 Remov...

Page 137: ...the current readings then reset to default values 3 Faulty shell temperature sensor 3 Using the resistance charts in Section 2 of the Benchmark Platinum Edge REFERENCE Manual GF 212 measure the resis...

Page 138: ...s wired correctly replace the switch 4 Defective Power Supply Board or fuse 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Defective IGST Board 5 Che...

Page 139: ...sed 2 Incorrect power supply transformer wiring 2 Check transformer wiring in AC Power Box against the power box transformer wiring diagram to ensure it is wired correctly LOW GAS PRESSURE 1 Incorrect...

Page 140: ...check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 3 Switch wired incorrectly 3 If the switch is wired correctly replace the switch 4 Defective Powe...

Page 141: ...not isolated floating if 4 to 20 mA 2 Check signal at source to ensure it is isolated 3 Edge Controller signal type selection switches not set for correct signal type voltage or current 3 Check DIP sw...

Page 142: ...closes it may be powered continuously Close the gas supply and remove power from the unit Refer fault to qualified service personnel 3 Defective switch or Actuator 3 Remove the electrical cover from...

Page 143: ...jector Figure 8 1a through Figure 8 1c and inspect Gas Injector to ensure it is not clogged or damaged 2 Defective Staged Ignition Solenoid Figure 8 1a through Figure 8 1c 2 Close the Manual Shutoff V...

Page 144: ...BLESHOOTING OMM 0137_D GF 211 7 16 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 144 of 146 Figure 10 1 SSOV Actuator With Gas Pressure Adjustment SKP25 BRASS HEX HEAD Remove to acces...

Page 145: ...Benchmark Platinum Edge Operation Service Manual CHANGE LOG OMM 0137_D GF 211 7 16 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 145 of 146 NOTES...

Page 146: ...on 4 4 2 Chris Blair 7 16 2019 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 add...