Before using the equipment, read the manual thoroughly. Failure
to follow safety instructions can result in serious consequences.
Keep the manual for future reference.

Edge Controller Operation:

Learn how to operate the Edge Controller by following the
instructions in Section 2 of the manual.

Start Sequence:

Follow the steps outlined in Section 3 for the correct start
sequence.

Initial Start-Up:

Refer to Section 4 for the initial start-up requirements. Use
the specified tools and instruments for combustion calibration as
detailed in the manual.

Safety Device Testing:

Perform tests on safety devices as described in Section 5.
Ensure proper functioning of low water level and water temperature
fault tests. Conduct interlock tests as well.

FAQ (Frequently Asked Questions):

Q: What should I do if I encounter a fault during
operation?

A: Refer to the troubleshooting section of the manual to
identify and resolve faults. If the issue persists, contact
technical support.

Q: Can this product be used with other fuel types not listed in
the specifications?

A: It is recommended to only use the specified fuel types
mentioned in the manual for safe and efficient operation of the
boiler.

“`

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

Di s c l ai m er
The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply. AERCO is not liable for errors appearing in this manual, not for incidental or consequential damages occurring in connection with the furnishing, performance, or use of these materials.

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CONTENTS
IM PORTANT
Read this Manual BEFORE using this equipment. Failure to read and follow all safety and use information can result in death, serious personal injury, property damage, or damage to the equipment. Keep this Manual for future reference.

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Table of Contents
TABLE OF CONTENTS ……………………………………………………………………… 3
FOREWORD ……………………………………………………………………………………… 6
SECTION 1: SAFETY PRECAUTIONS………………………………………………………… 9
1.1 WARNINGS & CAUTIO NS ………………………………………………………………………………………………………………………………………9 1.2 EMERGENCY SHUTDOW N……………………………………………………………………………………………………………………………………10 1.3 PROLONGED SHUTDOWN……………………………………………………………………………………………………………………………………10 1.4 IMPORTANT REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS …………………………………………………………….11
SECTION 2: EDGE CONTROLLER OPERATION…………………………………………. 13
2.1 INTRODUCTIO N …………………………………………………………………………………………………………………………………………………..13 2.2 LOGIN AND PASSWORD ENTRY …………………………………………………………………………………………………………………………..14
SECTION 3: START SEQUENCE…………………………………………………………….. 15
3.1 INTRODUCTIO N …………………………………………………………………………………………………………………………………………………..15 3.2 START SEQUENCE ………………………………………………………………………………………………………………………………………………..15 3.3 START/STOP LEVELS …………………………………………………………………………………………………………………………………………….23 3.4 START/STOP LEVELS AIR/FUEL & ENERGY INPUT……………………………………………………………………………………………..24
3.4.1 BMK750/1000 Air/Fuel Valve Position And Energy Input …………………………………………………………………………….24 3.4.2 BMK1500 Air/Fuel Valve Position and Energy Input …………………………………………………………………………………….26 3.4.3 BMK2000 Air/Fuel Valve Position and Energy Input …………………………………………………………………………………….27 3.4.4 BMK2500 Air/Fuel Valve Position and Energy Input …………………………………………………………………………………….28 3.4.5 BMK3000 Air/Fuel Valve Position and Energy Input …………………………………………………………………………………….29 3.4.6 BMK4000 Air/Fuel Valve Position and Energy Input …………………………………………………………………………………….30 3.4.7 BMK5000N Air/Fuel Valve Position and Energy Input ………………………………………………………………………………….31 3.4.8 BMK5000 Air/Fuel Valve Position and Energy Input …………………………………………………………………………………….32 3.4.9 BMK6000 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 CALIBRATIO N ………………………………………………………………………………..35
4.2.1 Required Tools & Instrumentation ……………………………………………………………………………………………………………….35 4.2.2 Installing Gas Supply Manometer…………………………………………………………………………………………………………………35 4.2.3 Accessing the Analyzer Probe Port……………………………………………………………………………………………………………….39 4.3 BENCHMARK 5000 & 6000 PILOT FLAME IGNITIO N ……………………………………………………………………………………………40 4.4 FUEL TYPES A ND COMBUSTION CALIBRATIO N ……………………………………………………………………………………………………40 4.5 COMBUSTIO N CALIBRATIO N ……………………………………………………………………………………………………………………………….40 4.5.1 NATURAL GAS Manual Combustion Calibration …………………………………………………………………………………………..41 4.5.2 PROPANE Gas Combustion Calibration ………………………………………………………………………………………………………..47 4.6 REASSEMBLY 51 4.7 DUAL FUEL SWITCHO VER…………………………………………………………………………………………………………………………………….52 4.8 OVER-TEMPERATURE LIMIT SWITCHES ……………………………………………………………………………………………………………….52 4.8.1 Adjusting the Automatic Reset Limit Switch Temperature …………………………………………………………………………..53 4.8.2 Resetting the Manual Reset Limit Switch……………………………………………………………………………………………………..53 4.8.3 Changing the Readout Between Fahrenheit and Celsius ……………………………………………………………………………..54
SECTION 5: SAFETY DEVICE TESTING……………………………………………………. 55
5.1 TESTING OF SAFETY DEVICES ………………………………………………………………………………………………………………………………55

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5.2 LOW GAS PRESSURE TEST ……………………………………………………………………………………………………………………………………55 5.2.1 Low Gas Pressure Test: BMK750 2500 ………………………………………………………………………………………………………55 5.2.2 Low Gas Pressure Test: BMK3000 6000 Only ……………………………………………………………………………………………58
5.3 HIGH GAS PRESSURE TEST …………………………………………………………………………………………………………………………………..60 5.3.1 HIGH GAS PRESSURE TEST: BMK750 2500 ………………………………………………………………………………………………..60 5.3.2 HIGH GAS PRESSURE TEST: BMK3000 6000 Only………………………………………………………………………………………63
5.4 LOW WATER LEVEL FAULT TEST ………………………………………………………………………………………………………………………….67
5.5 WATER TEMPERATURE FAULT TEST ……………………………………………………………………………………………………………………68 5.6 INTERLOCK TESTS ………………………………………………………………………………………………………………………………………………..69
5.6.1 Remote Interlock Test…………………………………………………………………………………………………………………………………..69 5.6.2 Delayed Interlock Test ………………………………………………………………………………………………………………………………….69 5.7 FLAME FAULT TEST………………………………………………………………………………………………………………………………………………70 5.8 AIR FLOW FAULT TESTS-BLOWER PROOF & BLOCKED INLET SWITCHES ……………………………………………………………..71 5.8.1 Blower Proof Switch Test ……………………………………………………………………………………………………………………………..71 5.8.2 Blocked Inlet Switch Test ……………………………………………………………………………………………………………………………..73 5.9 SSOV PROOF OF CLOSURE SWITCH CHECK ………………………………………………………………………………………………………….74 5.10 PURGE SW ITCH OPEN DURING PURGE ……………………………………………………………………………………………………………..75 5.11 IGNITIO N SWITCH OPEN DURING IGNITION ……………………………………………………………………………………………………..77
5.12 SAFETY PRESSURE RELIEF VALVE TEST ………………………………………………………………………………………………………………77
SECTION 6: STANDALONE MODES OF OPERATION…………………………………. 78
6.1 OUTDOOR RESET MODE ……………………………………………………………………………………………………………………………………..78 6.1.1 Outdoor Air Temperature Sensor Installation ………………………………………………………………………………………………78 6.1.2 Outdoor Reset Mode Star tup ……………………………………………………………………………………………………………………….78
6.2 CONSTANT SETPOINT MODE……………………………………………………………………………………………………………………………….79 6.3 REMOTE S ETPOINT MODE …………………………………………………………………………………………………………………………………..80 6.4 DIRECT DRIVE MODES …………………………………………………………………………………………………………………………………………80 6.5 AERCO CONTROL SYSTEM (ACS) ………………………………………………………………………………………………………………………….81
6.6 COMBINA TIO N CONTROL SYSTEM (CCS) …………………………………………………………………………………………………………….81 6.6.1 Combination Control System Field Wiring ……………………………………………………………………………………………………83 6.6.2 Combination Control System Setup and Startup ………………………………………………………………………………………….83
SECTION 7: BOILER SEQUENCING TECHNOLOGY ……………………………………. 84
7.1 INTRODUCTIO N …………………………………………………………………………………………………………………………………………………..84 7.1.1 Installation Notes …………………………………………………………………………………………………………………………………………85
7.2 BST IMPLEMENTATIO N INSTRUCTION…………………………………………………………………………………………………………………85 7.2.1 BST Setup: Constant Setpoint……………………………………………………………………………………………………………………….87 7.2.2 BST Setup: Remote Setpoint…………………………………………………………………………………………………………………………88 7.2.3 BST Setup: Outdoor Air Temperature Reset …………………………………………………………………………………………………89
SECTION 8: MAINTENANCE………………………………………………………………… 90
8.1 MAINTENANCE SCHEDUL E ………………………………………………………………………………………………………………………………….90 8.2 BENCHMARK 750-5000N IGNITER-INJECTOR………………………………………………………………………………………………………91
8.2.1 Pilot Ignition Benchmark 5000-6000…………………………………………………………………………………………………………92 8.3 FLAME DETECTOR ……………………………………………………………………………………………………………………………………………….93 8.4 O2 SENSOR (IF EQUIPPED) ……………………………………………………………………………………………………………………………………93
8.4.1 Air Eductor Air Pump Maintenance (if equipped) BMK5000 & 6000 ………………………………………………………..95 8.5 SAFETY DEVICE TESTING ……………………………………………………………………………………………………………………………………..95
8.6 BURNER INSP ECTION …………………………………………………………………………………………………………………………………………..95 8.7 CONDENSATE DRAIN TRAP ………………………………………………………………………………………………………………………………….98

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8.8 AIR FILTER CLEANING AND REPLACEMENT …………………………………………………………………………………………………………98 8.9 WATER QUALITY ………………………………………………………………………………………………………………………………………………….99 8.10 REFRACTORY REPLACEMENT BMK5000 & 6000 ONLY …………………………………………………………………………………..99 8.11 SHUTTING BO ILER DOWN FOR EXTENDED PERIOD ……………………………………………………………………………………….. 100
8.11.1 Benchmark 5000 & 6000 Long Term Blower Storage ……………………………………………………………………………… 100 8.12 RETURNING THE BO ILER TO SERVICE AFTER SHUTDOWN …………………………………………………………………………….. 101 8.13 RECOMMENDED PERIODIC TESTING ……………………………………………………………………………………………………………… 101 8.14 RECOMMENDED SPARES ……………………………………………………………………………………………………………………………….. 102
SECTION 9: AERTRIM OPERATION (IF EQUIPPED)…………………………………. 104
9.1 AERTRIM INTRODUCTIO N………………………………………………………………………………………………………………………………… 104 9.2 AERTRIM ACTIVATION ……………………………………………………………………………………………………………………………………… 105 9.3 OPERATION DETAILS ………………………………………………………………………………………………………………………………………… 105 9.4 O2 SENSOR CALIBRATION…………………………………………………………………………………………………………………………………. 106 9.5 AERTRIM MENU VALUES AND DEFAULTS ………………………………………………………………………………………………………… 107 9.6 AERTRIM MAINTENANCE AND TROUBLESHOOTING ……………………………………………………………………………………….. 118
SECTION 10: TROUBLESHOOTING……………………………………………………….. 119
10.1 INTRODUCTION ……………………………………………………………………………………………………………………………………………… 119 10.2 ADDITIONAL FAULTS W ITHOUT SPECIFIC FAUL T MESSAGES…………………………………………………………………………. 127
SECTION 11: WIRING DIAGRAMS………………………………………………………… 128
11.1 BENCHMARK 750 2000 SCHEMATICS …………………………………………………………………………………………………………. 128 11.2 BENCHMARK 2500 3000 SCHEMATICS ……………………………………………………………………………………………………….. 132 11.3 BENCHMARK 4000 5000N SCHEMA TICS …………………………………………………………………………………………………….. 136 11.4 BENCHMARK 5000 6000 SCHEMATICS ……………………………………………………………………………………………………….. 142

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FORWARD
FOREWORD
The AERCO Benchmark (BMK) 750 through 6000 natural gas and propane fueledboilersaremodulating and condensing units. They represent a true industry advance that meets the needsof today’senergy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark’smodulating capability relates energy input directly tofluctuatingsystemloads. These BMK models provide extremely high efficiency operation and are ideally suited for modernlow temperatures, as well as conventional heating systems.

I M P ORTA NT!
· All descriptions provided in this document apply to the Benchmark Series of boilers.
· All measurements apply to both natural gas and propane models, unless otherwise specif ied.

The Benchmark models operate within the following input and output ranges:

Benchmark Boiler Intake and Output Ranges

MODEL

INPUT RANGE (BTU/HR.)

MINIMUM

MAXIMUM

BMK750

50,000 (14.6 kW)

750,000 (220 kW)

BMK1000

50,000 (14.6 kW)

1,000,000 (293 kW)

BMK1500

75,000 (22 kW)

1,500,000 (440 kW)

BMK2000

100,000 (29.3 kW) 2,000,000 (586 kW)

BMK2500

167,000 (48.9 kW) 2,500,000 (732 kW)

BMK3000

200,000 (58.6 kW) 3,000,000 (879 kW)

BMK4000

267,000 (78.2 kW) 4,000,000 (1172 kW)

BMK5000N

250,000 (73.3 kW) 4,990,000 (1462 kW)

BMK5000

400,000 (117 kW)

5,000,000 (1465 kW)

BMK6000

400,000 (117 kW)

6,000,000 (1758 kW)

OUTPUT RANGE (BTU/HR.)

MINIMUM

MAXIMUM

47,750 (14 kW)

716,250 (210 kW)

48,300 (14.15 kW) 968,000 (284 kW)

64,500 (18.9 kW)

1,395,000 (409 kW)

86,000 (25.2 kW)

1,860,000 (545 kW)

144,000 (42.2 kW) 2,395,000 (702 kW)

174,000 (51.0 kW) 2,874,000 (842 kW)

232,000 (68.0 kW) 3,800,000 (1113 kW)

218,000 (63.9 kW) 4,740,000 (1389 Kw)

348,000 (102 kW) 4,750,000 (1392 kW)

348,000 (102 kW) 5,700,000 (1670 kW)

The output of the boiler is a function of the unit’s firing rate (valve position) and return water temperature.

When installed and operated in accordance with this Instruction Manual,the BMK750 2000 and 5000& 6000 comply with the NOx emission standards outlined in: South CoastAirQuality ManagementDistrict (SCAQMD), Rule 1146.2. In addition, the BMK2500 6000 complies with the Bay Area Air Quality Management District regulation 9, Rule 7.

Whether in singular or modular arrangements, BMK boilers offer maximum venting flexibility with minimum installation space requirements. These boilers are Category II and IV, positive pressure appliances. Single and/or multiple breeched units can operate in the following vent configurations:

· Room Combustion Air: o Vertical Discharge o Horizontal Discharge
· Ducted Combustion Air: o Vertical Discharge o Horizontal Discharge
These boilers are capable of being vented utilizing Polypropyleneand AL29-4Cventsystems.Inaddition, the BMK750 & 1000 models are also approved for PVC and CPVC, ventsystems(excludingthestate of Massachusetts).

Benchmark’s advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration.

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AERCO Technical Terminology Meanings

TERMINOLOGY

MEANING

A (Amp)

Ampere

ACS

AERCO Control System, AERCO’s boiler management systems

ADDR

Address

AGND

Analog Ground

ALRM

Alarm

ANSI

American National Standards Institute,

ASME

American Society of Mechanical Engineers

AUX

Auxiliary

BAS

Building Automation System, often used interchangeably with EMS (see below)

Baud Rate BMK (Benchmark)

Symbol rate, or the number of distinct symbol changes (signaling events) transmitted per second. NOT equal to bits per second unless each symbol is 1 bit. AERCO’s Benchmark series boilers

BMS or BMS II

AERCO Boiler Management Systems

BLDG (Bldg)

Building

BST

AERCO on-board Boiler Sequencing Technology

BTU

British Thermal Unit. A unit of energy approximately equal to the heat required to

raise 1 pound (0.45 kg) of water 1°F (0.55 °C)

BTU/HR

BTUs per Hour (1 BTU/hr = 0.29 W)

CCS

Combination Control System

CFH

Cubic Feet per Hour (1 CFH = 0.028 m3/hr)

Carbon Monoxide

COMM (Comm)

Communication

Cal.

Calibration

CNTL

Control

CPU

Central Processing Unit

DBB

Double Block and Bleed, a gas train containing 2 Safety Shutoff Valves (SSOVs)

and a solenoid operated vent valve.

DIP

Dual In-Line Package, a type of switch

ECU

Electronic Control Unit (O2 sensor)

Edge Controller

A control system developed by AERCO used in all Benchmark boilers.

EMS

Energy Management System; often used interchangeably with BAS

Factory Mutual. Used to define boiler gas trains.

GF-xxxx

Gas Fired (an AERCO document numbering system)

GND

Ground

HDR

Header

Hex

Hexadecimal Number (0 9, A F)

Horsepower

Heat Exchanger

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

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AERCO Technical Terminology Meanings

TERMINOLOGY

MEANING

Internet Protocol

ISO

International Organization for Standardization

Lbs.

Pounds (1 lb. = 0.45 kg)

LED

Light Emitting Diode

Low Nitrogen Oxide

MA (mA)

Milliampere (0.001)

MAX (Max)

Maximum

MBH

1000 BTUs per Hour

MIN (Min)

Minimum

Modbus®

A serial, half-duplex data transmission protocol developed by AEG Modicon

NC (N.C.)

Normally Closed

NO (N.O.)

Normally Open

NOx

Nitrogen Oxide

NPT

National Pipe Thread

O.D.

Outside Diameter

OMM, O&M

Operation and Maintenance Manual

onAER PCB

AERCO’s on-line remote monitoring system Printed Circuit Board

PMC Board

Primary Micro-Controller (PMC) board, contained in the Edge

POC

Proof of Closure

PPM

Parts per Million

PSI

Pounds per Square Inch (1 PSI = 6.89 kPa)

PTP

Point-to-Point (usually over RS232 networks)

P&T

Pressure and Temperature

ProtoNode

Hardware interface between BAS and a boiler or water heater

PWM

Pulse Width Modulation

RES.

Resistive

RS232 (or EIA-232)

A standard for serial, full-duplex data transmission based on the RS232 Standard

RS485 (or EIA-485)

A standard for serial, half-duplex data transmission 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

Terminating Resistor

A resistor placed at each end of a daisy-chain or multi-drop network to prevent reflections that may cause invalid data in the communication

Tip-N-Tell

A device that indicates if a package was tipped during shipping

A business that tests and validates products

VAC

Volts, Alternating Current

VDC

Volts, Direct Current

VFD

Variable Frequency Drive

VPS

Valve Proving System

Watt

W.C.

Water Column, a unit of pressure (1 W.C. = 249 Pa)

µA

Micro amp (1 millionth of an ampere)

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SECTION 1: SAFETY PRECAUTIONS
SECTION 1: SAFETY PRECAUTIONS
1.1 Warnings & Cautions
Installers and operating personnel MUST observe all safety regulations. The following warningsand cautions are general and must be given the same attention as specific precautions included inthese instructions. In addition to the requirements in this manual, installation MUST conform with localbuilding codes, or, in the absence of local codes, ANSI Z223.1 (National FuelGasCodePublication No.NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Whereapplicable, the equipmentshall be installed in accordance with the current Installation Codefor GasBurning AppliancesandEquipment,CSA B149.1, and applicable Provincial regulations for the class, whichshould becarefully followedinall cases. Authorities having jurisdiction should be consulted before installations are made.
I M P ORTA NT!
This manual is an integral part of the product and must be maintained in legible condition. It must begiven to the user by the installer and kept in a saf e place f or f uture ref erence.
WARNING!
· Do not use matches, candles, f lames, or other sources of ignition to check f or gas leaks.
· Fluids under pressure may cause injury to personnel or damage to equipment when released. Besure to shut of f all incoming and outgoing water shutof f valves. Caref ully decrease all trapped pressures to zero bef ore perf orming maintenance.
· Bef ore attempting to perf orm any maintenance on the unit, shut of f all gas and electrical inputs to theunit.
· The exhaust vent pipe of the unit operates under a positive pressure and theref ore must be completely sealed to prevent leakage of combustion products into living spaces.
· Electrical voltages up to 120 VAC (BMK750 2000), 208 or 480 VAC (BMK2500 BMK3000), 480 VAC (BMK4000 & 5000N), or 208, 480 or 575 VAC (BMK5000 & 6000) and 24 volts AC may be used inthis equipment. Theref ore, the cover on the unit’s power box (located behind the f ront panel door) must be always installed, except during maintenance and servicing.
· A single-pole (120 VAC units) or three-pole (220 VAC and higher units) switch must be installed on the electrical supply line of the unit. The switch must be installed in an easily accessible position to quickly and saf ely disconnect electrical service. D o not af f ix switch to unit sheet metal enclosures.
CA UTI ON!
· Many soaps used f or gas pipe leak testing are corrosive to metals. The piping must berinsed thoroughly with clean water af ter leak checks have been completed.
· DO NOT use this boiler if any part has been under water. Call a qualif ied service technician to inspect and replace any part that has been under water.

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SECTION 1: SAFETY PRECAUTIONS
1.2 Emergency Shutdown
If overheating occurs or the gas supply fails to shut off, close the manual shutoff valve (Figure 1-1) located external to the unit.
NOTE: Installer must identif y location of emergency shutdown manual gas valve to operating personnel.

VALVE CLOSED

VALVE OPEN

Figure 1-1: External Manual Gas Shutoff Valve
In addition, to ensure safety an emergency shutdown procedure that addresses the following points should be designed and implement at the site:
· For automatically operated unattended boilers located in a boiler room, provide a manually operated remote shutdown switch or circuit breaker located just inside or outside each boiler room door. Design the system so activation of the emergency shutdown switch or circuit breaker will immediately shut off the fuel supply to the unit(s).
· For automatically operated unattended boilers in a location other than a boiler room,providea manually operated remote shutdown switch or circuit breaker marked for easy identificationat 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 occupied control room, providean emergency shutdown switch in the control room that is hard-wired to immediately shut off the fuel upon activation.

1.3 Prolonged Shutdown
In an emergency, turn off electrical power to the boiler and close themanualgasvalve located upstream from the unit. The installer must identify the emergency shut-off device.
If the unit is being shut down for an extended period, such as a year or more, completetheinstructions in Section 8.10: Shutting Boiler Down for Extended Period.
When returning a unit to service after a prolonged shutdown, it is recommended thatthe instructionsin Section 4: Initial Startup Procedures and Section 5: Safety Device Testingbeperformed toverify thatall system-operating parameters are correct.

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SECTION 1: SAFETY PRECAUTIONS
1.4 IMPORTANT Requirements for Massachusetts Installations
Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements:
· The boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
· Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap.
· The vent termination must be located a minimum of 4 feet above grade level. If sidewall venting is used, the installation must conform to the following requirements extracted from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard-wired carbon monoxide detector with an alarm and battery back-up is installed 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 secure the services of qualified licensed professionals for the installation of hard-wired carbon monoxide detectors.
a. If the side wall horizontally vented gas fueledequipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery-operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. (Continued)
4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 1: SAFETY PRECAUTIONS
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Section 10 entitled “Equipment Not Required to Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design 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 SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
………………. [End of Extracted Information From 248 CMR 5.08 (2)] …………………

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 2: EDGE CONTROLLER OPERATION
SECTION 2: EDGE CONTROLLER OPERATION
2.1 Introduction
This section provides a brief outline of how to gain access to Benchmark Boiler’s Edge Controller functionality. Full instructions for using the Edge Controller to set up, configure and operate a Benchmark Boiler are included in the Edge Controller Manual.
NOTE: The Edge Controller Manual is document number OMM-0139.
The Edge Controller is shown below. This panel contains all the controls, indicators and displays necessary to operate, adjust and troubleshoot the boiler.
The Edge Controller’s front panel consists of a touchscreen display along withavariety of indicatorsand buttons.
1

Multi-Function Bar, shows either:

1 · Fire Rate

· Valve Position

Parameter Indicator f or both temperature

read-outs:

2 · LEFT: Inlet or Setpoint temperature

· RIGHT: Outlet or System Header

temperature
5

Temperature scale indicator: Fahrenheit or Celsius

Conf igurable temperature read-outs (2):

4 · LEFT: Inlet or Setpoint temperature · RIGHT: Outlet or System Header

temperature

Operation Mode Indicators (2):

5 · LEFT: Demand or Manual

· RIGHT: Manager or Client (BST only)

6 Edge Controller Touchscreen

7 Sof t Keys

8 onAER Indicator Light

9 Ready Light

10 Enable/Disable Switch
10
Low Water Level Buttons (2):
11 · TEST: Initiates Low Water test · RESET: Resets unit af ter LowWater test
11

Figure 2-1 Edge Controller Front Panel

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 2: EDGE CONTROLLER OPERATION

2.2 Login and Password Entry The Edge Controller has multiple levels of password protection.

Level 1
2

Password No password
159

Description The default. Many parameters are visible but “Read Only.” Allows routine maintenance to be performed. Appropriate for AERCO Trained technicians (ATT).

A higher-level password is reserved for AERCO Master Technicians (AMT). It is distributed on an individual basis. To enter a password:

1. On the Edge Controller, go toMain Menu Advanced Setup Access.TheEnterPassword screen appears.

2. Use the number keypad to enter the password (each number appears asa*),then press Save.You will have access to the functionality associated with the level of the password entered.

Figure 2.2: Enter Password Screen
3. Once you have successfully logged into the system, the MainMenu appears. All Edgefunctionality is accessed through one of the six Main Menu items.

Figure 2-3: Edge Controller Main Menu
NOTE: Full instructions f or using the Edge Controller are in the Edge Controller Manual (OMM-0139).

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
SECTION 3: START SEQUENCE
3.1 Introduction The information in this section provides a guide to starting the Benchmark Boiler using the Edge Controller. It is imperative that the initial startup of this unit be performed by factory trainedpersonnel. Operation prior to initial startup by factory trained personnel may void the equipment warranty. In addition, the following WARNINGS and CAUTIONS must always be observed.
WARNING!
· All of the installation procedures in the Benchmark Edge INSTALLATION Manual (OMM-136) must be completed bef ore the initial start-up of the unit.
· Electrical voltages up to 120 VAC (BMK750 2000) and 208 or 460 VAC(BMK2500 5000N) or 208, 460 or 575 VAC (BMK5000 & 6000) and 24 volts AC may be used in this equipment. It must be serviced only by f actory certif ied service technicians.
· Do not attempt to dry f ire the unit. Starting the unit without a f ull water level can seriously damagetheunit and may result in injury to personnel or property damage. This situation will void any warranty.
· Initial startup of the unit must be perf ormed by AERCO f actory trained personnel. Operation prior to initial startup by f actory trained personnel may void the equipment warranty. In addition, the f ollowing WARNINGS and CAUTIONS must be observed at all times .
3.2 Start Sequence When the Edge Controller Enable/Disable switch isset totheEnable position, it checks allpre-purge safety switches to ensure they are closed. These switches include:
· High Water Temperature switch · High Gas Pressure switch · Low Gas Pressure switch · Low Water Level switch · Safety Shut-Off Valve (SSOV) Proof of Closure (POC) switch
NOTE: The Blocked Inlet and downstream Blower Proofswitches are not checked priorto starting thepre-purge.
If all of the above switches are closed, the READY light (above the Enable/Disable switch)willlight when the switch is in the Enable position and the unit will be in the STANDBY mode.
NOTE: If any of the Pre-Purge saf ety device switches are open, or the required conditions arenot observed throughout the start sequence, appropriate f ault messages will be displayed.
When there is a demand for heat, the following events occur: 1. The Controller’s red DEMAND LED status indicator will light. 2. The unit checks all five pre-purge safety switches listed at the beginning of this section.The Edge
Controller’s ignition sequence screen walks you through the ignition screensand demonstrates(or highlights) which switches are not met. SSOV locations are shown in Figure 3-1a through 3-1d.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
TO AIR/FUEL VALVE
MANUAL SHUT-OFF VALVE

NATURAL GAS INLET

LOW GAS PRESSURE SWITCH

SSOV

Figure 3-1a: BMK750 & 1000 SSOV Location (P/N 22322 shown)
NATURAL GAS INLET

MANUAL SHUT-OFF VALVE

TO AIR/FUEL
VALVE
SSOV

HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH

Figure 3-1b: BMK1500 & 2000 SSOV Location (P/N 22314 shown)

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SECTION 3: START SEQUENCE

NATURAL GAS INLET

MANUAL SHUT-OFF VALVE

TO AIR/FUEL VALVE

SSOV
LOW GAS PRESSURE SWITCH

Figure 3-1c: BMK2500: SSOV Location (P/N 22318 shown)
NATURAL GAS INLET

TO AIR/FUEL VALVE
MANUAL SHUT-OFF VALVE
HIGH GAS PRESSURE SWITCH

SSOV
LOW GAS PRESSURE SWITCH

Figure 3-1d: BMK3000/4000/5000N: SSOV Location (P/N 22310 shown)

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE

TO AIR/FUEL VALVE

DOWNSTREAM SSOV WITH POC

UPSTREAM SSOV

MANUAL SHUTOFF VALVE

GAS INLET

HIGH GAS
PRESSURE SWITCH – BMK6000: 10.5″ W.C., 2.6 kPa – BMK5000: 11.0″ W.C., 2.7 kPa

UPSTREAM LOW GAS
PRESSURE SWITCH – BMK6000: 8.5″ W.C., 2.1 kPa – BMK5000: 8.0″ W.C., 2.0 kPa

Figure 3-1e: BMK5000-6000: SSOV Location BMK6000 Shown

3. The Auxiliary Delay occurs for a configurable length of time and the Delayed Interlocksareclosed.

4. Once all required safety device switches are closed, a purge cycle is initiated, and the following events occur:

a. The Blower relay energizes and turns on the blower.

b. The Air/Fuel Valve rotates to the full-open purge position andclosesthe purgeposition switch. The dial on the Air/Fuel Valve (Figure 3-2a and 3-2b) will read 100 toindicate thatit isfull-open (100%).

c. The Fire Rate bar graph on the Controller’s front face shows 100%.

STEPPER MOTOR

AIR INLET
100

TO BLOWER

Figure 3-2a: BMK750 & 1000 Air/Fuel Valve in Purge Position

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
TO BLOWER STEPPER MOTOR
PURGE VALVE POSITION
DIAL AT 100%
AIR IN
Figure 3-2b: BMK1500 6000 Air/Fuel Valve in Purge Position 5. Next, the Blower Proof and Blocked Inlet switches close (Figure 3-4a and 3-4b). On the Ignition
Sequence screen, the Purging indicator turns grey while purging isunderway (Figure3-3), andPurge Timer displays the purge cycle’s elapsed time in seconds.

Figure 3-3: Ignition Sequence Screen Purging
BLOWER PROOF SWITCH BLOCKED INLET SWITCH

Figure 3-4a: BMK750 & 1000 Blower Proof Switch

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
AIR/FUEL VALVE OUTLET TO BLOWER

BLOWER PROOF SWITCH
BLOCKED INLET
SWITCH

AIR/FUEL VALVE INLET FROM GAS TRAIN

Figure 3-4b: BMK1500 6000 Blower Proof Switch
6. Upon completion of the purge cycle, the Controller initiates an ignition cycle, and the following events occur:
a) The Air/Fuel Valve rotates to the low-fire (Ignition) position and closes the ignition switch.The Dial on the Air/Fuel Valve (Figure 3-5) will read between 25 and 35 toindicate thatthe valve isin the low fire position.
b) The Spark Cleaning cycle begins (default duration = 7 sec.) and theIgnition Sequencescreen’s Spark Cleaning indicator (Figure 3-3) turns grey. This cycle turns on theignition transformer to produce a spark (with no gas flowing) to remove moisture and carbon buildup from thespark element. During this cycle the Controller displays the Cleaning Igniter status message.
c) Following the Spark Cleaning cycle, power isapplied to thegasSafety Shut-off Valve (SSOV). When the SSOV indicates the Gas Valve is OPEN (POC) and the Ignition Sequencescreen’sIgnition indicator (Figure 3-3) turns grey.
d) If no spark is present 3 seconds into the ignition trial, the Controller abortstheIgnition Cycle and shuts down the boiler. Refer to Section 10: Troubleshooting for guidance if this occurs.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE

TO BLOWER

STEPPER MOTOR

IGNITION VALVE POSITION
DIAL AT 25% to 35%

AIR IN
Figure 3-5: Air/Fuel Valve in Ignition Position
7. Up to 4 seconds are allowed for ignition to be detected. The ignition circuit isturned off onesecond after the flame is detected.
8. After 2 seconds of continuous flame, the flame strength 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 (depending on which was chosen in Section 6.2.2: Front Panel Configuration of the Edge Controller Manual) will continuously display onthe Controller’sbargraph.
Once the demand for heat has been satisfied, the Edge Controller will turn off the SSOV gas valve.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE

BMK5000 & 6000 Function Timing Chart for Proved Pilot Control System

Operating State

Pre-purge

PFEP

MFEP

Standby T = 0 T = 30 T = 37

T = 44

Run

Component

PFEP

MFEP

Edge Controller

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 Closure C-NC SKP15 Proof of Closure C-NO

SKP25 Power through R1 Power through R2 and AUX Proof of Closure C-NC Proof of Closure C-NO

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE

3.3 Start/Stop Levels
The start and stop levels are the Air/Fuel Valve positions (% open) that start andstop theunit, based on load. These levels are Factory preset as follows:

TABLE 3-1a: Start/Stop Levels NATURAL GAS

BMK 750/

BMK 750/1000 DF

BMK 1500

1000

BMK 2000

Start Level: 22%

24%

20%

24%

Stop Level: 18%

18%

16%

18%

Ignition Position

35%

30%

29%

BMK 2500
24% 16%
29%

BMK 3000
20% 14%
29%

BMK 4000
27% 23%
45%

BMK 5000N
24% 18%
40%

BMK 4000 &
5000N DF 24% 18%
35%

BMK 5000
24% 18%
35%

BMK 6000
24% 18%
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%

Stop Level: 18%

18%

16%

18%

14%

18%

Ignition Position

35%

30%

29%

35%

50%

NOTE: These settings do not normally require adjustment. NOTE: The energy input of the boiler is not linearly related to the Air/Fuel Valve position.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
3.4 Start/Stop Levels Air/Fuel & Energy Input The Tables below show the relationship between the energy input and Air/Fuel Valve position for the BMK models covered in this document.
3.4.1 BMK750/1000 Air/Fuel Valve Position And Energy Input

TABLE 3-2a: BMK750/1000 Air/Fuel Valve Position NATURAL GAS

Air/Fuel Valve Position (% Open)

BMK750

ENERGY INPUT (BTU/HR)
BMK1000

10%

18% (Stop Level)

50,000 (14.7 kW)

20%

52,000 (15.2 kW)

54,000 (15.8 kW)

30%

108,000 (31.7 kW)

140,000 (41.0 kW)

40%

246,000 (72.1 kW)

297,000 (87.0 kW)

50%

369,000 (108.1 kW)

443,000 (126.9 kW)

60%

465,000 (136.3 kW)

564,000 (165.3 kW)

70%

554,000 (162.4 kW)

660,000 (193.4 kW)

80%

637,000 (186.7 kW)

789,000 (231.2 kW)

90%

733,000 (214.8 kW)

933,000 (273.4 kW)

100%

750,000 (219.8 kW)

1,000,000 (293.1 kW)

TABLE 3-2b: BMK750/1000 Air/Fuel Valve Position PROPANE GAS

Air/Fuel Valve Position (% Open)

BMK750

Energy Input (BTU/Hr)

BMK1000

10%

18% (Stop Level)

50,000 (14.7 Kw)

50,000 (14.7 kW

20%

71,000 (20.8 kW)

30%

128,000 (37.5 kW)

181,000 (53.0 kW)

40%

373,000 (109.3 kW)

400,000 (117.2 kW)

50%

508,000 (148.9 kW)

562,000 (164.7 kW)

60%

565,000 (165.6 kW)

703,000 (206.0 kW)

70%

621,000 (182.0 kW)

791,000 (231.8 kW)

80%

660,000 (193.4 kW)

865,000 (253.5 kW)

90%

723,000 (211.9 kW)

963,000 (282.2 kW)

100%

750,000 (219.8 kW)

1,000,000 (293.1 kW)

BOILER ENERGY INPUT (% OF FULL CAPACITY)

BMK750

BMK1000

6.7%

6.9%

5.4%

14%

33%

30%

49%

44%

62%

56%

74%

66%

85%

79%

98%

93%

100%

Boiler Energy Input (% of Full Capacity)

BMK750 0 0
6.7% 9.5%

BMK1000 0 0
5.0% 7.1%

17%

18%

50%

40%

68%

56%

75%

70%

83%

79%

88% 96% 100%

87% 96% 100%

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE

TABLE 3-2c: BMK750/1000 DUAL FUEL Air/Fuel Valve Position NATURAL GAS

Air/Fuel Valve Position (% Open)

Energy Input (BTU/Hr)

BMK750 Dual Fuel

BMK 1000 Dual Fuel

Boiler Energy Input (% of Full Capacity)

BMK750 Dual BMK 1000 Dual

Fuel

18% (Stop Level)

48,850 (14.3 Kw)

6.5%

4.9%

20%

62,000 (18.2 Kw)

8.3%

6.2%

30%

132,000 (38.7 Kw)

17.6%

13.2%

40%

239,000 (70.0 Kw)

31.9%

23.9%

50%

358,000 (104.9 Kw)

47.7%

35.8%

60%

488,300 (143.1 Kw)

65.1%

48.8%

70%

571,000 (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%

TABLE 3-2d: BMK750/1000 DUAL FUEL Air/Fuel Valve Position PROPANE GAS

Energy Input (BTU/Hr)

Boiler Energy Input (% of Full Capacity)

Air/Fuel Valve Position (% Open)

BMK750 Dual Fuel

BMK 1000 Dual Fuel

BMK750 Dual Fuel

BMK 1000 Dual Fuel

18% (Stop Level)

48,850 (14.32 Kw)

7.1%

5.3%

20%

62,000 (18.2 Kw)

8.7%

6.5%

30%

132,000 (38.7 Kw)

16.7%

12.5%

40%

239,000 (70.0 Kw)

30.8%

23.1%

50%

358,000 (104.9 Kw)

44.9%

33.6%

60%

488,300 (143.1 Kw)

63.6%

47.7%

70%

571,000 (167.3 Kw)

633,500 (185.7 Kw)

72.7%

60.9%

80%

633,500 (185.7 Kw)

756,000 (221.6 Kw)

81.1%

71.0%

90%

693,200 (203.2 Kw)

894,000 (262.0 Kw)

85.7%

88.8%

100%

750,000 (219.8 Kw)

1,000,000 (293.1 Kw)

100.0%

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SECTION 3: START SEQUENCE
3.4.2 BMK1500 Air/Fuel Valve Position and Energy Input

TABLE 3-3a: BMK1500 Air/Fuel Valve Position NATURAL GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR)

16% (Stop Level)

75,000 (22.3 kW)

20%

127,000 (37.2 kW)

30%

366,000 (107.2 kW)

40%

629,000 (184.3 kW)

50%

822,000 (240.9 kW)

60%

977,000 (286.2 kW)

70%

1,119,000 (327.9 kW)

80%

1,255,000 (367.7 kW)

90%

1,396,000 (409.0 kW)

100%

1,502,000 (440.1 kW)

TABLE 3-3b: BMK1500 Air/Fuel Valve Position PROPANE GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR)

18% (Stop Level)

75,000 (21.9 kW)

20%

93,700 (27.5 kW)

30%

254,000 (74.4 kW)

40%

505,000 (148.0 kW)

50%

680,000 (199.3 kW)

60%

807,000 (236.5 kW)

70%

947,000 (277.5 kW)

80%

1,157,000 (339.1 kW)

90%

1,379,000 (404.1 kW)

100%

1,503,000 (440.5 kW)

BOILER ENERGY INPUT (% OF FULL CAPACITY)
5.0% 8.5% 24.4% 41.9% 54.7% 65.0% 74.5% 83.5% 92.9% 100%
BOILER ENERGY INPUT (% OF FULL CAPACITY)
5.0% 6.2% 16.9% 33.7% 45.3% 53.8% 63.1% 77.1% 91.9% 100%

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SECTION 3: START SEQUENCE
3.4.3 BMK2000 Air/Fuel Valve Position and Energy Input

TABLE 3-4a: BMK2000 Air/Fuel Valve Position NATURAL GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR)

18% (Stop Level)

100,000 (29.3 kW)

20%

143,000 (41.9 kW)

30%

388,000 (113.7 kW)

40%

759,000 (222.4 kW)

50%

1,069,000 (313.2 kW)

60%

1,283,000 (375.9 kW)

70%

1,476,000 (432.5 kW)

80%

1,675,000 (490.1 kW)

90%

1,833,000 (537.1 kW)

100%

2,000,000 (586.0 kW)

TABLE 3-4b: BMK2000 Air/Fuel Valve Position PROPANE GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR)

18% (Stop Level)

100,000

20%

126,600

30%

363,000

40%

677,000

50%

898,000

60%

1,070,000

70%

1,242,000

80%

1,523,000

90%

1,845,000

100%

2,000,000

BOILER ENERGY INPUT (% OF FULL CAPACITY)
5.7% 11% 23% 37% 51% 61% 74% 83% 93% 100%
BOILER ENERGY INPUT (% OF FULL CAPACITY)
5.0% 6.3% 18.2% 33.9% 44.9% 53.5% 62.1% 76.2% 92.3% 100%

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SECTION 3: START SEQUENCE
3.4.4 BMK2500 Air/Fuel Valve Position and Energy Input

TABLE 3-5a: BMK2500 Air/Fuel Valve Position NATURAL GAS, Single Fuel

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR)

BOILER ENERGY 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)

18% (Stop Level)

155,000

30%

400,000

40%

808,000

50%

1,055,000

60%

1,330,000

70%

1,671,000

80%

1,998,000

90%

2,280,000

100%

2,500,000

BOILER ENERGY INPUT (% OF FULL CAPACITY)
6.2% 16% 32% 42% 53% 67% 80% 91% 100%

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
3.4.5 BMK3000 Air/Fuel Valve Position and Energy Input

TABLE 3-6a: BMK3000 Air/Fuel Valve Position NATURAL GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR.)

14% (Stop Level)

200,000 (58.6 kW)

30%

520,000 (152 kW)

40%

880,000 (258 kW)

50%

1,270,000 (372 kW)

60%

1,680,000 (492 kW)

70%

2,100,000 (615 kW)

80%

2,390,000 (700 kW)

90%

2,650,000 (777 kW)

100%

3,000,000 (879 kW)

TABLE 3-6b: BMK3000 Air/Fuel Valve Position PROPANE GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR)

18% (Stop Level)

200,000

30%

520,000

40%

920,000

50%

1,270,000

60%

1,570,000

70%

1,960,000

80%

2,330,000

90%

2,700,000

100%

3,000,000

BOILER ENERGY INPUT (% OF FULL CAPACITY)
6.7% 17% 29% 42% 56% 70% 80% 88% 100%
BOILER ENERGY INPUT (% OF FULL CAPACITY)
6.7% 17% 31% 42% 52% 65% 78% 90% 100%

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
3.4.6 BMK4000 Air/Fuel Valve Position and Energy Input

TABLE 3-7a: BMK4000 Air/Fuel Valve Position NATURAL GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR.)

23% (Stop Level)

228,180

30%

456,900

40%

822,800

50%

1,205,000

60%

1,684,000

70%

2,388,000

80%

3,107,000

90%

3,582,000

100%

4,000,000

BOILER ENERGY INPUT (% OF FULL CAPACITY)
5.7% 11.4% 20.6% 30.1% 42.1% 59.7% 77.7%% 89.6% 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 Valve Position PROPANE

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR.)

18% (Stop Level)

241,000

20%

338,000

30%

825,000

40%

1,388,000

50%

1,922,000

60%

2,418,000

70%

2,801,000

80%

3,158,000

90%

3,545,000

100%

4,000,000

BOILER ENERGY INPUT (% OF FULL CAPACITY)
6.0% 8.5% 21% 35% 48% 60% 70% 79% 89% 100%

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE

3.4.7 BMK5000N Air/Fuel Valve Position and Energy Input

TABLE 3-8a: BMK 5000N Air/Fuel Valve Position NATURAL GAS

AIR/FUEL VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR.)

18% (Stop Level)

256,000

30%

776,300

40%

1,563,000

50%

2,198,000

60%

2,601,000

70%

3,111,000

80%

3,755,000

90%

4,391,000

100%

4,966,000

BOILER ENERGY INPUT (% OF FULL CAPACITY)
6.5% 15.6% 31.5% 44.3% 52.4% 62.6% 75.6% 88.4% 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 VALVE POSITION (% OPEN)

ENERGY INPUT (BTU/HR.)

BOILER ENERGY INPUT (% OF FULL CAPACITY)

18% (Stop Level)

241,000

4.8%

20%

338,000

6.8%

30%

825,000

17%

40%

1,388,000

28%

50%

1,922,000

38%

60%

2,418,000

48%

70%

3,028,000

61%

80%

3,672,000

73%

90%

4,316,000

86%

100%

4,999,000

100%

Table 3-8c applies to the BMK5000N Propane only model and the Dual Fuel-Propane model.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
3.4.8 BMK5000 Air/Fuel Valve Position and Energy Input

TABLE 3-9a: BMK5000 Air/Fuel Valve Position and Energy Input

Air Fuel Valve Position (% Full Open)

BTU/Hr

Boiler Energy Input % of Full Capacity

10%

18% (Stop Level)

400,000 (117 kW)

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)

Inlet

Outlet

Energy Input in BTU/hr

56″ (13.9 kPa)

6.8″ (1.70 kPa)

5,000,000 (1465 kW)

14″ (3.49 kPa)

6.8″ (1.70 kPa)

5,000,000 (1465 kW)

10″ (3.23 kPa)

6.8″ (1.70 kPa)

5,000,000 (1465 kW)

Oxygen (%O2)
5.7 5.7 5.7

Dating (% Full Fire)
0% 0% 0%

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 3: START SEQUENCE
3.4.9 BMK6000 Air/Fuel Valve Position and Energy Input

TABLE 3-10a: BMK6000 Air/Fuel Valve Position and Energy Input

Air Fuel Valve Position (% Full Open)

BTU/Hr

Boiler Energy Input % of Full Capacity

10%

18% (Stop Level)

385,000 (113 kW)

20%

400,000 (117 kW)

30%

540,000 (158 kW)

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)

Inlet

Outlet

Energy Input in BTU/hr

56″ (13.9 kPa)

8″ (1.99 kPa)

6,000,000 (1758 kW)

14″ (3.49 kPa)

8″ (1.99 kPa)

6,000,000 (1758 kW)

13″ (3.23 kPa)

8″ (1.99 kPa)

5,860,000 (1717 kW)

Oxygen (%O2)
5.40 5.40 5.45

Dating (% Full Fire)
0% 0% 2%

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
SECTION 4: INITIAL START-UP
4.1 Initial Start-Up Requirements The following are the prerequisites for the initial start-up of the Benchmark boiler:
· Complete the installation per the Benchmark Edge: INSTALLATION Manual (OMM-0136), including gas supply piping, vent installation and condensate drain piping. Starting a unit without proper piping, venting, or electrical systems may void the product warranty.
· Set proper controls and limits (see Section 2 or Section 6 in the Edge Controller Manual). Initial start-up consists of the following:
· REMOVE THE AIR FILTER BAG BEFORE STARTING THE UNIT. Combustion calibration (Section 4.4: Combustion Calibration)
· Test safety devices (Section 5: Safety Device Testing) Start-up must be successfully completed before putting the unit into service. The start-up instructions below should be followed precisely in order to operate the unit safely and athigh thermalefficiency and low flue gas emissions.
Initial unit start-up must be performed by AERCO factory trained personnel, whoare trained inthe startup and service of Benchmark boilers.
An AERCO GasFired Startup Sheet, included with eachBenchmark unit,mustbe completed foreach unit for warranty validation and a copy must be returned promptly to AERCO via e-mail at: STARTUP@AERCO.COM.
WARNING!
DO NOT ATTEMPT TO DRY FIRE THE UNIT. Starting the unit without a f ull water level can seriously damage the unit and may result in injury to personnel and/or property damage. This situation will void any warranty.
REMOVE THE AIR FILTER BAG BEFORE STARTING THE UNIT.
NOTE: AERCO recommends that the Standby Blower Voltage parameter bekept at 2.00 volts (thedefault set at the f actory) to prevent f lue gas recirculation. To check, go to the Controller’s Main Menu Advanced Setup Performance FireControl Operating Control and verif y that the Standby Blower Voltage parameter is set to 2.00 V. However, individually vented units in positive pressure boiler rooms may set Standby Blower Voltage between 2.00 and 0 volts to compensate.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
4.2 Tools & Instruments For Combustion Calibration
To properly perform combustion calibration, the proper instruments and tools must be used and correctly attached to the unit. The following sections outline the necessary tools andinstrumentation as well as their installation.
4.2.1 Required Tools & Instrumentation The following tools and instrumentation are necessary to perform combustion calibration:
· Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; CarbonMonoxide(CO) andNitrogen Oxide (NOx) resolution to 1 PPM
· 0 to 16 inch W.C. (0 to 4.0 kPa) manometer or equivalent gauge and plastic tubing · 1/4-inch NPT-to-barbed fittings for use with gas supply manometer · Small and large flat blade screwdrivers · Tube of silicone 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 iswithin 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 Sections4.4.1 (NaturalGas)and 4.4.2(Propane).
Figures 4-1a through 4-1e show where the gas supply manometer is installed on boththe upstreamand downstream locations.
Gas Supply Manometer Installation Instructions BMK750 5000N 1. Turn off the main gas supply upstream of the unit.
2. Remove the top panel and/or front panel from the boiler to access the gas train. 3. Remove the 1/4″ NPT plug from the leak detection ball valve on the upstreamor downstreamside
of the SSOV, as needed during testing, as shown in Figure 4-1a 4-1e. 4. Install an NPT-to-barbed fitting into the tapped plug port. 5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16″ W.C. (4.0
kPa) manometer.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
TO AIR/FUEL VALVE

SSOV

MANUAL SHUTOFF VALVE

1/4″ NTP PLUG (Install manometer here f or
downstream combustion calibration reading)
LEAK DETECTION BALL VALVE

1/4″ NTP PLUG (Install manometer here f or upstream combustion calibration reading)
LEAK DETECTION BALL VALVE

NATURAL GAS INLET
Figure 4-1a: 1/4 Inch Gas Plug Location BMK750 & 1000 (P/N 22322 shown)
NATURAL GAS INLET

MANUAL SHUT-OFF
VALVE

TO AIR/FUEL
VALVE

SSOV
HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH

1/4″ NPT PLUG (Install manometer here f or
downstream combustion
calibration reading)

LEAK DETECTION BALL VALVES

1/4″ NPT PLUG (Install manometer here f or
upstream combustion
calibration reading)

Figure 4-1b: 1/4 Inch Gas Plug Location BMK1500 & 2000 (P/N 22314 shown)

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP

1/4″ NPT PLUG (Install manometer here
f or downstream
combustion calibration
reading)

HIGH GAS PRESSURE SWITCH

NATURAL GAS INLET SSOV

LEAK DETECTION BALL VALVE
MANUAL SHUTOFF VALVE

TO AIR/FUEL VALVE

LOW GAS PRESSURE SWITCH
LEAK DETECTION BALL VALVE
1/4″ NPT PLUG (Install manometer here f or upstream combustion calibration reading)

Figure 4-1c: BMK2500 1/4 Inch Gas Plug Location BMK2500 (P/N 22318 shown)

NATURAL GAS INLET

SSOV

TO AIR/FUEL
VALVE
MANUAL SHUT-OFF VALVE
HIGH GAS PRESSURE WITCH

LOW GAS PRESSURE SWITCH
LEAK DETECTION BALL VALVE

LEAK DETECTION BALL VALVE

1/4″ NPT PLUG (Install manometer here f or downstream
combustion calibration reading)

1/4″ NPT PLUG (Install manometer here f or upstream
combustion calibration reading)

Figure 4-1d: 1/4 Inch Gas Plug Location BMK3000 (P/N 22310 shown)

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP

DOWNSTREAM SSOV WITH POC

HIGH GAS PRESSURE SWITCH

TO AIR/FUEL VALVE
MANUAL SHUT-OFF
VALVE

LOW GAS PRESSURE SWITCH
UPSTREAM LEAK DETECTION BALL VALVE

Figure 4-1e: Port Location for Combustion Calibration BMK4000-5000N
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 in Figure 4-1f.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP

MANUAL SHUT-OFF
VALVE

TO AIR/FUEL VALVE
DOWNSTREAM SSOV WITH POC

UPSTREAM LEAK DETECTION BALL VALVE

Alternative location f or manometer if hose barb is pref erred

GAS PORT (Install manometer here f or upstream combustion calibration reading)
LOW GAS PRESSURE SWITCH

GAS PORT (Install manometer here f or
downstream combustion
calibration reading)

HIGH GAS PRESSURE SWITCH

Figure 4-1f: Port Location for Combustion Calibration BMK5000-6000

4.2.3 Accessing the Analyzer Probe Port
Benchmark units contain a 1/4″ NPT port on the side of the exhaust manifold, as shown inFigure 4-2. Prepare the port for the combustion analyzer probe as follows:
1. Refer to Figure 4-2 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 this time.

DRAIN VALVE

PRIMARY HOT WATER INLET

ANALYZER PROBE PORT

CONDENSATE DRAIN

Figure 4-2: Analyzer Probe Port Location (BMK1500 shown)

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
4.3 Benchmark 5000 & 6000 Pilot Flame Ignition Benchmark 5000 and 6000 boilers are equipped with an interrupted pilot ignition system. The pilot is ignited by a spark discharge within the Pilot Burner inside the combustionchamber.Theinput of the Pilot flame is approximately 18,000 BTU/hr. (5.3 kW). The Pilot Burner flame will stay ignited until themain Burner flame has stabilized and FLAME PROVEN appears on the Controller’s display.
The Pilot gas supply regulator reduces the supply pressure as follows: · On standard pressure models, it reduces line pressure to 4.9″ W.C. (1.2 kPa). · On Low Gas Pressure models, it reduces line pressure to 2.0″ W.C. (0.5 kPa).
The Pilot Burner should be inspected at the beginning of each heating season, or every 6 monthsof continuous operation. It is constructed of high quality, heat resistant stainless steel, however some darkening of the metal is expected. No adjustment of the Pilot should be required, however the gas pressure downstream of the regulator should be checked if an ignition issue is encountered.Refer to Figure 4-1 for test port location.
The Pilot Burner flame is proven by two Pilot Flame Detectors, located aboveandbelow thePilot Burner. These are optical sensors inserted into tubes with quartz windows; they observethe Pilotthrough holes in the refractory insulation. They have a red LED which changes from flashingtosteady-ON when they encounter the flicker of a flame that meets or exceeds the internal sensing threshold. (Only oneof the two detectors need to sense the pilot flame throughout the ignition period). The holesin therefractory should be checked annually to ensure that the path to the Injector-Ignitor is clear.
NOTE: The Pilot Flame Detectors switch the signal to neutral when the f lame is proven.
4.4 Fuel Types and Combustion Calibration All BMK models are preconfigured at the factory to use either natural gasorpropane gasandareavailable in dual fuel versions (natural gas and propane) (see Section 4.6). Both fuel types require different combustion calibration values, so be sure to follow the instructions for the fuel being used.
· Natural Gas combustion calibration: Section 4.4.1 · Propane combustion calibration: Section 4.4.2
4.5 Combustion Calibration
The Benchmark boiler is combustion calibrated for Standard NOx emissions(<20ppm).Forjurisdictions that require Ultra-Low NOx operation (<9 ppm), see Table 4-2 for details. The gas pressure mustbe within the ranges shown in Table 4-2 for each model of boiler at full fire.
Recalibration as part of initial start-up is necessary due to changes in thelocalaltitude, gasBTUcontent, gas supply piping and supply regulators. Combustion Calibration Test Datasheetsare shipped witheach unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
It is important to perform the combustion calibration procedure below to provide optimum performance and keep readjustments to a minimum.

BRASS HEX HEAD (Remove to access Gas Pressure Adjustment Screw).

TAC SCREW

Figure 4-3: Gas Pressure Adjustment Screw and TAC Screw Location

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
WARNING!
Combustion calibration and AERtrim can both alter the voltage sent to the blower and can thus interfere with each other. If AERtrim is enabled, and a change is made to any calibration point during combustion calibration, you must make a corresponding chang e to the same calibration point in AERtrim (see Section 9.4: AERtrim O2 Sensor Auto Calibration). If you fail to make the change in AERtrim, AERtrim 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.
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 systempumpsarerunning. 3. Open the NATURAL GAS supply valve to the unit.
4. Turn external AC power to the unit ON. 5. On the Controller, go to: Main Menu Calibration Manual Combustion. If necessary,entera
technician level password.
6. The first Manual Combustion Calibration screen appears. Complete the threestepslisted before continuing with the instructions below. In addition, if your unit is running AERtrim, you mustturn that feature off before continuing, as AERtrim will interfere with combustion calibration.

Figure 4-4: First Manual Combustion Calibration Screen
7. Connect the gas pressure manometer to the upstream side of the gas train’s SSOV (seeSection 4.2.2) and then connect the Combustion Analyzer and Multimeter (per Section 4.2.3) and ensure that the heating loop is capable of dissipating sufficient heat at full fire.
8. Verify that the incoming (upstream) gas pressure to the unit is within the allowable range(see the Benchmark Gas Supply Guide (TAG-0047).
9. Once you have completed the previous step, move the manometer (or use asecondary one)tothe downstream side of the SSOV and press Next to continue.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
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 Calibration screen appears. It provides twomethodsto ramp the unit’s valve position up or down:
· Method 1: Toggle through the pre-set calibration points till you reach the desired valve position, then press Go to go to that point (left image below).
· Method 2: Enable Fine VP Step, then manually press the + or buttonsonceper1%to bring the unit to the desired valve position (right image below).

PRE-SET CALIBRATION CONTROLS

FINE VALVE POSITION CONTROLS

PRESET CALIBRATION POINTS METHOD

FINE VP STEP METHOD

Figure 4-6: Manual Combustion Calibration Screens

12. Set the Controller’s Enable/Disable switch to Enable.

13. Change the valve position to 30%, press the Go button, then verify that the unit has ignited andis operating as expected.

14. Use the (Right) arrow key to change the valve position to 100%, then press Go.

15. Verify that the manifold gas pressure on the downstream side of the SSOV is within the 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 flat-tip screwdriver, slowly
rotating the gas pressure adjustment (in 1/4-turn increments)clockwiseto increasegaspressure or
counterclockwise to reduce it. The resulting gas pressure reading onthe downstream manometer
should fall in the range listed below.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP

TABLE 4-1: REFERENCE Natural Gas Manifold Gas Pressure Range @ 100% Fire Rate

Model

Single Fuel Units

Dual Fuel Units *

BMK750 BMK1000 BMK1500

2.0″ ± 0.2″ W.C. (0.50 ± 0.05 kPa) 2.4″ ± 0.4″ W.C. (0.60 ± 0.10 kPa) 3.6″ ± 0.1″ W.C. (0.90 ± 0.02 kPa)

See NOTE 1 4.9″ ± 0.2″ W.C. (1.22 ± 0.05 kPa) 3.6″ ± 0.1″ W.C. (0.90 ± 0.02 kPa)

BMK2000

3.4″ ± 0.2″ W.C. (0.85 ± 0.05 kPa)

6.3″ ± 0.1″ W.C. (1.57 ± 0.02 kPa)

BMK2500

2.0″ ± 0.1″ W.C. (0.50 ± 0.02 kPa)

5.8″ ± 0.1″ W.C. (1.44 ± 0.02 kPa)

BMK3000 BMK4000 BMK5000N BMK5000

2.1″ ± 0.2″ W.C. (0.52 ± 0.05 kPa) 3.0″ ± 0.2″ W.C. (0.75 ± 0.05 kPa) 1.8″ ± 0.2″ W.C. (0.45 ± 0.05 kPa) 6.3″ ± 0.2″ W.C. (1.56 ± 0.05 kPa)

6.0″ ± 0.2″ W.C. (1.49 ± 0.05 kPa) 4.9″ ± 0.2″ W.C. (1.22 ± 0.05 kPa) 4.9″ ± 0.2″ W.C. (1.22 ± 0.05 kPa) 6.3″ ± 0.2″ W.C. (1.57 ± 0.05 kPa)

BMK5000 (Low Gas Pressure)

2.6″ ± 0.2″ W.C. (0.65 ± 0.02 kPa)

N/A

BMK6000

7.9″ ± 0.2″ W.C. (1.97 ± 0.05 kPa)

BMK6000 (Low Gas Pressure)

1.9″ ± 0.2″ W.C. (0.50 ± 0.05 kPa)

N/A

* This column lists natural gas pressures on dual f uel units. For propane values, see Section 4.5.2.

NOTE 1: For BMK750 Dual Fuel, measure Natural Gas Manif old Pressure at 80% FireRate. Range shallbe5.0″ +/0.2″ W.C. (1.24 ± 0.05 kPa).

16. With the valve position still at 100%, insert the combustion analyzer probe into the exhaust
manifold probe opening (see Figure 4-2a 4-2c in Section 4.2.3) and allow enough time for the combustion analyzer reading to stabilize.

17. Compare the combustion analyzer’s oxygen (O2) reading to the O2 value in the Readingcolumn (Figure 4-6). If they differ, go to the Main Menu Calibration Input/Output O2 Sensor screen and adjust the O2 Offset parameter, up to ±3%, to make the on-board O2sensor match the value from the combustion analyzer. If your combustion analyzer is correctly calibrated,and theonboard O2 sensor cannot be made to match the analyzer, the sensor may bedefective andneed tobe replaced.

18. Compare the O2 value in the Target and Reading columns. If they don’t match, adjust theBlower
Voltage until the O2 value in both columns match; use either the + or controls, or press on the field and type the value directly.

19. If adjusting the blower voltage is not sufficient to get the O2 Reading column to match theTarget column, then repeat Step 15 to adjust the gas pressure up or down within the range shown inthe table, then repeat Step 18. Continue repeating Steps 15 and 18 until the gas pressure iswithinthe 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 GasPressurefield. Note, this field appears only when Valve Position % = 100%.
21. Compare the measured nitrogen oxide (NOx) and carbon monoxide (CO) readings tothe Target values in Table 4-2 (reference only). If you chose the NOx <=9 ppm in step 9,use the valuesin the Ultra-Low NOx columns. If you are not in a “NOx-limited” area and/or do not have a NOx measurement in your analyzer, set the O2 to the value in the Standard NOx column below.

TABLE 4-2: NATURAL GAS Calibration Target Values @ 100% Valve Position

Model 750

Standard NOx

O2 %

NOx

5.5% ± 0.2% 20 ppm

Ultra-Low NOx

O2 %

NOx

6.0% ± 1.0% 9 ppm

1000

5.5% ± 0.2% 20 ppm

6.0% ± 1.0% 9 ppm

CO
<100 ppm <100 ppm

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1500 2000 2500 3000 3000 DF 4000/5000N * 5000/6000

5.2% ± 0.2% 6.0% ± 0.2% 5.6% ± 0.2% 5.1% ± 0.2% 5.3% ± 0.2% 5.5% ± 0.2% 5.5% ± 0.5%

20 ppm 20 ppm 20 ppm 20 ppm 20 ppm 20 ppm 20 ppm

5.7% ± 1.0% 6.0% ± 1.0% 6.0% ± 0.2% 6.0% ± 1.0%

9 ppm 9 ppm –
9 ppm 9 ppm

<100 ppm <100 ppm <100 ppm <100 ppm <100 ppm <100 ppm <100 ppm

* The 4000, 4000DF, 5000N and 5000NDF can operate at 4.5% O2 at fullfire in jurisdictions that donot have NOx restrictions.
NOTE: These instructions assume that the inlet air temperature isbetween 50°F and100°F (10°C 37.8°C). If NOx readings exceed the target values in Table 4-1 or Table 4-3, increase theO2levelup to 1% higher than the Target value. You must then record the increased O2 value on the Combustion Calibration sheet.

22. On Benchmark 3000 – 6000 units only, record the manifold(downstream)gaspressure at100%. This value will be used in Section 5.2.2: LowPressure Gas Test, and Section5.3.2: HighPressure Gas Test.

23. Once the O2 level is within the specified range at 100%:
· Enter the Flame Strength, NOx and CO readings from the Combustion Analyzerand multimeter in the Manual Combustion Calibration screen’s Reading column.

· Enter the same values, plus the O2 value, on the Combustion Calibration DataSheetprovided with the unit.
24. Lower the Valve Position to the next calibration point using the (Left) arrow key (if using Method1 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 Tablebelow corresponding to your model. The O2, NOx and CO should stay within the ranges shown

TABLE 4-3a: NATURAL GAS BMK Final Valve Positions: BMK750/1000

Valve Position

Standard NOx

Ultra-Low NOx

Single Fuel Dual Fuel

80%

70%

O2 %

NOx

5.5% ± 0.2% 20 ppm

O2 %

NOx

6.0% ± 1.0% 9 ppm

60%

5.5% ± 0.2% 20 ppm 6.0% ± 1.0% 9 ppm

45%

40%

5.5% ± 0.2% 20 ppm 6.0% ± 1.0% 9 ppm

30%

5.5% ± 0.2% 20 ppm 6.0% ± 1.0% 9 ppm

18%

5.5% ± 0.2% 20 ppm 6.0% ± 1.0% 9 ppm

CO
<100 ppm <100 ppm <50 ppm <50 ppm <50 ppm

TABLE 4-3b: NATURAL GAS Final Valve Positions: BMK1500-2000

Valve Position

Standard NOx

Ultra-Low NOx

1500 2000

O2 %

NOx

O2 %

NOx

70%

6.0% ± 0.2% 20 ppm

5.5% ± 1.0%

9 ppm

50%

6.3% ± 0.2% 20 ppm

5.8% ± 1.0%

9 ppm

40%

7.0% ± 0.2% 20 ppm

6.0% ± 1.0%

9 ppm

30%

7.0% ± 0.2% 20 ppm

6.0% ± 1.0%

9 ppm

16% 18% 7.0% ± 0.2% 20 ppm

8.0% ± 1.0%

9 ppm

CO
<100 ppm <100 ppm <50 ppm <50 ppm <50 ppm

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TABLE 4-3c: NATURAL GAS Final Valve Positions: BMK1500/2000 Dual Fuel

Valve % 70%

BMK1500 DF 6.0% ± 0.2%

O2 %

BMK2000 DF 6.5% ± 0.2%

NOx 20 ppm

50%

6.3% ± 0.2%

6.5% ± 0.2%

40%

7.0% ± 0.2%

6.5% ± 0.2%

20 ppm 20 ppm

30%

7.0% ± 0.2%

6.5% ± 0.2%

16%

8.0% ± 0.2%

5.5% ± 0.2%

20 ppm 20 ppm

TABLE 4-3d: NATURAL GAS Final Valve Positions: BMK2500 3000

BMK2500 Single and Dual Fuel

Single Fuel

Dual Fuel

NOx

Valve % 70% 50% 40% 30% 16%

O2 % 5.9% ± 0.2% 6.0% ± 0.2% 6.3% ± 0.2% 6.3% ± 0.2% 6.0% ± 0.2%

Valve % 70% 45% 30% 20% 16%

O2 % 5.9% ± 0.2% 6.2% ± 0.2% 6.0% ± 0.2% 5.8% ± 0.2% 6.0% ± 0.2%

20 ppm 20 ppm 20 ppm 20 ppm 20 ppm

BMK3000 Single and Dual Fuel

70%

5.1% ± 0.2%

85%

50%

6.1% ± 0.2%

65%

40%

5.0% ± 0.2%

45%

30%

6.4% ± 0.2%

30%

14%

6.4% ± 0.2%

14%

5.4% ± 0.2% 5.5% ± 0.2% 5.7% ± 0.2% 5.6% ± 0.2% 6.2% ± 0.2%

20 ppm 20 ppm 20 ppm 20 ppm 20 ppm

TABLE 4-3e: NATURAL GAS Final Valve Positions: BMK4000

Valve Position

Standard NOx

Ultra-Low NOx

Single Fuel

O2 %

NOx

O2 %

NOx

70%

5.5% ± 0.2%

20 ppm

6.0% ± 0.2%

9 ppm

50%

5.5% ± 0.2%

20 ppm

6.0% ± 0.2%

9 ppm

40%

5.5% ± 0.2%

20 ppm

6.0% ± 0.2%

9 ppm

30%

5.5% ± 0.2%

20 ppm

6.0% ± 0.2%

9 ppm

23%

6.0% ± 0.2%

20 ppm

6.5% ± 0.2%

9 ppm

TABLE 4-3f: NATURAL GAS Final Valve Positions: 5000N

Valve Position

Standard NOx

O2 %

NOx

Ultra-Low NOx

O2 %

NOx

70%

5.5% ± 0.2%

20 ppm

7.5% ± 0.2%

9 ppm

50%

5.5% ± 0.2%

20 ppm

7.5% ± 0.2%

9 ppm

40%

5.5% ± 0.2%

20 ppm

7.5% ± 0.2%

9 ppm

30%

5.5% ± 0.2%

20 ppm

7.5% ± 0.2%

9 ppm

18%

6.0% ± 0.2%

20 ppm

7.5% ± 0.2%

9 ppm

CO <100 ppm <100 ppm <50 ppm <50 ppm <50 ppm
CO
<100 ppm <100 ppm <50 ppm <50 ppm <50 ppm
<100 ppm <100 ppm <50 ppm <50 ppm <50 ppm
CO <100 ppm <100 ppm <50 ppm <50 ppm <50 ppm
CO <100 ppm <100 ppm <50 ppm <50 ppm <50 ppm

TABLE 4-3g: NATURAL GAS Final Valve Positions: BMK4000/5000N Dual Fuel

Valve Position

Standard NOx

O2 %

NOx

Ultra-Low NOx

O2 %

NOx

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70%

5.5% ± 0.2%

20 ppm

6.0% ± 0.2%

50%

5.5% ± 0.2%

20 ppm

6.5% ± 0.2%

40%

5.5% ± 0.2%

20 ppm

6.5% ± 0.2%

30%

5.5% ± 0.2%

20 ppm

6.5% ± 0.2%

18%

5.5% ± 0.2%

20 ppm

5.5% ± 0.2%

9 ppm 9 ppm 9 ppm 9 ppm 9 ppm

<100 ppm <100 ppm <50 ppm <50 ppm <50 ppm

TABLE 4-3h: NATURAL GAS Final Valve Positions: BMK5000, Single & DF

Valve Position

Standard NOx

Ultra-Low NOx

Single Dual

Fuel

O2 %

NOx

O2 %

NOx

70%

5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

50%

5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

40%

5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

30%

5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

18%

6.0% ± 1. 0%

<20 ppm

6.5% ± 1.5%

9 ppm

CO
<100 ppm <100 ppm <50 ppm <50 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

Single Dual

Fuel

O2 %

NOx

O2 %

NOx

70%

85% 5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

50%

65% 5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

40%

45% 5.5% ± 0.5%

<20 ppm

6.0% ± 1.0%

9 ppm

CO
<100 ppm <100 ppm <50 ppm

30%

30% 5.5% ± 0.5%

18%

18% 6.0% ± 1.0%

<20 ppm <20 ppm

6.0% ± 1.0% 6.5% ± 1.5%

9 ppm 9 ppm

<50 ppm <50 ppm

NOTE: BMK6000 Low Gas Pressure (LGP) Model does not offer Ultra Low NOx settings.
26. If the oxygen level at the lowest valve position is too high, and the Blowervoltageisattheminimum value, you can adjust the TAC screw, which is recessed in the topof theAir/Fuel Valve(seeFigure 43). Rotate the screw 1/2 turn clockwise (CW) to add fuel and reduce the O2tothe specifiedlevel. Recalibration MUST be performed again from 60% or 50% down to the lowest valve position after making a change to the TAC screw.

This completes the NATURAL GAS combustion calibration procedure.

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4.5.2 PROPANE Gas Combustion Calibration
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 systempumpsarerunning. 3. Open the PROPANE supply valve to the unit. 4. Turn external AC power to the unit ON. 5. Go to: Main Menu Calibration Manual Combustion. 6. The first Manual Combustion Calibration screen appears. Complete the threestepslisted 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, asshown in Section 4.2.2 and connect the Combustion Analyzer and Multimeter,asshown inSection4.2.3, and ensure that the heating loop is capable of dissipating sufficient heat at full fire.
8. Verify that the incoming gas pressure to the unit is within the allowable range (see TAG-0047).
9. Once you have completed the previous step, move the manometer (or use asecondary one)tothe downstream side of the SSOV and press Next to continue.
10. For the NOx requirement choose None.

Figure 4-8: Choose NOx Requirement
11. The main Manual Combustion Calibration screen appears. It provides twomethodsto ramp the unit’s valve position up or down: · Method 1: Toggle through the pre-set calibration points till you reach the desired valve position, then press Go to go to that point (left image below).
· Method 2: Enable Fine VP Step, then manually press the + or buttonsonceper1%to bring the unit to the desired valve position (right image below).

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PRE-SET CALIBRATION CONTROLS

VALVE POSITION CONTROLS

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 Go, then verify unit has ignited and is operating.
14. Use the (Right) arrow key to change the valve position to 100%, then press Go.
15. Verify the gas pressure on the downstream side of the SSOV iswithin therange shown inTable 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 orcounterclockwisetoreduce it.The resulting gas pressure reading on the downstream manometer should fallin therange listed below.

TABLE 4-4: PROPANE Gas Pressure Range @ 100% Fire Rate

Model

Nominal Gas Pressure

BMK750P

3.9″ W.C. ± 0.2″ W.C. (0.97 kPa ± 0.05 kPa)

BMK1000P BMK750DF

6.3″ W.C. ± 0.2″ W.C. (1.58 kPa ± 0.05 kPa) See NOTE 2

BMK1000DF

1.8″ W.C. ± 0.1″ W.C. (0.45 kPa ± 0.02 kPa)

1500DF & 1500P 2000DF & 2000P 2500DF & 2500P 3000DF & 3000P 4000DF & 4000P

1.4″ W.C. ± 0.1″ W.C. (0.35 kPa ± 0.02 kPa) 2.5″ W.C. ± 0.1″ W.C. (0.62 kPa ± 0.02 kPa) 2.0″ W.C. ± 0.1″ W.C. (0.50 kPa ± 0.02 kPa) 1.6″ W.C. ± 0.1″ W.C. (0.40 kPa ± 0.02 kPa) 1.5″ W.C. ± 0.1″ W.C. (1.12 kPa ± 0.02 kPa)

5000NDF & 5000NP

1.5″ W.C. ± 0.1″ W.C. (1.12 kPa ± 0.02 kPa)

5000DF & 5000P

2.0″ ± 0.2″ W.C. (0.50 to 0.05 kPa)

6000DF & 6000P

4.2″ ± 0.2″ W.C. (1.05 to 0.05 kPa)

NOTE 2: For BMK750 Dual Fuel, measure PropaneGas Manifold Pressure at 85% Fire Rate. Range shallbe 1.8″

+/- 0.1″ W.C. (0.45 kPa ± 0.02 kPa)

16. With the valve still at 100%, insert the combustion analyzer probe into the exhaust manifold probe opening (see Section 4.2.3) and allow enough time for the combustion analyzer reading tostabilize.

17. Compare the oxygen (O2) reading to the O2 value in the Reading column (Figure 4-9).If they differ, go to the Main Menu Calibration Input/Output O2 Sensor screen andadjust the O2 Offset parameter, up to ±3%, to make the on-board O2 sensor match the value from the combustion analyzer. If your combustion analyzer is correctly calibrated, and the on-board O2 sensor cannotbe 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 theBlower Voltage until the values match; use either the + or controls, or type the value directly.

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20. Enter the downstream manometer’s gas pressure reading in the Downstream GasPressurefield. Note, this field appears only when Valve Position % = 100%.

21. Compare the measured nitrogen oxide (NOx) and carbon monoxide (CO) readings tothe Target
values in Table 4-5 . If you are not in a “NOx-limited” area and/or do not haveaNOx measurement in your analyzer, set the O2 to the value in the Oxygen (O2) % column in the table below.

TABLE 4-5: PROPANE Calibration Readings at 100% Valve Position

Model

Oxygen (O2) %

Nitrogen Oxide (NOx)

750 & 1000

5.5% ± 0.2%

100 ppm

1500

5.2% ± 0.2%

100 ppm

2000

6.0% ± 0.2%

100 ppm

2500

5.0% ± 0.2%

100 ppm

3000

5.2% ± 0.2%

100 ppm

4000

4.5% ± 0.2%

100 ppm

5000N

4.5% ± 0.2%

100 ppm

5000

5.5% ± 0.5%

100 ppm

6000

5.0% ± 0.5%

100 ppm

Carbon Monoxide (CO) <150 ppm <150 ppm <150 ppm <150 ppm <150 ppm <150 ppm <150 ppm <150 ppm <150 ppm

NOTE: These instructions assume that the inlet air temperature isbetween 50°F and100°F (10°C 37.8°C). If NOx readings exceed the target values in Table 4-4, above, or Table 4-6, below, increase theO2levelup to 1%
higher than the Target value. You must then record the increased O2value on the Combustion Calibrationsheet.

22. On Benchmark 3000 – 6000 units only, record the manifold(downstream)gaspressure at100%. This value will be used in Section 5.2.2: LowPressure Gas Test, and Section5.3.2: HighPressure Gas Test.

23. Once the O2 level is within the specified range at 100%: · Enter the Flame Strength, NOx and CO readings from the CombustionAnalyzerand multimeter in the Manual Combustion Calibration screen’s Reading column.

· Enter the same values plus O2 value on the Combustion Calibration Data Sheet provided.
24. Lower the Valve Position to the next calibration point using the (Left) arrow key (if using Method1 in step 11) or the Fine Valve Position (Minus) key (if using Method 2).

BMK750P & 1000P: 80% BMK1500/2000/2500 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 below.

TABLE 4-6a: PROPANE Final Valve Positions: BMK750 5000N

Valve Position

Oxygen (O2) %

Nitrogen oxide (NOx)

BMK750/1000 SINGLE Fuel

80%

5.5% ± 0.2%

<100 ppm

60%

5.5% ± 0.2%

<100 ppm

Carbon Monoxide (CO)
<150 ppm <150 ppm

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TABLE 4-6a: PROPANE Final Valve Positions: BMK750 5000N

Valve Position

Oxygen (O2) %

Nitrogen oxide (NOx)

45%

5.5% ± 0.2%

<100 ppm

30%

6.3% ± 0.2%

<100 ppm

18%

5.5% ± 0.2%

<100 ppm

BMK750/1000 DUAL Fuel

70%

5.5% ± 0.2%

<100 ppm

50%

5.5% ± 0.2%

<100 ppm

40%

5.5% ± 0.2%

<100 ppm

30%

5.5% ± 0.2%

<100 ppm

18%

5.5% ± 0.2%

<100 ppm

BMK1500

70%

5.2% ± 0.2%

<100 ppm

50%

5.3% ± 0.2%

<100 ppm

40%

6.2% ± 0.2%

<100 ppm

30%

7.0% ± 0.2%

<100 ppm

18%

8.5% ± 0.2%

<100 ppm

BMK2000

70%

6.5% ± 0.2%

<100 ppm

50%

6.5% ± 0.2%

<100 ppm

40%

6.5% ± 0.2%

<100 ppm

30%

6.5% ± 0.2%

<100 ppm

18%

5.5% ± 0.2%

<100 ppm

BMK2500

70%

5.4% ± 0.2%

<100 ppm

45%

5.6% ± 0.2%

<100 ppm

30%

6.0% ± 0.2%

<100 ppm

22%

5.8% ± 0.2%

<100 ppm

18%

6.0% ± 0.2%

<100 ppm

BMK3000

85%

5.2% ± 0.2%

<100 ppm

65%

5.4% ± 0.2%

<100 ppm

45%

6.0% ± 0.2%

<100 ppm

30%

6.4% ± 0.2%

<100 ppm

18%

6.4% ± 0.2%

<100 ppm

BMK4000

70%

4.5% ± 0.2%

<100 ppm

50%

5.5% ± 0.2%

<100 ppm

40%

5.5% ± 0.2%

<100 ppm

30%

5.5% ± 0.2%

<100 ppm

18%

5.5% ± 0.2%

<100 ppm

BMK5000N

70%

4.5% ± 0.2%

<100 ppm

50%

5.5% ± 0.2%

<100 ppm

40%

5.5% ± 0.2%

<100 ppm

30%

5.5% ± 0.2%

<100 ppm

Carbon Monoxide (CO) <150 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <150 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <150 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <150 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <100 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <150 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <150 ppm <100 ppm <100 ppm
<150 ppm <150 ppm <150 ppm <100 ppm

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TABLE 4-6a: PROPANE Final Valve Positions: BMK750 5000N

Valve Position

Oxygen (O2) %

Nitrogen oxide (NOx)

18%

5.5% ± 0.2%

<100 ppm

Carbon Monoxide (CO) <100 ppm

TABLE 4-6b: PROPANE Final Valve Positions: BMK5000 & 6000

Valve Position

Single-Fuel

Dual-Fuel

Oxygen (O2) % Nitrogen Oxide (NOx)

BMK5000

70%

5.5% ± 0.5%

<100 ppm

50%

5.5% ± 0.5%

<100 ppm

40%

5.5% ± 0.5%

<100 ppm

30%

5.5% ± 0.5%

<100 ppm

18%

6.0% ± 1.0%

BMK6000

<100 ppm

70%

85%

5.5% ± 0.5%

50%

65%

5.5% ± 0.5%

<100 ppm <100 ppm

40%

45%

5.5% ± 0.5%

<100 ppm

30%

5.5% ± 0.5%

<100 ppm

18%

6.0% ± 1.0%

<100 ppm

Carbon Monoxide (CO)
<150 ppm <150 ppm <150 ppm <150 ppm <150 ppm
<150 ppm <150 ppm <150 ppm <150 ppm <150 ppm

NOTE: If NOx readings exceed the target values in Table 4-6a and 4-6b, increase the O2levelup to 1% higherthan the listed calibration range in the table. Record the increased O2 value on the Combustion Calibrationsheet.
26. If the oxygen level at the lowest valve position is too high, and the Blowervoltageisattheminimum value, you can adjust the TAC screw, which is recessed in the topof theAir/Fuel Valve(seeFigure 43). Rotate the screw 1/2 turn clockwise (CW) to add fuel and reduce the O2tothe specifiedlevel. Recalibration MUST be performed again from 60% or 50% down to the lowest valve position after making a change to the TAC screw.
This completes the PROPANE gas combustion calibration procedure.

4.6 Reassembly Once the combustion calibration adjustments are properly set, the unit canbereassembled for service.
1. Set the Enable/Disable switch to the disabled position. 2. Disconnect AC power from the unit. 3. Shut off the gas supply to the unit.
4. Remove the manometer and barbed fittings and reinstall the NPT plug using asuitable pipe thread compound.
5. Remove the combustion analyzer probe from the 1/4″ vent hole in the exhaust manifold and then replace the 1/4″ NPT plug in the vent hole.
6. Replace all previously removed sheet metal enclosures on the unit.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
4.7 Dual Fuel Switchover All Benchmark Dual Fuel models contain a fuel selector switch, located to the right of the I/O board, behind the front panel.

I/O BOARD and cover

FUEL SELECTOR SWITCH

Figure 4-10: Dual Fuel Switch
Switchover from NATURAL GAS to PROPANE Instructions: 1. Set the Edge Controller’s Enable/Disable switch to Disable. 2. Close the external Natural Gas 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 the front door panel 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 panel previously removed from the boiler.
4.8 Over-Temperature Limit Switches
The unit contains two configurable over-temperature limit controls, positioned behind the unit’s front panel, under the Edge Controller:
· Automatic Reset: If the unit’s operating temperature exceeds the limit set on the switch,the unit goes into an alarm mode and shuts the unit down. When the temperature falls10 degrees below the limit, the unit automatically resumes operation without operator intervention. The limit range is manually adjustable from 32°F to 200°F (0°C to 93°C). The defaultvalueis190°F (88°C).
· Manual Reset: If the unit’s operating temperature exceeds the limit set on the switch, the switch goes into an alarm mode and shuts the unit down. The unitcannot berestarteduntilthe switch is reset manually. The limit is preset to 210°F (98.9°C) and should notbechanged.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP
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 switches can display temperatures in Fahrenheit or Celsius. · The Auto-Reset switch is preset to 190ºF (88°C) but can be adjusted as needed to suite local conditions, as described below.

AUTO-RESET SWITCH

MANUAL RESET SWITCH

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. 1. Power the unit ON and remove the front panel to expose the Over-Temperature Limit switches.
2. Press the Automatic Reset Limit Switch’s SET button: SP appears in the display. 3. Press the SET button again. The current setting stored in memory is displayed. 4. Press the or arrow buttons to change the display to the desired temperature setting. 5. When the desired temperature is displayed, press the SET button. 6. Press both the SET and arrow buttons together at the same time. This step storesthe setting in
memory; note that OUT1 appears in the upper-left corner of the display as confirmation.

INCREASE TEMPERATURE
DECREASE TEMPERATURE
Figure 4-12: Auto-Reset Over-Temperature Limit Switch
4.8.2 Resetting the Manual Reset Limit Switch Perform the following steps to rest the Manual Reset Limit Switch after it has gone into Alarm mode, and after the temperature has fallen at least 10 degrees below the limit. 1. Power the unit ON 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.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 4: INITIAL START-UP

RESET

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. 1. Press and hold both the Increase and Decrease arrows at the same timefor about 4seconds. The
display shows the temperature in Celsius and °F changes to °C. 2. To change the display back to Fahrenheit, repeat step 1.
INCREASE
DECREASE
Figure 4-14: Changing the Display to Celsius

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
SECTION 5: SAFETY DEVICE TESTING
5.1 Testing Of Safety Devices
Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion-relatedsafety devices before, during and after the start sequence. The followingtestscheck to ensure that thesystem is operating 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.
NOTE: Manual and Auto modes are required to perf orm the f ollowing tests . See OMM-139 Section 4.1. NOTE: It is necessary to remove the f ront door and side panels to perf orm the tests described below.
ELECTRICAL HAZ ARD WARNING
Electrical voltages of 120 VAC (BMK750 2000), 208 or 480 VAC (BMK2500 BMK3000), 480 VAC (BMK4000 & 5000N), or 208, 480 or 575 VAC (BMK5000 & 6000) and 24 volts AC may be used inthis equipment. Remove power prior to wire removal or other procedures that may cause electrical shock.

5.2 Low Gas Pressure Test

Complete the instructions in Section 5.2.1 for BMK750 2500 units, or in Section5.2.2 for BMK3000 6000 units, which have different Low and High Gas Pressure switches.

5.2.1 Low Gas Pressure Test: BMK750 2500 To simulate a low gas pressure fault, refer to Figure 5-1a to 5-1c and perform the following steps:

1. Remove the front panel from the boiler to access the gas train components. 2. Close the leak detection ball valve located at the Low Gas Pressure switch.

3. Remove the 1/4″ NPT plug from the ball valve at the Low Gas Pressure switch.

4. Install a 0 – 16″ W.C. (0 4.0 kPa) manometer or gauge where the 1/4″ plug was removed. 5. Slowly open the 1/4″ ball valve near the Low Gas Pressure switch. 6. On the Controller, go to Main Menu Diagnostics Manual Run.

7. Enable the Manual Mode parameter. The Comm LED will go off and the MANUAL LED willlight.

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.

10. The unit should shut down and display Fault Lockout – Gas Pressure Fault atapproximately the pressure shown in Table 5-1 (the pressure setting of the Low Gas Pressure switch):

TABLE 5-1: LOW Gas Pressure, ± 0.2″ W.C. (± 50 Pa)

Benchmark Model

Natural Gas

BMK750/1000 FM SINGLE-Fuel

2.6″ W.C. (648 Pa)

BMK750/1000 DUAL-Fuel

5.2″ W.C. (1294 Pa)

BMK1500/2000 FM & DBB Single-Fuel

3.6″ W.C. (896 Pa)

BMK1500/2000 Dual-Fuel

4.4″ W.C. (1,096 Pa)

BMK1500/2000 DBB Dual-Fuel

2.6″ W.C. (648 Pa)

BMK2500 FM & DBB Single-Fuel

3.6″ W.C. (896 Pa)

BMK2500 Dual-Fuel

7.5″ W.C. (1,868 Pa)

BMK2500 DBB Dual-Fuel

7.5″ W.C. (1,868 Pa)

Propane
7.5″ W.C. (1,868 Pa) 5.2″ W.C. (1294 Pa) 2.6″ W.C. (648 Pa) 2.6″ W.C. (648 Pa) 3.6″ W.C. (897 Pa) 3.6″ W.C. (897 Pa)

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
11. Close the ball valve near the Low Gas Pressure switch (opened in Step 5). 12. Fully open the external manual gas shut-off valve and press the Controller’s CLEAR button. 13. The fault message should clear, the FAULT indicator should go off, and the unit should restart. 14. Upon test completion, close the ball valve, remove the manometer and replacethe 1/4″ NPT plug.

MANUAL SHUT-OFF VALVE
HIGH GAS PRESSURE SWITCH

TO AIR/FUEL VALVE

(P/N 22322 shown)

SSOV

LOW GAS PRESSURE SWITCH

GAS INLET

1/4″ NPT PLUG Install manometer here for LOW gas
pressure fault test.

LOW GAS PRESSURE LEAK DETECTION BALL VALVE (shown closed)

Figure 5-1a: BMK750/1000 LOW Gas Pressure Test Components

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

NATURAL GAS INLET

MANUAL SHUT-OFF VALVE

TO AIR/FUEL
VALVE
HIGH GAS PRESSURE
SWITCH

SSOV
LOW GAS PRESSURE SWITCH

1/4″ NPT PLUG Install manometer here for LOW gas pressure fault test.
LOW GAS BALL VALVE
Figure 5-1b: BMK1500/2000 LOW Gas Pressure Test Components (P/N 22314 shown)

HIGH GAS PRESSURE SWITCH

NATURAL GAS INLET

SSOV

MANUAL SHUT-OFF VALVE

TO AIR/FUEL
VALVE

LOW GAS PRESSURE SWITCH

LOW GAS BALL VALVE

1/4″ NPT PLUG Install manometer here for LOW gas
pressure fault test.

Figure 5-1c: BMK2500 LOW Gas Pressure Test Components (P/N 22190 shown)

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

5.2.2 Low Gas Pressure Test: BMK3000 6000 Only
To simulate a low gas pressure fault on BMK3000 6000 units, refer to Figure 5-2a 5-2c, below, and perform the following steps:

1. Close the external gas supply ball valve upstream of the unit (not shown).
2. Remove the front panel from the boiler to access the gas train components.
3. Locate the port on the top of the Low Gas Pressure switch and loosen the screw inside afew turns to open it. Do not remove this screw completely. Alternatively, you can remove the 1/4-inchplug 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 toa 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 (NaturalGasunits) or Step 21 of Section 4.4.2 (Propane units) and plug it into the following formula, whichcalculatesthe minimum allowable gas pressure:

BMK3000

FM Natural Gas pressure ____ x 0.5 + 0.7 = ______ min gas pressure DBB Natural Gas pressure ____ x 0.5 + 1.6 = ______ min gas pressure Propane Gas pressure ____ x 0.5 + 0.6 = ______ min gas pressure

BMK4000

FM Natural Gas pressure ____ x 0.5 + 0.6 = ______ min gas pressure DBB Natural Gas pressure ____ x 0.5 + 0.6 = ______ min gas pressure Propane Gas pressure ____ x 0.5 + 1.1 = ______ min gas pressure

BMK5000N

FM Natural Gas pressure ____ x 0.5 + 0.9 = ______ min gas pressure DBB Natural Gas pressure ____ x 0.5 + 0.9 = ______ min gas pressure Propane Gas pressure ____x 0.5 + 1.6 = ______ min gas pressure

FM Natural Gas pressure ____ x 0.5 + 6.0 = ______ min gas pressure

BMK5000

LGP* Natural Gas pressure ____ x 0.5 + 0.9 = ______ min gas pressure

Propane Gas pressure ____ x 0.5 + 3.7 = ______ min gas pressure

FM Natural Gas pressure ____ x 0.5 + 6.0 = ______ min gas pressure

BMK6000

LGP* Natural Gas pressure ____ x 0.5 + 1.3 = ______ min gas pressure Propane Gas pressure ____ x 0.5 + 3.7 = ______ min gas pressure

* LGP refers to Low Gas Pressure models

6. Remove the cover from the Low Gas Pressure switch and set the dial indicator to2(theminimum). 7. Open the external gas supply ball valve upstream of the unit. 8. 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 supply pressure until the CO reading is approximately 300 ppm.
11. Take a reading of the inlet gas pressure. If the inlet pressure is below the minimum calculatedin step 5, above, then increase the pressure to match the calculated minimum.
12. Slowly turn the Low Gas Pressure indicator until the unit shuts down due to a gas pressure fault.
13. Readjust the inlet gas pressure to what it was prior to the test. 14. Press the Edge Controller’s CLEAR button to clear the fault.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

15. The fault message should clear, the red FAULT LED go off, and the unit should restart.
16. For Dual Fuel units, repeat the previous procedure on the Propane gas train, starting with the Propane Low Gas Pressure Switch.

SSOV

NATURAL GAS INLET

MANUAL SHUTOFF VALVE
LOW Gas Pressure Port Install manometer here f or Low Gas Pressure test

TO AIR/FUEL
VALVE

LOW GAS PRESSURE SWITCH
LOW GAS BALL VALVE

HIGH GAS PRESSURE
SWITCH

Alternative LOW Gas Pressure Port
(P/N 22310 shown)

Figure 5-2a: BMK3000 LOW and HIGH Gas Pressure Test Components

HIGH GAS

NATURAL GAS INLET

PRESSURE

SSOV SWITCH

MANUAL SHUTOFF VALVE

TO AIR/FUEL
VALVE

LOW GAS PRESSURE
SWITCH

(P/N 22373-3 shown)

LOW Gas Pressure Port Install manometer here f or
Low Gas Pressure test

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
Figure 5-2b: BMK4000/5000N LOW and HIGH Gas Pressure Test Components

TO AIR/FUEL
VALVE

MANUAL SHUT-OFF
VALVE

Alternative location

NATURAL GAS Low Gas Pressure Test Port Install manometer here
Alternative location

Dual Fuel gas train showing both Natu ral Gas and Propane gas trains

PROPANE Low Gas Pressure Test Port Install manometer here

Figure 5-2c: BMK5000N/6000 LOW and HIGH Gas Pressure Test Components

5.3 High Gas Pressure Test
Complete the instructions in Section 5.3.1 for BMK750 2500 units, or in Section5.3.2 for BMK3000 6000 units, which have different High Gas Pressure switches.
5.3.1 HIGH GAS PRESSURE TEST: BMK750 2500 1. Close the leak detection ball valve located at the High Gas Pressure switch. 2. Remove the 1/4″ NPT plug from the High Gas pressure leak detection ball valve shown inFigures5-
3a through 5-3c. 3. Install a 0 – 16″ W.C. (0 4.0 kPa) manometer or gauge where the 1/4″ plug was removed. 4. Slowly open the leak detection ball valve. 5. On the Controller, go to: Main Menu Diagnostics Manual Run. 6. Enable the Manual Mode control. 7. Set the valve position between 25% and 30% using the + (Plus) and (Minus) controls.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

8. With the unit running, monitor the gas pressure on the manometer installed in step 2 and record the gas pressure reading.

9. Slowly increase the gas pressure using the adjustment screw on the SSOV while countingthe number of turns you make.

10. The FAULT indicator should start flashing and the unit should shutdownand display aFaultLockout
– Gas Pressure Fault message at approximately the value shownin Table5-2 (thepressure 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.

TABLE 5-2: HIGH Gas Pressure, ± 0.2″ W.C. (± 50 Pa)

Benchmark Model

Natural Gas

BMK750/1000 FM Single-Fuel

4.7″ W.C. (1.17 kPa)

BMK750/1000 DUAL-Fuel

7.0″ W.C. (1.74 kPa)

BMK1500/2000 Single-Fuel

4.7″ W.C. (1.17 kPa)

BMK1500/2000 DBB Single-Fuel

4.7″ W.C. (1.17 kPa)

BMK1500/2000 Dual-Fuel

4.7″ W.C. (1.17 kPa)

BMK1500/2000 DBB Dual-Fuel

3.5″ W.C. (0.87 kPa)

BMK2500 FM & DBB Single-Fuel

3.0″ W.C. (0.75 kPa)

BMK2500 Dual-Fuel

7.0″ W.C. (1,74 kPa)

BMK2500 DBB Dual-Fuel

7.0″ W.C. (1,74 kPa)

Propane
4.7″ W.C. (1.17 kPa) 2.6″ W.C. (0.65 kPa) 4.7″ W.C. (1.17 kPa) 3.5″ W.C. (0.87 kPa) 2.6″ W.C. (0.65 kPa) 2.6″ W.C. (0.65 kPa)

11. Reduce the gas pressure by returning the SSOV adjustment screw back toitsoriginal position before starting step 9 (the value recorded in step 8). This pressure should be within the rangeused during combustion calibration, shown in Table 4-1 (Natural Gas) and Table 4-4 (Propane gas).

12. Press the CLEAR button on the Edge Controller to clear the fault.

13. The fault message should clear, the FAULT indicator go off and the unit restart(if in Manualmode).

14. Upon test completion, close the ball valve and remove the manometer. Replacethe 1/4″NPTplug removed in step 2.

MANUAL SHUT-OFF VALVE

TO AIR/FUEL VALVE

HIGH GAS PRESSURE SWITCH

(P/N 22322 shown)

LOW GAS PRESSURE SWITCH
SSOV

GAS INLET
HIGH GAS PRESSURE BALL VALVE

1/4″ NTP PLUG (Install manometer here for
High Gas Pressure Test)

Figure 5-3a: BMK750/1000 HIGH Gas Pressure Test Components

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

NATURAL GAS INLET

MANUAL SHUT-OFF
VALVE

TO AIR/FUEL
VALVE
SSOV

HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH

(P/N 22314 shown)

HIGH GAS BALL VALVE

1/4″ NPT PLUG (Install manometer here for HIGH gas pressure fault test)

Figure 5-3b: BMK1500/2000: HIGH Gas Pressure Fault Test

1/4″ NPT PLUG (install
manometer here for HIGH
GAS PRESSURE FAULT TEST)
HIGH GAS BALL VALVE
MANUAL SHUT-OFF
VALVE

HIGH GAS PRESSURE SWITCH
TO AIR/FUEL VALVE

NATURAL GAS INLET
SSOV
LOW GAS PRESSURE SWITCH

(P/N 22190 shown)
Figure 5-3c: BMK2500: HIGH Gas Pressure Fault Test

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
5.3.2 HIGH GAS PRESSURE TEST: BMK3000 6000 Only To simulate a high gas pressure fault, refer to Figure 5-4a and 5-4b and perform the following steps:
1. Shut off the external gas supply by closing the external gas supply ball valve.
2. Locate the port on the side of the High Gas Pressure switch and loosen the screw in theport afew turns to open it. Do not completely remove the screw. Alternatively, youcanremove the1/4-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) manometer.
4. Apply the reading of the manifold pressure taken in Step 21 of Section 4.4.1 (natural gasunits) or Step 21 of Section 4.4.2 (propane units) and plug it into the following formula, whichcalculatesthe maximum allowable gas pressure:

BMK3000

Natural Gas Pressure ______ x 1.5 = ______ max gas pressure

BMK4000 & 5000N Natural Gas Pressure ______ x 1.5 = ______ max gas pressure

BMK5000 & 6000

Natural Gas Pressure ______ x 1.5 = ______ max gas pressure Propane Gas Pressure ______ x 1.5 = ______ max gas pressure

5. Remove the cover from the High Gas Pressure switch and set the dial indicator to 20 (max).

6. Open the external gas supply ball valve upstream of the unit. 7. On the Controller, go to: Main Menu Diagnostics Manual Run and enable ManualMode.

8. Use the + (Plus) and (Minus) controls to bring the unit up to 100%.
9. Slowly increase the manifold gas supply pressure by turning the GasPressure AdjustmentScrew in the Downstream SSOV (Figure 5-2) while reading the CO level on the combustion analyzer.Adjust the manifold pressure until the CO reading is approximately 300 ppm. Note the numberof turns you make, as you will turn it back to its original position in step 13, below.

10. Take a reading of the manifold gas pressure. If the manifold pressure is greaterthan themaximum calculated in step 3, then use the Gas Pressure Adjustment Screw todecreasethe manifold pressure until it is at the maximum allowed.

11. Slowly turn the indicator dial on the High Gas Pressure switch until the unitshuts downdueto agas 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 to clear the fault. 15. Fire the unit back up to ensure gas pressure out of the SSOV is set as it was originally.

16. Upon test completion, close the ball valve and remove the manometer fitting from the port, and then turn the port screw clockwise till the port is closed.

17. For Dual Fuel gas trains, repeat this procedure on the Propane gas train, starting withopening the port on the Propane High Gas Pressure Switch, as shown in Figure 5-4b.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

MANUAL SHUTOFF VALVE
HIGH Gas
Pressure Port Install manometer here f or High Gas
Pressure test

SSOV
TO AIR/FUEL
VALVE

NATURAL GAS INLET
HIGH GAS PRESSURE
SWITCH
LOW GAS PRESSURE SWITCH

HIGH GAS BALL VALVE
(P/N 22310 shown)

Alternative HIGH Gas Pressure Port

Figure 5-4a: BMK3000 HIGH Gas Pressure Test Components

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

HIGH Gas Pressure Port
Install manometer here f or High Gas Pressure
test
LEAK DETECTION BALL VALVE

HIGH GAS PRESSURE
SWITCH

NATURAL GAS INLET

MANUAL SHUTOFF VALVE

TO AIR/FUEL VALVE

(P/N 22373-3 shown)

LOW GAS PRESSURE
SWITCH

LOW Gas Pressure Port Install manometer here f or
Low Gas Pressure test
Figure 5-4b: BMK4000/5000N HIGH Gas Pressure Test Components

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING

Alternative location f or manometer if hose barb is pref erred

NATURAL GAS HIGH GAS
PRESSURE SWITCH
– BMK6000 10.5″ W.C., 2.6 kPa – BMK5000 11.0″ W.C., 2.7 kPa

NATURAL GAS HIGH Gas
Pressure Port Install manometer here f or High
Gas Pressure test

DOWNSTREAM SSOV WITH POC
SWITCH

PROPANE Gas Pressure Port Install manometer here f or High Gas Pressure test

PROPANE HIGH GAS PRESSURE SWITCH – BMK6000 10.5″ W.C., 2.6 kPa – BMK5000 4.5″ W.C., 1.1 kPa

Alternative location f or manometer if hose barb is pref erred
Figure 5-4c: BMK5000/6000 High Gas Pressure Test Components

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
5.4 Low Water Level Fault Test To simulate a low water level fault, proceed as follows:
1. Set the Controller’s Enable/Disable switch to Disable. 2. Close the water shut-off valves in the supply and return piping to the unit. 3. Slowly open the drain valve on the rear of the unit. If necessary, the unit’s relief valve may be
opened to aid in draining.
4. Continue draining the unit until a Low Water Level fault message is displayed and the FAULT indicator 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 remainoff and the
unit should not start. If the unit does start, shut the unit off immediately and refer fault to qualified service personnel.
9. Close the drain and pressure relief valve used in draining the unit. 10. Open the water shut-off valve in the return piping to the unit.
11. Open the water supply shut-off valve to the unit to refill. 12. After the shell is full, press the LOW WATER LEVEL RESET button to resetthe lowwatercutoff. 13. Press the CLEAR button to reset the FAULT LED and clear the displayed error message.
Set the Enable/Disable switch to Enable. The unit is now ready for operation.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
5.5 Water Temperature Fault Test A high-water temperature fault is simulated using the Automatic Reset Over-Temperature switch. 1. Start the unit in the normal operating mode and allow the unit to stabilize at its setpoint. 2. On the Automatic Reset Over-Temperature switch, note the current setting, then:
a. Press the Set button two times, to activate a setting change. b. Use the Down arrow to lower the setting to a temperature below the Outlet temperature
displayed on the Controller’s front face (see Figure 5-5b). c. Press the Set and Down arrow at the same time to save that temperature setting.
TEMPERATURE ADJUSTMENT CONTROLS

AUTOMATIC RESET SWITCH

MANUAL RESET
SWITCH

Figure 5-5a: Over Temperature Limit Switches
NOTE: If the Controller’s is not configured to display outlet temperature, go to the Main Menu Advanced Setup Unit Front Panel Configuration screen and set theUpper-Right Display parameter to Water Outlet.

OUTLET TEMPERATURE INDICATOR

OUTLET TEMPERATURE
Figure 5-5b: Edge Controller Front Face
3. Once the Automatic Reset Over-Temperature switch setting is just below the actual outlet water temperature the unit should shut down, the FAULT indicator should flash,and aHigh-Water Temp Switch Open message should be displayed. It should not be possible to restart the unit.
4. Repeat Step 2 to return the Automatic Reset switch but press the Up arrow to its original setting.
5. The unit should start once the setting is above the actual outlet water temperature.
6. Repeat steps 1 4 on the Manual Reset switch. However, unlike the Automatic Resetswitch,the unit will not restart automatically when the original temperature isrestored. YoumustpresstheRST (Reset) button to restart the unit.

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
5.6 Interlock Tests The unit is equipped with three interlock circuits, called the Remote Interlock,and DelayedInterlock. These circuits are connected to the I/O board’s connector strip J6, labeled RemoteInterlock, Delayed Interlock 1 and Delayed Interlock 2 (see Section2.11.1: I/OBoardConnections in theBenchmark -Edge: INSTALLATION Manual (OMM-0136). These circuits can shut down the unitin theeventan interlock is opened. These interlocks are shipped from the factory jumpered (closed). However, they may be utilized in the field as a remote stop and start, an emergency cut-off, or to provethat adevice such asa pump, gas booster, or louver is operational.
5.6.1 Remote Interlock Test 1. Remove the I/O Box cover and locate the Remote Interlock terminals on connector strip J6. 2. On the Controller, go to: Main Menu Diagnostics Manual Run.
3. Enable the Manual Mode control.
4. Set the valve position between 25% and 30% using the + (Plus) and (Minus) 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 viathe externaldevice 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 Interlock Open message should automatically
clear, and the unit should restart.
5.6.2 Delayed Interlock Test 1. Remove the I/O Box cover and locate the Delayed Interlock 1 terminals on connector strip J6. 2. On the Controller, go to: Main Menu Diagnostics Manual Run. 3. Enable the Manual Mode control. 4. Set the valve position between 25% and 30% using the + (Plus) and (Minus) controls. 5. If there is a jumper across the Delayed Interlock 1 terminals, remove oneside of the jumper. If the
interlock is connected to a proving switch of an external device, disconnectone of the wiresleading to the proving switch.
6. The unit should shut down and display a Delayed Interlock Openfaultmessage. The FAULT LED should be flashing.
7. Reconnect the wire or jumper removed in step 5 to restore the interlock. 8. Press the CLEAR button to reset the fault. 9. The unit should start. 10. Repeat the above for the Delayed Interlock 2 terminals.

OMM-0137_N · 1/ 14/ 2025

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Benchmark -Edge [ii]: Operation-Service Manual
SECTION 5: SAFETY DEVICE TESTING
5.7 Flame Fault Test
Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows:
1. Set the Controller’s Enable/Disable switch to Disable. 2. On the Controller, go to: Main Menu Diagnostics Manual Run. 3. Enable the Manual Mode control.
4. Set the valve position between 25% and 30% using the + (Plus) and (Minus) controls. 5. Close the gas train’s Manual Shutoff valve locatedbetween theSafety Shut-Off Valve (SSOV) andthe
Air/Fuel Valve, as shown on Figure 5-3a to 5-3c, above.
6. It may be necessary to jump out the High Gas Pressure switch. 7. Set the Controller’s Enable/Disable switch to Enable to start the unit. 8. The unit should purge and light the Pilot flame and then shut down after reaching the mainBurner
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 andthe 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 2000: the unit will execute an IGNITION RETRY cycle: · The unit will execute a shutdown purge cycle for 15secondsand display WaitFaultPurge. · The unit will execute a 30 second re-ignition delay and display Wait Retry Pause. · The unit will then execute a standard ignition sequence and display Wait Ignition Retry. · Since the Manual Shutoff valve is still closed, the unit will fail the ignition retry sequence. It will shut down and display Flame Loss During Ign following theIGNITION RETRY cycle.
b. BMK2500 5000N: the unit will Lockout and Flame Loss During Run will flashin thedisplay. 13. Open the manual gas valve closed in step 11.
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Documents / Resources

WATTS 750 Boilers with Edge Controller [pdf] Instruction Manual
750, 6000, 750 Boilers with Edge Controller, Boilers with Edge Controller, Edge Controller, Controller

References

User Manual

WATTS 750 Boilers with Edge Controller Instruction Manual

750 Boilers with Edge Controller

Product Information

Specifications:

Product Usage Instructions:

Safety Precautions:

Edge Controller Operation:

Start Sequence:

Initial Start-Up:

Safety Device Testing:

FAQ (Frequently Asked Questions):

Q: What should I do if I encounter a fault during
operation?

Q: Can this product be used with other fuel types not listed in
the specifications?

Documents / Resources

References

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