Watts AERCO Benchmark OMM-0136 Operation And Service Manual Download

Page: 124 / 153

Benchmark Platinum-Edge [II]: Operation-Service Manual

SECTION 8

– MAINTENANCE

OMM-

0137_E • GF-211 • 12/13/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

124

153

8.14 RECOMMENDED SPARES

NOTE:

Refer to the parts list illustrations in the

Benchmark Platinum-Edge: REFERENCE

Manual

(GF-212) for the locations of the parts listed below.

For a list of 12- and 24-Month Maintenance Kits, see Section 8.1:

Maintenance Schedule

TABLE 8-4: Recommended Emergency Spare Parts

DESCRIPTION

BMK

750/1000

BMK

1500/2000

BMK

2500-4000

VAC Blower Replacement Kit

58061

58038

58063-1

– 460V

58063-2

– 208V

SSOV Actuator/Regulator Combo - Used on:

•

ALL FM gas trains

•

Downstream

SSOV on DBB gas trains

64048

SSOV Actuator Without Proof of Closure
Switch - Used on:

•

Upstream

SSOV on DBB gas trains

27086-1

TABLE 8-5: Recommended Emergency Spare Parts

–

BMK5000 & 6000

DESCRIPTION

PART NUMBER

Actuator Replacement Kit: SSOV with P.O.C. Switch Kit

27086

‐

Actuator Replacement Kit: SSOV with Regulator, POC Switch &
Damping Orifice

64106

Pilot Regulator w/ 2

‐

6" Spring

24384

Pilot Solenoid Valve, 1/4" NPT

FRU Kit

58089

Temperature Switch - Manual Reset

123552

Ignitor Rod

FRU Kit

(component of Flame Rod Assy. 65150)

65182

TABLE 8-6: Optional Spare Parts

DESCRIPTION

PART NUMBER

Edge Controller

64142

Burner

BMK750 & 1000

46026

BMK1500

46042

BMK2000

46044

BMK2500

46039

BMK3000

46038

BMK4000

46060

BMK5000 & 6000

46025

Oxygen Sensor

61026

Summary of Contents for AERCO Benchmark OMM-0136

Page 1: ...ude 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 Combusti...

Page 2: ...Air Fuel Valve Position and Energy Input 28 3 4 6 BMK4000 Air Fuel Valve Position and Energy Input 29 3 4 7 Benchmark 5000 Air Fuel Valve Position and Energy Input 30 3 4 8 Benchmark 6000 Air Fuel Va...

Page 3: ...CT DRIVE MODES 82 6 5 AERCO CONTROL SYSTEM ACS 83 6 6 COMBINATION CONTROL SYSTEM CCS 84 6 6 1 Combination Control System Field Wiring 85 6 6 2 Combination Control System Setup and Startup 85 SECTION 7...

Page 4: ...ement 118 8 11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD 119 8 11 1 Benchmark 5000 6000 Long Term Blower Storage 119 8 12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN 121 8 13 RECOMMENDED PERIODIC TE...

Page 5: ...93 kW 48 300 14 15 kW 968 000 284 kW BMK1500 75 000 22 kW 1 500 000 440 kW 64 500 18 9 kW 1 395 000 409 kW BMK2000 100 000 29 3 kW 2 000 000 586 kW 86 000 25 2 kW 1 860 000 545 kW BMK2500 167 000 48 9...

Page 6: ...n Society of Mechanical Engineers AUX Auxiliary BAS Building Automation System often used interchangeably with EMS see below Baud Rate Symbol rate or simply the number of distinct symbol changes signa...

Page 7: ...nger Hz Hertz Cycles Per Second I D Inside Diameter IGN Ignition IGST Board Ignition Stepper Board contained in Edge Controller INTLK INTL K Interlock I O Input Output I O Box Input Output I O Box cur...

Page 8: ...32 A standard for serial full duplex FDX transmission of data based on the RS232 Standard RS485 or EIA 485 A standard for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rt...

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

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

Page 11: ...d 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 ala...

Page 12: ...ign 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...

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

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

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

Page 16: ...ing of this section The Edge Controller s ignition sequence screen walks you through the ignition screens and demonstrates or highlights which switches are not met SSOV locations are shown in Figure 3...

Page 17: ...am 5 pm EST Page 17 of 153 Start Sequence Figure 3 1c BMK2500 SSOV Location P N 22318 shown Figure 3 1d BMK3000 4000 SSOV Location P N 22310 shown TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS PRES...

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

Page 19: ...l Valve in Purge Position 5 Next the Blower Proof and Blocked Inlet switches close Figure 3 4a and 3 4b On the Ignition Sequence screen the Purging indicator turns grey while purging is underway Figur...

Page 20: ...n 7 sec and the Ignition Sequence screen s Spark Cleaning indicator Figure 3 3 turns grey This cycle turns on the ignition transformer to produce a spark with no gas flowing to remove moisture and car...

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

Page 22: ...ontroller 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 C...

Page 23: ...750 BMK 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 BMK 4000 BMK 5000 BMK 6000 Start Level 22 22 20 24 24 20 27 24 24 Stop Level 18 18 16 18 16 14 23 18 18 Ignition Position 35 35 29 29 29 29 45 35 50 T...

Page 24: ...40 246 000 72 1 kW 297 000 87 0 kW 33 30 50 369 000 108 1 kW 443 000 126 9 kW 49 44 60 465 000 136 3 kW 564 000 165 3 kW 62 56 70 554 000 162 4 kW 660 000 193 4 kW 74 66 80 637 000 186 7 kW 789 000 2...

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

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

Page 27: ...NERGY 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...

Page 28: ...ENERGY INPUT OF FULL CAPACITY 14 Stop Level 200 000 58 6 kW 6 7 30 520 000 152 kW 17 40 880 000 258 kW 29 50 1 270 000 372 kW 42 60 1 680 000 492 kW 56 70 2 100 000 615 kW 70 80 2 390 000 700 kW 80 9...

Page 29: ...f 153 3 4 6 BMK4000 Air Fuel Valve Position and Energy Input TABLE 3 6a BMK4000 Air Fuel Valve Position NATURAL GAS AIR FUEL VALVE POSITION OPEN ENERGY INPUT BTU HR BOILER ENERGY INPUT OF FULL CAPACIT...

Page 30: ...ut BTU Hr of Full Capacity 10 0 0 18 Stop Level 400 000 117 kW 8 30 997 217 292 kW 20 40 1 667 848 489 kW 33 50 1 992 380 584 kW 40 60 2 486 881 729 kW 50 70 2 981 381 874 kW 60 80 3 780 230 1108 kW 7...

Page 31: ...gy Input BTU Hr of Full Capacity 10 0 0 18 Stop Level 385 000 113 kW 6 20 400 000 117 kW 7 30 540 000 158 kW 9 40 770 000 226 kW 13 50 1 160 000 340 kW 19 60 1 650 000 484 kW 28 70 2 386 000 699 kW 40...

Page 32: ...nchmark Platinum Edge II Operation Service Manual SECTION 3 START SEQUENCE OMM 0137_E GF 211 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 32 of 153 This page intentionally blan...

Page 33: ...instructions below should be followed precisely in order to operate the unit safely and at high thermal efficiency and low flue gas emissions Initial unit start up must be performed by AERCO factory t...

Page 34: ...d on the upstream side of the SSOV to verify that the gas supply pressure is within the required range of 4 W C and 14 W C Mounted on the downstream side of the SSOV to monitor the gas pressure during...

Page 35: ...L VALVE LEAK DETECTION BALL VALVES 1 4 NPT PLUG Install manometer here for upstream combustion calibration reading HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE SSOV TO AIR FU...

Page 36: ...manometer here for downstream combustion calibration reading HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE NATURAL GAS INLET NATURAL GAS INLET TO AIR FUEL VALVE LEAK DETECTION...

Page 37: ...SURE SWITCH TO AIR FUEL VALVE MANUAL SHUT OFF VALVE DOWNSTREAM SSOV WITH POC SWITCH HIGH GAS PRESSURE SWITCH UPSTREAM LEAK DETECTION BALL VALVE TO AIR FUEL VALVE HIGH GAS PRESSURE SWITCH MANUAL SHUT O...

Page 38: ...as and BMK models 1500 to 6000 are available in dual fuel versions natural gas and propane Both fuel types require different combustion calibration values and so care must be taken to ensure to follow...

Page 39: ...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 O...

Page 40: ...n the allowable range see the Benchmark Pre Installation Gas Supply Guide TAG 0047 GF 2030 9 Once you have completed the previous step move the manometer or use a secondary one to the downstream side...

Page 41: ...rn increments clockwise to increase gas pressure or counterclockwise to reduce it The resulting gas pressure reading on the downstream manometer should fall in the range listed below TABLE 4 1 REFEREN...

Page 42: ...er s gas pressure reading in the Downstream Gas Pressure field Note this field appears only when Valve Position 100 21 Compare the measured nitrogen oxide NOx and carbon monoxide CO readings to the Ta...

Page 43: ...depending on model The O2 NOx and CO should stay within the ranges shown in these tables TABLE 4 3a NATURAL GAS BMK Final Valve Positions BMK750 1000 750 1000 Valve Position Standard NOx Ultra Low NOx...

Page 44: ...0 2 20 ppm 100 ppm 50 6 1 0 2 65 5 5 0 2 20 ppm 100 ppm 40 5 0 0 2 45 5 7 0 2 20 ppm 50 ppm 30 6 4 0 2 30 5 6 0 2 20 ppm 50 ppm 14 6 4 0 2 14 6 2 0 2 20 ppm 50 ppm TABLE 4 3e NATURAL GAS Final Valve P...

Page 45: ...gure 4 3 Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the O2 to the specified level Recalibration MUST be performed again from 60 or 50 down to the lowest valve position after making...

Page 46: ...the unit is within the allowable range see the Benchmark Pre Installation Gas Supply Guide TAG 0047 GF 2030 9 Once you have completed the previous step move the manometer or use a secondary one to th...

Page 47: ...downstream manometer should fall in the range 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 7 6 W C 0 2...

Page 48: ...gen O2 column in the table below TABLE 4 5 PROPANE Calibration Readings at 100 Valve Position Model Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO 750 1000 5 5 0 2 100 ppm 150 ppm 1500 5 2 0 2 100 pp...

Page 49: ...0 80 5 5 0 2 100 ppm 150 ppm 60 5 5 0 2 100 ppm 150 ppm 45 5 5 0 2 100 ppm 150 ppm 30 6 3 0 2 100 ppm 100 ppm 18 5 5 0 2 100 ppm 100 ppm BMK1500 70 5 2 0 2 100 ppm 150 ppm 50 5 3 0 2 100 ppm 150 ppm 4...

Page 50: ...2 value on the Combustion Calibration sheet 26 If the oxygen level at the lowest valve position is too high and the Blower voltage is at the minimum value you can adjust the TAC screw which is recesse...

Page 51: ...AL START UP OMM 0137_E GF 211 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 51 of 153 Reassembly Instructions 6 Replace all previously removed sheet metal enclosures on the unit...

Page 52: ...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...

Page 53: ...e 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 Fahrenh...

Page 54: ...N and remove the front panel to expose the Over Temperature Limit switches 2 Press the Manual Reset Limit Switch s RST Reset button 3 You can now restart the unit Figure 4 13 Manual Reset Over Tempera...

Page 55: ...erating as designed Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTES Manua...

Page 56: ...off and the MANUAL LED will light 8 Adjust the Air Fuel Valve position between 25 and 30 using the Plus and Minus controls 9 While the unit is firing slowly close the external manual gas shut off valv...

Page 57: ...re Test Components SSOV GAS INLET TO AIR FUEL VALVE LOW GAS PRESSURE LEAK DETECTION BALL VALVE shown closed HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE 1 4 NPT PLUG Install...

Page 58: ...e 1 4 inch plug shown in Figure 5 2a and 5 2b and install a hose barb fitting in that location 4 Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 16 W C 0 4 0...

Page 59: ...lowly 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 calculated in step...

Page 60: ...Gas Pressure Test Instructions BMK3000 6000 Only Figure 5 2a LOW and HIGH Gas Pressure Test Components BMK3000 Shown Figure 5 2b LOW and HIGH Gas Pressure Test Components BMK4000 Shown NATURAL GAS INL...

Page 61: ...f 153 LOW Gas Pressure Test Instructions BMK3000 6000 Only Figure 5 2c LOW and HIGH Gas Pressure Test Components BMK6000 Shown MANUAL SHUT OFF VALVE TO AIR FUEL VALVE NATURAL GAS Low Gas Pressure Test...

Page 62: ...he gas pressure using the adjustment screw on the SSOV while counting the number of turns you make 10 The FAULT indicator should start flashing and the unit should shut down and display a Fault Lockou...

Page 63: ...Figure 5 3a BMK750 1000 HIGH Gas Pressure Test Components Figure 5 3b BMK1500 2000 HIGH Gas Pressure Fault Test SSOV GAS INLET TO AIR FUEL VALVE HIGH GAS PRESSURE BALL VALVE 1 4 NTP PLUG Install mano...

Page 64: ...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 S...

Page 65: ...e until it is at the maximum allowed 11 Slowly turn the indicator dial on the High Gas Pressure switch until the unit shuts down due to a gas pressure fault This is the setpoint 12 Press the RESET but...

Page 66: ...ure Test Instructions BMK3000 6000 ONLY Figure 5 4b HIGH Gas Pressure Test Components BMK4000 Shown HIGH GAS PRESSURE SWITCH NATURAL GAS INLET HIGH Gas Pressure Port Install manometer here for High Ga...

Page 67: ...shown DOWNSTREAM SSOV WITH POC SWITCH NATURAL GAS HIGH Gas Pressure Port Install manometer here for High Gas Pressure test PROPANE Gas Pressure Port Install manometer here for High Gas Pressure test A...

Page 68: ...icator 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...

Page 69: ...ontroller s is not configured to display outlet temperature go to the Main Menu Advanced Setup Unit Front Panel Configuration screen and set the Upper Right Display parameter to Water Outlet Figure 5...

Page 70: ...us controls 5 If there is a jumper across the Remote Interlock terminals remove one side of the jumper If the interlock is being controlled by an external device either open the interlock via the exte...

Page 71: ...ter reaching the main Burner Ignition cycle and display Flame Loss During Ign 9 Open the Manual Shutoff valve closed in step 5 and press the CLEAR soft key 10 Restart the unit and allow it to prove fl...

Page 72: ...ET SWITCHES These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5 6a 5 6b and 5 6c 5 8 1 Blower Proof Switch Test Figure 5 6a Blower Proof Blocked Inlet...

Page 73: ...setting indicator dial 0 3 in the Figure below COVER WITH LABEL COVER REMOVED Figure 5 7 Blower Proof Switch 4 Set the Controller s Enable Disable switch to Enable and wait for the boiler to go into t...

Page 74: ...e alligator clip away from bare metal parts until step 4b Figure 5 8 Connecting the Flame Signal Generator 4 On the Controller go to Main Menu Diagnostics Manual Run and then put the unit in Manual Mo...

Page 75: ...ition between 25 and 30 using the Plus and Minus controls 4 Remove the cover from the SSOV by loosening the screw shown in Figure 5 9 Lift off the cover to access the terminal wiring connections 5 Dis...

Page 76: ...t in Manual Mode 3 Set the valve position between 25 and 30 using the Plus and Minus controls 4 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it see Figure 5 10 5 Re...

Page 77: ...Purge Switch Open During Purge Check Instructions Figure 5 11a Air Fuel Purge and Ignition Locations BMK750 1000 Figure 5 11b Air Fuel Purge and Ignition Locations BMK1500 4000 TO BLOWER Purge Positi...

Page 78: ...nual Run and then put the unit in Manual Mode 3 Set the valve position between 25 and 30 using the Plus and Minus controls 4 Remove the Air Fuel Valve cover Figure 5 10 above by rotating the cover cou...

Page 79: ...ction parameters can be customized to suit the needs of the specific application 6 1 OUTDOOR RESET MODE The Outdoor Reset mode of operation is based on outside air temperatures As the outside air temp...

Page 80: ...ollowing parameters to define the total outside air temperature span which will be used for Setpoint control OAR Min Outside Temp The minimum outside temperature the system can read it is tied to the...

Page 81: ...f 2 On the Controller go to Main Menu Advanced Setup Unit Application Configuration 3 Press SH Operating Mode and choose Constant Setpt 4 Press SH Setpoint and choose the desired setpoint 6 3 REMOTE S...

Page 82: ...a remote signal which is typically sent from an Energy Management System EMS or from a Building Automation System BAS The Direct Drive mode can be driven by a current or voltage signal The default se...

Page 83: ...CO Control System The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible For this mode of operation an ACS Header Temp Sensor must be installed between...

Page 84: ...n boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the...

Page 85: ...To setup a boiler for Combination mode Combination Control System Setup Instructions 1 As a prerequisite verify that the unit is not a BST Client or Manager Go to Main Menu Advanced Setup BST Cascade...

Page 86: ...hmark Platinum Edge II Operation Service Manual SECTION 6 MODES OF OPERATION OMM 0137_E GF 211 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 86 of 153 This page intentionally bl...

Page 87: ...ager and all other units on the network are defined as Client units The Manager monitors the system Header Temperature and also monitors all Client unit s status information efficiently controlling al...

Page 88: ...n is working properly as a BST system install the ProtoNode device f Make sure that the Modbus load and bias resistors are properly configured for the system to operate with the ProtoNode installed g...

Page 89: ...int with Direct Wired Header Temp Sensor Step 1 HEADER TEMP SENSOR WIRING BST MANAGER Unit 1 On the BST Manager unit connect the Header Temp Sensor to the I O board terminal strip J3 terminals 4 Suppl...

Page 90: ...set the Parameters to the Values in each menu listed in the table below Menu Screen Name Parameters Values Cascade Configuration Unit Mode BST Manager Hdr Temp Sensor Header Temp Application Configura...

Page 91: ...18 22 AWG cable 2 Connect the Header Temp Sensor to pins 2 and 3 of the Modbus Transmitter units using shielded pair 18 22 AWG cable 3 Install a jumper wire between pins 1 and 2 of the Modbus Transmit...

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

Page 93: ...r 18 22 AWG cable is recommended for Header Temp Sensor wiring There is no polarity to be observed The ground for the shield is at the Shield terminal on the I O the board The sensor end of the shield...

Page 94: ...e Communication Set the Unit Address parameter to the communication address of the unit On the BST Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each me...

Page 95: ...2 and 3 of the Modbus Transmitter 3 Install a jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield term...

Page 96: ...ON 4 CONFIGURATION On All Boiler 1 Go to Main Menu Advanced Setup BST Cascade Cascade Configuration Set the Unit Mode parameter to BST Client 2 Go to Main Menu Advanced Setup BST Cascade Cascade Commu...

Page 97: ...ed between 2 and 10 feet 0 61 and 3 1m downstream of the LAST boiler in the plant s supply water header Shielded pair 18 22 AWG cable is recommended for Header Temp Sensor wiring There is no polarity...

Page 98: ...Unit Address parameter to the communication address of the unit On the BST Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu in the table below M...

Page 99: ...er using shielded pair 18 22 AWG cable 4 Install a jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield...

Page 100: ...e observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 3 OPTION 6 CONFIGURATION On All Boiler 1 Go to Main Menu Advanced...

Page 101: ...pair 18 22 AWG cable 3 Install a jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Ground the shield to any Shield terminal on the I...

Page 102: ...the BST Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu in the table below Menu Screen Name Parameters Values Cascade Configuration Unit Mode BS...

Page 103: ...nnect the shield to any Shield terminal such as terminal 3 or 8 on strip J3 2 Connect the Header Temp Sensor to pins 2 and 3 of the Modbus Transmitter using shielded pair 18 22 AWG cable 3 Install a j...

Page 104: ...d Setup BST Cascade Cascade Communication Set the Unit Address parameter to the communication address of the unit On the BST Manager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameter...

Page 105: ...r Injector BMK750 4000 only Inspect Inspect replace if necessary Replace 15 mins 8 3 Pilot Ignition Rod BMK5000 6000 only Inspect Inspect replace if necessary Replace 15 mins 8 4 Flame Detector Inspec...

Page 106: ...urner Blower gaskets air filter cleaning kit 58025 16 LWCO air pump filter air filter cleaning kit 8 2 IGNITER INJECTOR BMK750 4000 The ignitor injector should be inspected annually and replaced at le...

Page 107: ...BMK1500 2000 Figure 8 1c Igniter Injector Flame Detector BMK2500 4000 Figure 8 1d Igniter Injector Orientation BMK2500 Shown BLOWER PLENUM IGNITER INJECTOR ASSEMBLY FLAME DETECTOR FLAME OBSERVATION PO...

Page 108: ...ed components Parts and instructions are included in 12 Month Maintenance Kit P N 58025 11 and all BMK5000 6000 24 Month Maintenance Kits Figure 8 2a Pilot Burner Main Pilot Flame Detector Figure 8 2b...

Page 109: ...d in both 12 Month Maintenance Kit P N 58025 01 BMK750 3000 and P N 58025 11 BMK5000 6000 and all BMK750 6000 24 Month Maintenance Kits 8 5 O2 SENSOR The Lean Oxygen Sensor P N 61026 should be cleaned...

Page 110: ...p Maintenance BMK5000 6000 Benchmark Platinum 5000 and 6000 units contain an Air Eductor assembly mounted just inside the O2 Sensor Cover on the unit s back panel see Figure 8 3b above It includes an...

Page 111: ...afety Device Testing in this guide for a description and instructions for performing these tests 8 7 BURNER INSPECTION The burner assembly should be inspected every 24 months to ensure that all compon...

Page 112: ...urner Assembly Exploded View BMK750 1000 Figure 8 5b BMK1500 2000 Burner Assembly Mounting Details AIR FUEL VALVE BURNER GASKET P N 81143 FLAME DETECTOR O2 SENSOR BLOWER GASKET P N 81064 BURNER BLOWER...

Page 113: ...unting Details BMK2500 4000 Figure 8 5d Burner Assembly Exploded View BMK5000 6000 BLOWER GASKET P N 81157 BLOWER PLENUM AIR FILTER P N 88014 A F VALVE PLENUM BLOWER BURNER PLATE 3 8 16 HEX NUTS 8 eac...

Page 114: ...at is free to move and condensate flows normally and the O Ring P N 84017 included in all 24 Month Maintenance Kits replaced if it is worn or damaged In addition you must ensure the vent under the rem...

Page 115: ...Instructions are included in the TID that accompanies the kit 8 10 REFRACTORY REPLACEMENT BMK5000 6000 ONLY Low mass fiber based material insulates the front and rear end plates of the combustion cham...

Page 116: ...ut each Access the nuts for removal through the side panel as shown in Figure 8 8 4 Remove the left rear panel which is held in place by 2 spring latches and 7 16 bolts inside the panel on the top rai...

Page 117: ...o opposing metal tabs located on the outer edge of the fiber blanket then alternately pull on the other two opposing tabs Continue this process until the fiber refractory package can be removed from t...

Page 118: ...pattern to ensure a uniform seal Torque bolts to approximately 20 ft lbs 18 To avoid exhaust leaks ensure that a uniform seal is established when reconnecting the flue system to the boiler Figure 8 1...

Page 119: ...of the heat exchanger chamber and base assembly WARNING If the temperature will ever fall below freezing failure to drain all water can cause heat exchanger tubes to crack and fail 8 11 1 Benchmark 50...

Page 120: ...age a Use a Megger each month to ensure that integrity of the winding insulation has been maintained Record the Megger readings Immediately investigate any significant drop in insulation resistance b...

Page 121: ...t be followed Placing the Boiler Back In Service After A Prolonged Shutdown Instructions 1 Review installation requirements included in Section 2 of the Benchmark Platinum Edge INSTALLATION Manual GF...

Page 122: ...ecifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Tech Verify factory settings Annually Service Tech Check with combustion calibration test equipment see S...

Page 123: ...guide High and low gas pressure interlocks Monthly Operator See Sections 5 2 Low Gas Pressure Test and 5 3 High Gas Pressure Test in this guide Air Fuel Valve purge position switch Annually Service Te...

Page 124: ...tor Combo Used on ALL FM gas trains Downstream SSOV on DBB gas trains 64048 64048 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV on DBB gas trains 27086 1 27086 1 27086 1 TA...

Page 125: ...d reliability while minimizing emissions It does this by first measuring post combustion oxygen percentages inside the combustion chamber This data is fed through the Electronic Control Unit ECU which...

Page 126: ...ctivation code and press Save 5 Scroll back to the top of the AERtrim Settings screen and set the AERtrim parameter to Enabled 6 Go to the AERtrim O2 Trim Parameters screen The O2 Target O2 Upper Limi...

Page 127: ...its to allow the user to select the optimal air fuel ratio for a particular boiler or application Figure 9 3 shows how the controller would react to an O2 reading above the upper limit The controller...

Page 128: ...cted air O2 level of 20 9 If the calculated offset is more than 3 O2 Warning Service Required message is displayed and the trim function is disabled Auto Calibration occurs only when the unit is in St...

Page 129: ...0 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 18 2 5 5 5 4 5 30 2 5 5 5 4 5 45 2 5 5 5 4 5 60 2 5 5 5 5 0 80 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper Limit must be at least 1 higher than...

Page 130: ...0 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 18 2 5 5 5 4 5 30 2 5 5 5 4 5 45 2 5 5 5 5 0 60 2 5 5 5 5 0 80 2 5 5 5 5 0 100 2 5 5 5 4 5 O2 Upper Limit must be at least 1 higher than...

Page 131: ...3 8 6 5 40 3 8 6 5 50 3 8 6 5 70 3 8 6 0 100 3 8 5 0 O2 Lower Limit must be at least 1 lower than O2 Upper 16 2 5 5 5 5 0 30 2 5 5 5 5 0 40 2 5 5 5 5 0 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2...

Page 132: ...5 30 3 8 6 0 40 3 8 6 0 50 3 8 5 5 70 3 8 5 5 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 18 2 5 5 5 5 0 30 2 5 5 5 5 5 40 2 5 5 5 5 5 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2...

Page 133: ...5 30 3 8 6 5 40 3 8 7 0 50 3 8 6 0 70 3 8 6 0 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 16 2 5 5 5 5 0 30 2 5 5 5 4 5 40 2 5 5 5 5 0 50 2 5 5 5 5 5 70 2 5 5 5 5 5 100 2 5 5 5 4 5 O2...

Page 134: ...5 30 3 8 7 3 40 3 8 7 5 50 3 8 7 0 70 3 8 5 5 100 3 8 5 0 O2 Lower must be at least 1 lower than O2 Upper 14 2 5 5 5 5 5 30 2 5 5 5 5 5 40 2 5 5 5 5 5 50 2 5 5 5 5 5 70 2 5 5 5 5 0 100 2 5 5 5 4 5 O2...

Page 135: ...6 0 30 3 8 5 5 40 3 8 5 5 50 3 8 5 5 70 3 8 5 5 100 3 8 5 5 O2 Lower must be at least 1 lower than O2 Upper 23 2 5 5 5 5 5 30 2 5 5 5 5 0 40 2 5 5 5 5 0 50 2 5 5 5 5 0 70 2 5 5 5 5 0 100 2 5 5 5 5 0 O...

Page 136: ...o the device may be required TABLE 9 1 AERtrim General Warnings Warning Cause Possible Solutions O2 Percentage Low O2 Levels less than 2 for more than 30 seconds auto reset when valve comes back in ra...

Page 137: ...up Performance AERtrim AERtrim Status screen TABLE 9 2 AERtrim Operation Interruption Errors Error Message Cause Possible Solutions BV Hi Err Trim operation exceeds allowable blower voltage limits Che...

Page 138: ...hmark Platinum Edge II Operation Service Manual SECTION 9 AERTRIM OPERATION OMM 0137_E GF 211 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 138 of 153 This page intentionally bl...

Page 139: ...essages are included in Section 9 6 above When a fault occurs in the unit proceed as follows to isolate and correct the fault Fault Correction Instructions 1 Observe the fault messages displayed on th...

Page 140: ...resistance reading or the resistance reading is greater than zero ohms replace the switch 6 Defective Blocked Inlet switch 6 Turn off unit and check the continuity of the Blocked Inlet switch If there...

Page 141: ...e to Blocked Inlet switch from Edge Controller 5 During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified se...

Page 142: ...is functional A jumper may be temporarily installed to test the interlock DIRECT DRIVE SIGNAL FAULT 1 Direct drive signal is not present Not yet installed Wrong polarity Signal defective at source Br...

Page 143: ...a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressure into and out of the valve is correct 3 Poor combustion calibration 3 Check combustion calibration using the proc...

Page 144: ...settings have been changed record the current readings then reset to default values 3 Faulty shell temperature sensor 3 Using the resistance charts in Section 2 of the Benchmark Platinum Edge REFERENC...

Page 145: ...ly open terminals If the switch is wired correctly replace the switch 4 Defective Power Supply Board or fuse 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply B...

Page 146: ...ersed 2 Incorrect power supply transformer wiring 2 Check transformer wiring in AC Power Box against the power box transformer wiring diagram to ensure it is wired correctly LOW GAS PRESSURE 1 Incorre...

Page 147: ...m check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 3 Switch wired incorrectly 3 If the switch is wired correctly replace the switch 4 Defective Po...

Page 148: ...s not isolated floating if 4 to 20 mA 2 Check signal at source to ensure it is isolated 3 Edge Controller signal type selection switches not set for correct signal type voltage or current 3 Check DIP...

Page 149: ...er closes it may be powered continuously Close the gas supply and remove power from the unit Refer fault to qualified service personnel 3 Defective switch or Actuator 3 Remove the electrical cover fro...

Page 150: ...Injector Figure 8 1a through Figure 8 1c and inspect Gas Injector to ensure it is not clogged or damaged 2 Defective Staged Ignition Solenoid Figure 8 1a through Figure 8 1c 2 Close the Manual Shutoff...

Page 151: ...UBLESHOOTING OMM 0137_E GF 211 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 151 of 153 Figure 10 1 SSOV Actuator with Gas Pressure Adjustment SKP25 BRASS HEX HEAD Remove to acc...

Page 152: ...Benchmark Platinum Edge II Operation Service Manual CHANGE LOG OMM 0137_E GF 211 12 13 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 152 of 153 NOTES...

Page 153: ...04 Added additional requirements to Section 1 2 Emergency Shutdown DIR 19 19 Modified long term shutdown procedure Section 8 11 DIR 19 24 Reordered and modified combustion calibration steps 13 22 in...

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