Watts Aerco BMK 5000, Operation And Service Manual

Page 1: ...9 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 20 1800 and above BMK750 5000N N 20 0125 and above BMK5000 6000 OMM 0137_J 12 20 2022 Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no ...

Page 2: ...l Valve Position and Energy Input 30 3 4 7 BMK5000N Air Fuel Valve Position and Energy Input 31 3 4 8 Benchmark 5000 Air Fuel Valve Position and Energy Input 32 3 4 9 Benchmark 6000 Air Fuel Valve Position and Energy Input 33 SECTION 4 INITIAL START UP 34 4 1 INITIAL START UP REQUIREMENTS 34 4 2 TOOLS INSTRUMENTS FOR COMBUSTION CALIBRATION 35 4 2 1 Required Tools Instrumentation 35 4 2 2 Installin...

Page 3: ...N 82 6 1 OUTDOOR RESET MODE 82 6 1 1 Outdoor Air Temperature Sensor Installation 82 6 1 2 Outdoor Reset Mode Startup 83 6 2 CONSTANT SETPOINT MODE 84 6 3 REMOTE SETPOINT MODE 84 6 4 DIRECT DRIVE MODES 85 6 5 AERCO CONTROL SYSTEM ACS 86 6 6 COMBINATION CONTROL SYSTEM CCS 87 6 6 1 Combination Control System Field Wiring 88 6 6 2 Combination Control System Setup and Startup 88 SECTION 7 BOILER SEQUEN...

Page 4: ...NDED SPARES 114 SECTION 9 AERTRIM OPERATION 116 9 1 AERTRIM INTRODUCTION 116 9 2 AERTRIM ACTIVATION 117 9 3 OPERATION DETAILS 117 9 4 AERTRIM O2 SENSOR AUTO CALIBRATION 119 9 5 AERTRIM MENU VALUES AND DEFAULTS 119 9 6 AERTRIM MAINTENANCE AND TROUBLESHOOTING 128 SECTION 10 TROUBLESHOOTING 130 10 1 INTRODUCTION 130 10 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 142 SECTION 11 WIRING DIAGRAMS...

Page 5: ...284 kW BMK1500 75 000 22 kW 1 500 000 440 kW 64 500 18 9 kW 1 395 000 409 kW BMK2000 100 000 29 3 kW 2 000 000 586 kW 86 000 25 2 kW 1 860 000 545 kW BMK2500 167 000 48 9 kW 2 500 000 732 kW 144 000 42 2 kW 2 395 000 702 kW BMK3000 200 000 58 6 kW 3 000 000 879 kW 174 000 51 0 kW 2 874 000 842 kW BMK4000 267 000 78 2 kW 4 000 000 1172 kW 232 000 68 0 kW 3 800 000 1113 kW BMK5000N 250 000 73 3 kW 4...

Page 6: ... American Society of Mechanical Engineers AUX Auxiliary BAS Building Automation 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 second unless each symbol is 1 bit long BMK Benchmark AERCO s Benchmark series boilers BMS or BMS II AERCO Boiler Management Syst...

Page 7: ...er Hz Hertz Cycles Per Second I D Inside Diameter IGN Ignition IGST Board Ignition Stepper Board contained 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 Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 0 001 MA...

Page 8: ...A standard for serial full duplex FDX transmission 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 SHLD Shld Shield SPDT Single Pole Double Throw a type of switch SSOV Safety Shut Off Valve TEMP Temp Temperature Terminating Resistor A resistor placed at each e...

Page 9: ...uture 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 released Be sure to shut off all incoming and outgoing water shutoff valves Carefully decrease all trapped pressures to zero before performing maintenance Before attempting to perform any maintenance on the uni...

Page 10: ...ded 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 of boiler mis operation Design the system so activation of the emergency shutdown switch or circuit breaker will immediately shut off the fuel For boilers monitored and or operated from a continuously 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 is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secu...

Page 12: ... 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 installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING S...

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 Function Bar shows either Fire Rate Valve Position 2 Parameter Indicator for both temperature read outs LEFT Inlet or Setpoint temperature RIGHT Outlet or System Header temperature 3 Temperature scale in...

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 number keypad to enter the password each number appears as a then press Save You will have access to the functionality associated with the level of the password entered Figure 2 2 Enter Password Screen...

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 performed by AERCO factory trained personnel Operation prior to initial startup by factory trained personnel may void the equipment warranty In addition the following WARNINGS and CAUTIONS must be observed at all times 3 2 ...

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 through 3 1d Figure 3 1a BMK750 1000 SSOV Location P N 22322 shown Figure 3 1b BMK1500 2000 SSOV Location P N 22314 shown TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS PRESSURE SWITCH HIGH GAS PRES...

Page 17: ...pm EST Page 17 of 167 Start Sequence Figure 3 1c BMK2500 SSOV Location P N 22318 shown Figure 3 1d BMK3000 4000 5000N SSOV Location P N 22310 shown TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS PRESSURE SWITCH SSOV SSOV TO AIR FUEL VALVE NATURAL GAS INLET HIGH GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE LOW GAS PRESSURE SWITCH NATURAL GAS INLET ...

Page 18: ...he Blower 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 100 to indicate that it is full open 100 c The Fire Rate bar graph on the Controller s front face shows 100 Figure 3 2a BMK750 1000 Air Fuel Valve in Purge Position STEPPER MOTOR TO BLOWER AIR I...

Page 19: ... 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 Figure 3 3 Ignition Sequence Screen Purging Figure 3 4a BMK750 1000 Blower Proof Switch TO BLOWER STEPPER MOTOR AIR IN PURGE VALVE POSITION DIAL AT 100 ...

Page 20: ... 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 spark element For the duration of this cycle the Controller displays the Cleaning Igniter status message c Following the Spark Cleaning cycle power is applied to the gas Safety Shut off Valve SSOV When t...

Page 21: ...s 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 depending on which was chosen in Section 6 2 2 Front Panel Configuration of the Edge Controller Manual will continuously display on the Controller s bar graph 10 Once the demand for heat has been satisfied the...

Page 22: ...roller 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 Coil Relay 1 C NC Relay 1 C NO Relay 2 Coil Power from R1 Relay 2 Coil Power from SKP 15 POC Relay 2 C NC Relay 2 C NO SKP15 Power from R1 Contacts SKP15 Power from R2 contact and POC C NO SKP15 Proof of ...

Page 23: ...K 2500 BMK 3000 BMK 4000 BMK 5000N BMK 4000 5000N DF BMK 5000 BMK 6000 Start Level 22 24 20 24 24 20 27 24 24 24 24 Stop Level 18 18 16 18 16 14 23 18 18 18 18 Ignition Position 35 30 29 29 29 29 45 40 35 35 50 TABLE 3 1b Start Stop Levels PROPANE GAS BMK 750 1000 BMK 750 1000 DF BMK 1500 BMK 2000 BMK 2500 BMK 3000 BMK 4000 BMK 5000N BMK 5000 BMK 6000 Start Level 22 24 20 24 26 22 24 24 24 24 Stop...

Page 24: ... 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 2 kW 85 79 90 733 000 214 8 kW 933 000 273 4 kW 98 93 100 750 000 219 8 kW 1 000 000 293 1 kW 100 100 TABLE 3 2b BMK750 1000 Air Fuel Valve Position PROPANE GAS Air Fuel Valve Position Open Energy Inp...

Page 25: ...0 167 3 Kw 633 500 185 7 Kw 76 1 63 4 80 633 500 185 7 Kw 756 000 221 6 Kw 84 5 75 6 90 693 200 203 2 Kw 894 000 262 0 Kw 92 4 89 4 100 750 000 219 8 Kw 1 000 000 293 1 Kw 100 0 100 0 TABLE 3 2d BMK750 1000 DUAL FUEL Air Fuel Valve Position PROPANE GAS Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity BMK750 Dual Fuel BMK 1000 Dual Fuel BMK750 Dual Fuel BMK 1000...

Page 26: ...W 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 83 5 90 1 396 000 409 0 kW 92 9 100 1 502 000 440 1 kW 100 TABLE 3 3b BMK1500 Air Fuel Valve Position PROPANE GAS AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACITY 18 Stop Level 75 000 21 9 kW 5 0 20 93 700 27...

Page 27: ...top 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 90 1 833 000 537 1 kW 93 100 2 000 000 586 0 kW 100 TABLE 3 4b BMK2000 Air Fuel Valve Position PROPANE GAS AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACITY 18 Stop L...

Page 28: ...GY 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 kW 81 90 2 300 000 674 1 kW 92 100 2 500 000 732 7 kW 100 TABLE 3 5b BMK2500 Air Fuel Valve Position PROPANE GAS AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACITY 1...

Page 29: ...ERGY 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 2 650 000 777 kW 88 100 3 000 000 879 kW 100 TABLE 3 6b BMK3000 Air Fuel Valve Position PROPANE GAS AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACITY 18 Stop Level 2...

Page 30: ...0 3 107 000 77 7 90 3 582 000 89 6 100 4 000 000 100 TABLE 3 7b BMK4000 Air Fuel Valve Position NATURAL GAS DUAL FUEL AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACITY 18 Stop Level 246 000 6 2 20 346 000 8 7 30 846 000 21 40 1 384 000 35 50 1 883 000 47 60 2 442 000 61 70 2 783 000 70 80 3 151 000 79 90 3 541 000 89 100 4 000 000 100 TABLE 3 7c BMK4000 Air Fuel...

Page 31: ...00 100 0 TABLE 3 8b BMK 5000N Dual Fuel Air Fuel Valve Position NATURAL GAS AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACITY 18 Stop Level 246 000 4 9 20 346 000 6 9 30 846 000 17 40 1 384 000 28 50 1 883 000 38 60 2 442 000 49 70 3 019 000 60 80 3 669 000 73 90 4 350 000 87 100 4 999 000 100 TABLE 3 8c BMK 5000N Air Fuel Valve Position PROPANE GAS AIR FUEL VAL...

Page 32: ... Hr of Full Capacity 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 76 90 4 375 500 1282 kW 88 100 5 000 000 1465 kW 100 TABLE 3 9b BMK5000 Gas Pressure De Rating Chart Gas Pressure SSOV in inches W C kPa Energy Input in BTU hr Oxygen O2 DeRating Full Fire Inlet Outlet 56 13...

Page 33: ...ut BTU Hr of Full Capacity 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 40 80 3 515 000 1030 kW 59 90 4 650 000 1362 kW 78 TABLE 3 10b BMK6000 Gas Pressure De Rating Chart Gas Pressure SSOV in inches W C kPa Energy Input in BTU hr Oxygen O2 DeRating Full Fire Inlet Outlet 56 13 9...

Page 34: ...tructions 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 trained personnel who are trained in the start up and service of Benchmark boilers An AERCO Gas Fired Startup Sheet included with each Benchmark unit must be completed for each unit for warranty validatio...

Page 35: ...cone adhesive 4 2 2 Installing Gas Supply Manometer A 16 W C 4 0 kPa gas supply manometer or gauge is used in the following ways Mounted on 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 the Combustion Calibration procedure described in Sections 4 4 1...

Page 36: ...ALVE 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 FUEL VALVE MANUAL SHUT OFF VALVE LEAK DETECTION BALL VALVE 1 4 NTP PLUG Install manometer here for downstream combustion calibration reading NATURAL GAS INLET 1 4 NTP PLUG Install manometer here for upstre...

Page 37: ...ometer 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 BALL VALVE 1 4 NPT PLUG Install manometer here for upstream combustion calibration reading HIGH GAS PRESSURE WITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE SSOV 1 4 NPT PLUG Install manometer here ...

Page 38: ...0N Gas Supply Manometer Installation Instructions BMK5000 6000 1 Turn off the main gas supply upstream of the unit 2 Remove the front panel from the boiler to access the gas train 3 Connect the manometer directly to the Low and High Gas Pressure Switches as shown in Figure 4 1f LOW GAS PRESSURE SWITCH TO AIR FUEL VALVE MANUAL SHUT OFF VALVE DOWNSTREAM SSOV WITH POC SWITCH HIGH GAS PRESSURE SWITCH ...

Page 39: ...d 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 this time Figure 4 2 Analyzer Probe Port Location BMK1500 shown PRIMARY HOT WATER INLET ANALYZER PROBE PORT CONDENSATE DRAIN DRAIN VALVE TO AIR FUEL VALVE HIGH GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE UPSTR...

Page 40: ... holes in the refractory insulation They have a red LED which changes from flashing to steady ON when they encounter the flicker of a flame that meets or exceeds the internal sensing threshold Only one of the two detectors need to sense the pilot flame throughout the ignition period The holes in the refractory should be checked annually to ensure that the path to the Injector Ignitor is clear NOTE...

Page 41: ...may ignore the combustion calibration value and adjust the O2 to the AERtrim value instead 4 5 1 NATURAL GAS Manual Combustion Calibration These instructions apply only to units running NATURAL GAS NATURAL GAS Manual Combustion Calibration Instructions 1 Ensure the Edge Controller s Enable Disable switch is set to Disable 2 Open the water supply and return valves to the unit and ensure that the sy...

Page 42: ... gas pressure to the unit is within the allowable range see the Benchmark Gas Supply Guide TAG 0047 GF 2030 9 Once you have completed the previous step move the manometer or use a secondary one to the downstream side of the SSOV and press Next to continue 10 Choose the NOx requirement for this installation None 20 PPM or 9 PPM Figure 4 5 Choose NOx Requirement 11 The main Manual Combustion Calibra...

Page 43: ...it The resulting gas pressure reading on the downstream manometer should fall in the range listed below TABLE 4 1 REFERENCE Natural Gas Manifold Gas Pressure Range 100 Fire Rate Model Single Fuel Units Dual Fuel Units BMK750 2 0 0 2 W C 0 50 0 05 kPa See NOTE 1 BMK1000 2 4 0 4 W C 0 60 0 10 kPa 4 9 0 2 W C 1 22 0 05 kPa BMK1500 3 6 0 1 W C 0 90 0 02 kPa 3 6 0 1 W C 0 90 0 02 kPa BMK2000 3 4 0 2 W ...

Page 44: ...tinue repeating Steps 15 and 18 until the gas pressure is within the range in Table 4 1 and the O2 Reading column matches 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 oxide NOx and carbon monoxide CO readings to the Target values in Table 4 2 show...

Page 45: ...rrow key if using Method 1 in step 11 or the Fine Valve Position Minus key if using Method 2 BMK750 1000 80 BMK1500 6000 70 25 Repeat step 17 18 and 21 at that valve position and the rest of the valve positions in Table below corresponding to your model The O2 NOx and CO should stay within the ranges shown in these tables TABLE 4 3a NATURAL GAS BMK Final Valve Positions BMK750 1000 Valve Position ...

Page 46: ...2 20 ppm 50 ppm 30 6 3 0 2 20 5 8 0 2 20 ppm 50 ppm 16 6 0 0 2 16 6 0 0 2 20 ppm 50 ppm BMK3000 Single and Duel Fuel 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 14 6 2 0 2 20 ppm 50 ppm TABLE 4 3e NATURAL GAS Final Valve Positions BMK4000 Valve Position Standard NOx Ultra Low NOx CO Sin...

Page 47: ... 50 ppm 18 6 0 1 0 20 ppm 6 5 1 5 9 ppm 50 ppm NOTE BMK5000 Low Gas Pressure LGP Model does not offer Ultra Low NOx settings TABLE 4 3i NATURAL GAS Final Valve Positions BMK6000 Single DF Valve Position Standard NOx Ultra Low NOx CO Single Fuel Dual Fuel O2 NOx O2 NOx 70 85 5 5 0 5 20 ppm 6 0 1 0 9 ppm 100 ppm 50 65 5 5 0 5 20 ppm 6 0 1 0 9 ppm 100 ppm 40 45 5 5 0 5 20 ppm 6 0 1 0 9 ppm 50 ppm 30 ...

Page 48: ...creen appears Complete the three steps listed before continuing with the instructions In addition if your unit is running AERtrim you must turn that feature off before continuing as AERtrim will interfere with combustion calibration 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 c...

Page 49: ...OV is within the required range shown in Table 4 4 If it isn t remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Adjust using a flat tip screwdriver slowly rotating the gas pressure adjustment in 1 4 turn increments clockwise to increase gas pressure or counterclockwise to reduce it The resulting gas pressure reading on the downstream manometer sh...

Page 50: ...Step 18 Continue repeating Steps 15 and 18 until the gas pressure is within the range in Table 4 4 and the O2 Reading column to matches 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 oxide NOx and carbon monoxide CO readings to the Target values in ...

Page 51: ...0 DF P 70 BMK3000 DF P 85 BMK4000 DF P 70 BMK5000N DF P 70 BMK5000P 6000P 70 BMK5000DF 6000DF 85 25 Repeat step 17 18 and 21 at that valve position and the rest of the valve positions in the Table corresponding to your model The O2 NOx and CO should stay within the ranges shown in these tables TABLE 4 6a PROPANE Final Valve Positions BMK750 5000N Valve Position Oxygen O2 Nitrogen oxide NOx Carbon ...

Page 52: ...5 5 0 2 100 ppm 100 ppm BMK2500 70 5 4 0 2 100 ppm 150 ppm 45 5 6 0 2 100 ppm 150 ppm 30 6 0 0 2 100 ppm 100 ppm 22 5 8 0 2 100 ppm 100 ppm 18 6 0 0 2 100 ppm 100 ppm BMK3000 85 5 2 0 2 100 ppm 150 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 BMK4000 70 4 5 0 2 100 ppm 150 ppm 50 5 5 0 2 100 ppm 150 ppm 40 5 5 0 2 100 ppm 150 ppm 3...

Page 53: ...n sheet 26 If the oxygen level at the lowest valve position is too high and the Blower voltage is at the minimum value you can adjust the TAC screw which is recessed in the top of the Air Fuel Valve see Figure 4 3 Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the O2 to the specified level Recalibration MUST be performed again from 60 or 50 down to the lowest valve position after ma...

Page 54: ...anel previously removed from the boiler Switchover from PROPANE to NATURAL GAS Instructions 1 Set the Edge Controller s Enable Disable switch to Disable 2 Close the external Propane Gas supply valve 3 Open the external Natural Gas supply valve 4 Locate the Fuel Selector Switch see Figure 4 10 behind the front door 5 Set the Fuel Selector Switch from PROPANE to NAT GAS 6 Replace the front door pane...

Page 55: ...he Auto Reset switch is preset to 190ºF 88 C but can be adjusted as needed to suite local conditions as described below Figure 4 11 Over Temperature Limit Switches 4 8 1 Adjusting the Automatic Reset Limit Switch Temperature Perform the following steps to adjust the Automatic Reset Limit Switch temperature setting Temperature Adjustment Instructions 1 Power the unit ON and remove the front panel t...

Page 56: ...nd 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 Temperature Limit Switch 4 8 3 Changing the Readout Between Fahrenheit and Celsius Perform the following steps to change the temperature reading between Fahrenheit or Celsius Changing the Readout Between Fahren...

Page 57: ...Benchmark Platinum Edge ii Operation Service Manual SECTION 4 INITIAL START UP OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 57 of 167 This page intentionally blank ...

Page 58: ...signed 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 and Auto modes of operation are required to perform the following tests For a full explanation see Section 4 1 Manual Run in the Edge Controller Manual GF 213 It is necessary to remove the front door and side pa...

Page 59: ...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 upstream of the unit not shown 10 The unit should shut down and display a Fault Lockout Gas Pressure Fault message at approximately the pressure shown in Table 5 1 the pressure setting of the Low Gas Pressure switch TABLE 5 1 ...

Page 60: ...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 manometer here for LOW gas pressure fault test NATURAL GAS INLET SSOV HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE 1 4 NPT PLUG Install manometer here for LOW gas pressure fault...

Page 61: ...a 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 kPa manometer 5 Apply the reading of the manifold pressure taken in Step 21 of Section 4 4 1 Natural Gas units or Step 21 of Section 4 4 2 Propane units and plug it into the following formula which calculates the minimum allowable gas ...

Page 62: ...itch and set the dial indicator to 2 the minimum 7 Open the external gas supply ball valve upstream of the unit 8 On the Controller go to Main Menu Diagnostics Manual Run and then enable the Manual Mode control 9 Adjust the Air Fuel Valve position to 100 using the Plus and Minus controls 10 While the unit is firing read the CO value on the combustion analyzer and slowly decrease the incoming gas s...

Page 63: ...4000 5000N LOW and HIGH Gas Pressure Test Components NATURAL GAS INLET HIGH GAS PRESSURE SWITCH SSOV TO AIR FUEL VALVE MANUAL SHUT OFF VALVE P N 22373 3 shown LOW GAS PRESSURE SWITCH LOW Gas Pressure Port Install manometer here for Low Gas Pressure test TO AIR FUEL VALVE MANUAL SHUT OFF VALVE SSOV LOW Gas Pressure Port Install manometer here for Low Gas Pressure test LOW GAS PRESSURE SWITCH HIGH G...

Page 64: ... Pressure Test Instructions BMK3000 6000 Only Figure 5 2c BMK5000N 6000 LOW and HIGH Gas Pressure Test Components MANUAL SHUT OFF VALVE TO 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 Propane gas trains Alternative location ...

Page 65: ...justment 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 Gas Pressure Fault message at approximately the value shown in Table 5 2 the pressure setting of the High Gas Pressure switch If the unit does not trip off within 0 2 W C of the pressure shown the switch needs to be replaced T...

Page 66: ...re Test Components Figure 5 3b BMK1500 2000 HIGH Gas Pressure Fault Test SSOV GAS INLET TO AIR FUEL VALVE HIGH GAS PRESSURE BALL VALVE 1 4 NTP PLUG Install manometer here for High Gas Pressure Test MANUAL SHUT OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH HIGH GAS BALL VALVE 1 4 NPT PLUG Install manometer here for HIGH gas pressure fault test NATURAL GAS INLET SSOV TO AIR FUEL VALVE H...

Page 67: ...wn 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 manometer 4 Apply the reading of the manifold pressure taken in Step 21 of Section 4 4 1 natural gas units or Step 21 of Section 4 4 2 propane units and plug it into the following formula which calculates the maximu...

Page 68: ...re 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 the setpoint 12 Press the RESET button on the High Gas Pressure switch see Figure 5 4 below 13 Readjust the manifold gas supply pressure to what it was before it was increased in step 9 14 Press the CLEAR button on the Edge Controller...

Page 69: ...0 ONLY Figure 5 4b BMK4000 5000N HIGH Gas Pressure Test Components HIGH GAS PRESSURE SWITCH NATURAL GAS INLET HIGH Gas Pressure Port Install manometer here for High Gas Pressure test TO AIR FUEL VALVE MANUAL SHUT OFF VALVE P N 22373 3 shown LOW GAS PRESSURE SWITCH LOW Gas Pressure Port Install manometer here for Low Gas Pressure test LEAK DETECTION BALL VALVE Alternative location for manometer if ...

Page 70: ...igh Gas Pressure Test Components 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 Alternative location for manometer if hose barb is preferred PROPANE HIGH GAS PRESSURE SWITCH BMK6000 10 5 W C 2 6 kPa BMK5000 4 5 W C 1 1 kPa NATURAL GAS HIGH GAS PRESSURE S...

Page 71: ...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 Enable Disable switch to Enable The READY light should remain off and the unit should not start If the unit does start shut the unit off immediately and refer fault to qualified service personnel 9 Clos...

Page 72: ...roller 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 Edge Controller Front Face 3 Once the Automatic Reset Over Temperature switch setting is approximately just below the actual outlet water temperature the unit should shut down the FAULT indicator shou...

Page 73: ... 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 external device or disconnect one of the wires leading to the external device 6 The unit should shut down and the Controller should display Interlock Open 7 Once the interlock connection is reconnected the ...

Page 74: ... 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 11 Once flame is proven close the Manual Shutoff valve located between the SSOV and the Air Fuel Valve see Figure 5 3a to 5 3c above 12 The unit should shut down and do one of the following a BMK750 ...

Page 75: ...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 Switch Locations BMK1500 5000N Figure 5 6b Blower Proof Blocked Inlet Switch Locations BMK750 1000 BLOWER PROOF SWITCH BLOCKED INLET SWITCH SSOV MANUAL SHUT OFF VALVE BLOWER PROOF SWITCH BLOCKED INLET S...

Page 76: ...ting 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 Purge sequence 5 After about 5 seconds with air flowing into the combustion chamber slowly turn the dial clock wise to higher value until the unit trips off with an Air Flow Fault During Purge message...

Page 77: ...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 then complete the following a Ramp the boiler up to 100 fire rate and then set the Controller s Enable Disable switch to Enable b When the Controller gets into the ignition phase it will show Ignitio...

Page 78: ...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 Disconnect wire 148 from the SSOV to open the Proof of Closure switch circuit 6 The unit should fault and display SSOV Switch Open 7 Replace wire 148 and press the CLEAR button 8 Set the Controller s Enabl...

Page 79: ...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 Remove one of the two wires 171 or 172 from the Purge switch Figure 5 11a 5 11c 6 Set the Controller s Enable Disable switch to Enable to start the unit 7 The unit should begin its start sequence then shu...

Page 80: ...rge Switch Open During Purge Check Instructions Figure 5 11a Air Fuel Purge and Ignition Locations BMK750 1000 Figure 5 11b Air Fuel Purge and Ignition Locations BMK1500 5000N TO BLOWER Purge Position Switch AIR IN VALVE POSITION DIAL AIR FUEL VALVE SWITCH WIRING BREAKOUT 172 171 170 169 Ignition Position Switch Ignition Position Switch Purge Position Switch AIR IN TO BLOWER ...

Page 81: ...al 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 counterclockwise 5 Remove one of the two wires 169 or 170 from the Ignition switch see Figure 5 11a 5 11c above 6 Set the Controller s Enable Disable switch to Enable to start the unit 7 The unit should be...

Page 82: ...e needs of the specific application 6 1 OUTDOOR RESET MODE The Outdoor Reset mode of operation is based on outside air temperatures As the outside air temperature decreases the supply header temperature will increase and vice versa For this mode it is necessary to install an outside air sensor 6 1 1 Outdoor Air Temperature Sensor Installation The outdoor air temperature sensor must be mounted on t...

Page 83: ...e following parameters to define 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 if OAR Min Outside Temp is 5 F and OAR Max Setpoint is 180 F when the outside temperature is 5 F or below the system will supply 180 F OAR Max Outside Temp Outdoor Air ...

Page 84: ... Off 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 SETPOINT MODE The unit s setpoint can be remotely controlled by an Energy Management System EMS or Building Automation System BAS The Remote Setpoint can be driven by a current or voltage signal NOT...

Page 85: ... by 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 setting for the Direct Drive mode is 4 20 mA 1 5 VDC With this setting a 4 to 20 mA signal sent by an EMS or BAS is used to change the unit s valve position from 0 to 100 A 4 mA 1V signal is equal to...

Page 86: ...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 Temp Sensor must be installed between 2 and 10 feet 0 61 and 3m downstream of the last boiler in the boiler plant s supply water header ACS can control up to 32 boilers via Modbus RS 485 network communication For ACS programming opera...

Page 87: ...tion 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 DHW PRIORITY boilers OPTION 2 When this option is selected the ACS Relay Panel must be used in conjunction with the ACS For this option the ACS controls a boiler plant containing up to eight combi...

Page 88: ...TUP To 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 Cascade Configuration Unit Mode Off 2 On the Controller go to Main Menu Advanced Setup Unit Application Configuration 3 Press SH Operating Mode and choose Combination 4 Press the Remote Signal par...

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Page 90: ...r 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 all units in order to achieve and maintain the required BST Setpoint Temperature When there is a demand the Manager will light off the lead boiler based on the BST Sequencing selection in the BST Cascade S...

Page 91: ...nd completely test the installation to verify 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 for the system to operate with the ProtoNode installed g Set the BST system for desired mode of operation Setpoint mode h Test the system completely with the Pro...

Page 92: ...atinum Edge ii Operation Service Manual SECTION 7 BOILER SEQUENCING TECHNOLOGY OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 92 of 167 Figure 7 2 BST BAS and Field Wiring SD A 1174 ...

Page 93: ...s of communication between the Manager and Client units or to the BAS or external signal sensor such as an outdoor sensor default Constant Setpoint Plant Failsafe Setpoint only if Plant Failsafe Mode Constant Setpoint Specify the Setpoint for all units in the cascade 6 The Client Address screen appears as a reminder to setup all Client units in the BST Cascade before continuing Once all Client uni...

Page 94: ...ere is a loss of communication between the Manager and Client units or to the BAS or external signal sensor such as an outdoor sensor default Constant Setpoint Plant Failsafe Setpoint only if Plant Failsafe Mode Constant Setpoint Specify the Setpoint for all units in the cascade 6 The Client Address screen appears as a reminder to setup all Client units in the BST Cascade before continuing Once al...

Page 95: ...gs that appear Unit Address The unique communication address of the current Manager unit Range 1 to 127 Min Max Address The address range in the BST cascade 1 up to the total number of units in the cascade for example 1 and 10 Max Address maximum 16 SSD Address The Client Client Device address This parameter is for backwards compatibility with the C More Control system Cascade Baud Rate Select the...

Page 96: ... will be used to create the associated OATR curve that trigger the unit to turn on and off and in Warm Weather Shutdown specify the threshold outside temperature above which the unit shuts down 17 If the unit will communicate with the site s BAS Building Automation System the Select BAS Mode screen appears Choose the communication protocol it will use or else press Off 18 Fill in the parameters to...

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Page 98: ...ector BMK750 5000N only Inspect Inspect replace if necessary Replace 15 mins 8 2 1 Pilot Burner BMK5000 6000 only Inspect Inspect replace if necessary Replace 15 mins 8 3 Flame Detector Inspect Inspect replace if necessary Replace 15 mins 8 4 O2 Sensor Inspect Inspect Clean 15 mins 4 4 Combustion Calibration Check Check 1 hr 8 5 Testing of Safety Devices See ASME CSD 1 Chart 45 mins 8 6 Burner Ins...

Page 99: ...r pump filter air filter 58025 15 LWCO air pump filter Burner Blower gaskets air filter cleaning kit 58025 16 LWCO air pump filter air filter cleaning kit 8 2 BENCHMARK 750 5000N IGNITER INJECTOR The ignitor injector should be inspected annually and replaced at least every 24 months of operation sooner if there is evidence of substantial erosion or carbon build up Parts and instructions are includ...

Page 100: ...Detector BMK1500 2000 Figure 8 1c Igniter Injector Flame Detector BMK2500 5000N Figure 8 1d Igniter Injector Orientation BMK2500 Shown BLOWER PLENUM IGNITER INJECTOR ASSEMBLY FLAME DETECTOR FLAME OBSERVATION PORT O2 SENSOR BLOWER PLENUM IGNITOR INJECTOR ASSEMBLY FLAME DETECTOR BURNER FLAME OBSERVATION PORT O2 SENSOR BURNER O2 SENSOR IGNITER INJECTOR INJECTOR TUBE INJECTOR TUBE POSITION INSIDE 75 A...

Page 101: ... The BMK5000 6000 Main Flame Detector P N 65182 is located on the Blower Flange near the top of the unit There are also two 2 optical Pilot Flame Detectors mounted on the Burner front plate see Figure 8 2 above The flame detector and Main Flame Detector on BMK 5000 6000 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...

Page 102: ...r Mounting Location BMK750 5000N BMK750 shown On the BMK5000 6000 it is located on the burner s rear plate on the rear of the unit REAR OF UNIT Figure 8 3b O2 Sensor Mounting Location BMK5000 6000 Lean O2 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 wi...

Page 103: ...des an air pump which draws an air sample from the combustion chamber past the O2 Sensor ensuring its accuracy The air pump contains an air pump filter P N 87008 should be inspected cleaned every 12 months and replaced every 24 months It is included in all BMK5000 6000 24 Month Maintenance Kits Air Pump Maintenance and Troubleshooting Instructions 1 Remove the Air Pump s plastic air filter cover a...

Page 104: ...ety Device Testing in this guide for a description and instructions for performing these tests 8 6 BURNER INSPECTION The burner assembly should be inspected every 24 months to ensure that all components are intact and functioning as designed This requires the replacement of one or two burner gaskets depending on BMK model and blower and gas train O Rings which are included in all 24 Month Maintena...

Page 105: ...ner Assembly Exploded View BMK750 1000 Figure 8 5b BMK1500 2000 Burner Assembly Mounting Details AIR FUEL VALVE BURNER GASKET P N 81143 FLAME DETECTOR O2 SENSOR BLOWER GASKET P N 81064 BURNER BLOWER BURNER PLATE AIR FILTER P N 59138 A F VALVE PLENUM BLOWER GASKET P N 81184 BURNER PLATE 3 8 16 HEX NUTS 8 each 1 2 NUTS BOLTS 4 ea PIPE FLANGE GASKET P N 81155 GAS TRAIN CONNECTS HERE ...

Page 106: ...ing Details BMK2500 5000N Figure 8 5d Burner Assembly Exploded View BMK5000 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 AIR FUEL VALVE IGNITER INJECTOR ASSEMBLY 5 8 NUTS BOLTS 4 each AIR FUEL VALVE BLOWER TO AIR FUEL VALVE O RING P N 88016 BLOWER FLANGE BLOWER 3 8 HEX NUTS WASHERS 8 EA BURNER GASKETS 2 P N 81159 BURNER...

Page 107: ... 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 In addition you must ensure the vent under the removable cover is free and clear of obstructions Figure 8 6 External Condensate Trap Cross Section Exploded View If your system includes a condensate neutralizer the active ingredient must be replaced per...

Page 108: ...u can order a 24 Month Maintenance kit that includes an air filter cleaning kit in place of a new filter NOTE Failure to clean or replace the air filter may affect stable combustion result in less efficient operation and may result in combustion reliability issues All 24 Month Maintenance Kits include one of two parts An Air Filter Cleaning Kit Appropriate if the filter is intact New Air Filter Ne...

Page 109: ... There are three kits available P N 58197 1 Front Refractory for units with Front Burner Plate 42255 P N 58197 2 Front Refractory for units with Front Burner Plate 43071 P N 58197 3 Rear Refractory Instructions for replacing both are included in technical Instruction Document TID 0221 included with the kit 8 10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD If the boiler is to be taken out of service fo...

Page 110: ...ge Maintenance NOTE A periodic inspection and maintenance log by date and action taken must be developed and maintained for each blower See example below Each item must be checked monthly Example Storage Maintenance Schedule Log Item Action Dates Checked 1 Re inspect units to insure any protective devices used are functioning properly Check for scratches in the finish which will allow corrosion or...

Page 111: ... 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 Review installation requirements included in Section 2 of the Benchmark Platinum Edge INSTALLATION Manual GF 210 2 Inspect all piping and connections to the unit 3 Inspect exhaust vent and air inlet duct work i...

Page 112: ...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 Section 4 2 Tools Instruments for Combustion Calibration in this guide and the O2 sensor see Section 8 4 O2 Sensor in this guide Flue vent stack and intake air duct Monthly Operator Visually inspection c...

Page 113: ...ide 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 Tech See Section 5 10 Purge Switch Open During Purge in this guide Air Fuel Valve ignition position switch Annually Service Tech See Section 5 11 Ignition Switch Open During Ignition in this guide Safety ...

Page 114: ...ALL FM gas trains Downstream SSOV on DBB gas trains 64048 64048 64048 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV on DBB gas trains 27086 1 27086 1 27086 1 Actuator Replacement Kit SSOV with P O C Switch Kit 27086 6 TABLE 8 5 Recommended Emergency Spare Parts BMK5000 6000 DESCRIPTION PART NUMBER Actuator Replacement Kit SSOV with P O C Switch Kit 27086 2 Actuator Repl...

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Page 116: ...reliability while minimizing emissions 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 Controller inside the boiler If the oxygen readings are outside of preset or user defined values the blower voltage is changed in small increments until the reading falls withi...

Page 117: ...vation code and press Save 5 Scroll back to the top of the AERtrim Settings screen and set the AERtrim parameter to Enabled 6 Go to the AERtrim O2 Trim Parameters screen The O2 Target O2 Upper Limit and O2 Lower Limit parameters are at default values but can be changed as needed NOTE For full instructions including all menu options see the Edge Controller Manual Section 6 6 1 AERtrim 9 3 OPERATION...

Page 118: ...s to allow the user to select the optimal air fuel ratio for a particular boiler or application Figure 9 3 shows how the controller would react to an O2 reading above the upper limit The controller will reduce the blower voltage BV until the O2 reading is within the Target Range provided the BV adjustments are within the BV limits for that unit at that fire rate The control will then store this as...

Page 119: ...ed air O2 level 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 example if the time and day for an auto calibration passes the Controller will wait for the boiler to cycle off and go into Standby mode before executing the sensor calibration function I...

Page 120: ...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 4 5 60 2 5 5 5 5 0 80 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper Limit must be at least 1 higher than O2 Lower 18 5 5 8 5 6 5 30 5 5 8 5 6 5 45 5 5 8 5 6 5 60 5 5 8 5 6 0 80 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK750 AERtrim Adjustment Range CALI...

Page 121: ...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 Upper Limit must be at least 1 higher than O2 Lower 18 5 5 8 5 6 5 30 5 5 8 5 6 5 45 5 5 8 5 6 0 60 5 5 8 5 6 0 80 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK1000 AERtrim Adjustment Range CAL...

Page 122: ... 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 Upper Limit must be at least 1 higher than O2 Lower 16 5 5 8 5 6 0 30 5 5 8 5 7 0 40 5 5 8 5 7 0 50 5 5 8 5 7 0 70 5 5 8 5 6 5 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK1500 AERtrim Adjustment Range CALI...

Page 123: ...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 Upper must be at least 1 higher than O2 Lower 18 5 5 8 5 7 0 30 5 5 8 5 6 5 40 5 5 8 5 6 5 50 5 5 8 5 6 0 70 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK2000 AERtrim Adjustment Range CALIBRATIO...

Page 124: ... 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 Upper must be at least 1 higher than O2 Lower 16 5 5 8 5 6 0 30 5 5 8 5 7 0 40 5 5 8 5 7 5 50 5 5 8 5 6 5 70 5 5 8 5 6 5 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK2500 AERtrim Adjustment Range CALIBRATI...

Page 125: ...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 Upper must be at least 1 higher than O2 Lower 14 5 5 8 5 7 0 30 5 5 8 5 7 8 40 5 5 8 5 8 0 50 5 5 8 5 7 5 70 5 5 8 5 6 0 100 5 5 8 5 5 5 O2 Offset 3 0 3 0 1 0 BMK3000 AERtrim Adjustment Range CALIBRATIO...

Page 126: ... 30 3 8 5 5 40 3 8 5 5 50 3 8 5 5 70 3 8 5 5 100 3 8 5 5 O2 Lower must be at least 1 lower than O2 Upper 23 2 5 5 5 5 5 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 5 0 O2 Upper must be at least 1 higher than O2 Lower 23 5 5 8 5 6 5 30 5 5 8 5 6 0 40 5 5 8 5 6 0 50 5 5 8 5 6 0 70 5 5 8 5 6 0 100 5 5 8 5 6 0 O2 Offset 3 0 3 0 1 0 BMK4000 AERtrim Adjustment Range CALIBRATI...

Page 127: ... 30 3 8 5 5 40 3 8 5 5 50 3 8 5 5 70 3 8 5 5 100 3 8 5 5 O2 Lower must be at least 1 lower than O2 Upper 18 2 5 5 5 5 5 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 5 0 O2 Upper must be at least 1 higher than O2 Lower 18 5 5 8 5 6 5 30 5 5 8 5 6 0 40 5 5 8 5 6 0 50 5 5 8 5 6 0 70 5 5 8 5 6 0 100 5 5 8 5 6 0 O2 Offset 3 0 3 0 1 0 BMK5000N AERtrim Adjustment Range CALIBRAT...

Page 128: ...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 range Dirty filter or poor combustion calibration recalibrate unit O2 Offset too low Increase Offset value Bad Sensor Replace O2 Sensor Malfunction O2 Levels less than 4 or more than 24 for more than 10 s...

Page 129: ... 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 air filter gas regulator combustion calibration BV Lo Err Check sensor calibration it may need to be replaced Max Iter Trim Operation reached maximum iteration Wait and try again Check sensor calibra...

Page 130: ...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 Edge Controller 2 Refer to the Fault Indication column in Troubleshooting Table 10 1 below and locate the Fault that best describes the existing conditions 3 Proceed to the Probable Cause column and s...

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Page 132: ...istance 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 an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 7 Bad inlet air temperature sensor 7 Check the actual inlet air temperature reading and measure re...

Page 133: ... 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 FAULT DURING IGNITION items 3 to 12 7 Missing or improperly connected Blocked Flue jumper 7 Check auxiliary box to be sure Blocked Flue input is jumpered and properly connected AIRFLOW FAULT DURING RUN 1 Blow...

Page 134: ...l is not isolated floating 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 switch on the Controller s Interface board to ensure it is set correctly for the type of signal being sent Check control signal type set in Advanced Setup BST Cascade Application Configuration screen FLAME LOSS ...

Page 135: ...T board failed to activate when commanded 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Relay is activated when not in Demand 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Poor combustion calibration 1 Check combustion calibration using procedures in Section 4 4 Combustion Calibration of this guide 2 Carboned heat exchanger ...

Page 136: ...ure switch setpoint 5 Check setpoint of unit and setpoint of Temperature switch Ensure that the temperature switch is set higher than the unit s setpoint 6 System flow rate changes are occurring faster than units can respond 6 If the system is a variable flow system monitor system flow changes to ensure that the rate of flow change is not faster than what the units can respond to HIGH WATER TEMPER...

Page 137: ...ery second If not replace IGST Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 1 Start the unit The Air Fuel Valve should rotate to the purge open position then back to ignition position towards closed during the ignition cycle If the valve does not rotate back to the ignition position check the Air Fuel Valve calibration If calibration is okay the problem m...

Page 138: ...g in AC Power Box against the power box transformer wiring diagram to ensure it is wired correctly LOW GAS PRESSURE 1 Incorrect supply gas pressure 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing Ensure it is above the value in Table 4 2 Natural Gas or Table 4 5 Propane 2 Defective Low Gas Pressure switch 2 Measure gas pressure at the Low Gas Pressure switch If it is gr...

Page 139: ...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 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 Check Heartbeat LED DS1 and verify it is blinking ON OFF...

Page 140: ...ot 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 switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in the Remote Signal parameter Advanced Setup Unit Application Configuration RESIDUAL FLA...

Page 141: ... 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 the SSOV and check switch continuity If the switch does not show continuity with the gas valve closed either adjust or replace the switch or actuator 4 Incorrectly wired switch 4 Ensure that the SSOV ...

Page 142: ...s not clogged or damaged 2 Defective Staged Ignition Solenoid Figure 8 1a through Figure 8 1c 2 Close the Manual Shutoff Valve Attempt to start the unit and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged Ignition Solenoid Fluctuating Gas Pressure 1 Gas pressure going into unit is fluc...

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Page 144: ... Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 144 of 167 SECTION 11 WIRING DIAGRAMS 11 1 BENCHMARK 750 2000 SCHEMATICS Benchmark 750 2000 Drawing Number 68094 rev B Sheet 1 of 4 ...

Page 145: ...tinum Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 145 of 167 Benchmark 750 2000 Drawing Number 68094 rev B Sheet 2 of 4 ...

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Page 148: ...tion Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 148 of 167 11 2 BENCHMARK 2500 3000 SCHEMATICS Benchmark 2500 3000 Drawing Number 68095 rev B Sheet 1 of 4 ...

Page 149: ...inum Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 149 of 167 Benchmark 2500 3000 Drawing Number 68095 rev B Sheet 2 of 4 ...

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Page 152: ... OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 152 of 167 11 3 BENCHMARK 4000 5000N SCHEMATICS Benchmark 4000 5000N Drawing Number 68101 rev C Sheet 2 of 6 New Image Old Image New Image Benchmark 4000 5000N Drawing Number 68101 rev C Sheet 1 of 6 ...

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Page 154: ...inum Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 154 of 167 Benchmark 4000 5000N Drawing Number 68101 rev C Sheet 3 of 6 ...

Page 155: ...inum Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 155 of 167 Benchmark 4000 5000N Drawing Number 68101 rev C Sheet 4 of 6 ...

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Page 158: ...tion Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 158 of 167 11 4 BENCHMARK 5000 6000 SCHEMATICS Benchmark 5000 6000 Drawing Number 68096 rev B Sheet 1 of 4 ...

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Page 161: ...inum Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 161 of 167 Benchmark 5000 6000 Drawing Number 68096 rev B Sheet 4 of 4 ...

Page 162: ...um Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 162 of 167 Benchmark 5000 6000 575V Drawing Number 68097 rev B Sheet 1 of 4 ...

Page 163: ...um Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 163 of 167 Benchmark 5000 6000 575V Drawing Number 68097 rev B Sheet 2 of 4 ...

Page 164: ...um Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 164 of 167 Benchmark 5000 6000 575V Drawing Number 68097 rev B Sheet 3 of 4 ...

Page 165: ...um Edge ii Operation Service Manual SECTION 11 WIRING DIAGRAMS OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 165 of 167 Benchmark 5000 6000 575V Drawing Number 68097 rev B Sheet 4 of 4 ...

Page 166: ...Benchmark Platinum Edge ii Operation Service Manual CHANGE LOG OMM 0137_J 12 20 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 166 of 167 NOTES ...

Page 167: ...with P N 66026 Sections 4 4 and 8 2 1 ang 8 3 Revised front and rear refractory instructions Section 8 9 ref PIR 1608 3 DIR 20 23 Revised Combustion Calibration values for BMK 4000 5000N for both Natural gas Section 4 5 1 and Propane Section 4 5 2 Added BMK 4000 5000N tables to Section 3 4 Start Stop Levels Added removal of air filter bag to startup procedure Section 4 1 ref ECN 1687 Updated Figur...