Watts Aerco BMK 750 Operation And Service Manual Download Page 144

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Benchmark with Edge [I]: Operation-Maintenance Manual

SECTION 8

– MAINTENANCE

OMM-0145_A99

• GF-218 • 9/18/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

144

157

8.14 RECOMMENDED SPARES

NOTE:

Refer to the parts list illustrations in the

Benchmark 750-6000 With Edge [I]: Install-

Startup Manual

(OMM-0144, GF-217)

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

– 3000

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 [i] Controller

64134

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 BMK 750

Page 1: ...ombustion Air Design Guide TAG 0047 GF 2030 Benchmark Gas Guide TAG 0048 GF 2060 Benchmark Power Design Guide Applies to serial numbers G 19 0001 and above BMK750 4000 N 19 0001 and above BMK5000 6000...

Page 2: ...e Position and Energy Input 41 3 4 3 BMK2000 Air Fuel Valve Position and Energy Input 42 3 4 4 BMK2500 Air Fuel Valve Position and Energy Input 43 3 4 5 BMK3000 Air Fuel Valve Position and Energy Inpu...

Page 3: ...NSTANT SETPOINT MODE 99 6 3 REMOTE SETPOINT MODE 99 6 4 DIRECT DRIVE MODES 100 6 5 AERCO CONTROL SYSTEM ACS 101 6 6 COMBINATION CONTROL SYSTEM CCS 101 6 6 1 Combination Control System Field Wiring 102...

Page 4: ...IR FILTER CLEANING AND REPLACEMENT 135 8 10 REFRACTORY REPLACEMENT BMK5000 6000 ONLY 135 8 10 1 Rear Refractory Replacement 136 8 10 2 Front Refractory Replacement 138 8 11 SHUTTING BOILER DOWN FOR EX...

Page 5: ...9 kW BMK2000 100 000 29 3 kW 2 000 000 586 kW 86 000 25 2 kW 1 860 000 545 kW BMK2500 167 000 48 9 kW 2 500 000 732 kW 144 000 42 2 kW 2 395 000 702 kW BMK3000 200 000 58 6 kW 3 000 000 879 kW 174 000...

Page 6: ...to bits per second unless each symbol is 1 bit long BMK Benchmark AERCO s Benchmark series boilers BMS or BMS II AERCO Boiler Management Systems BLDG Bldg Building BST AERCO on board Boiler Sequencing...

Page 7: ...otocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 0 001 Ampere MAX Max Maximum MBH 1000 BTUs per Hour M...

Page 8: ...rd for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shield SPDT Single Pole Double Throw a type of switch SSOV Safe...

Page 9: ...NING Do not use matches candles flames or other sources of ignition to check for gas leaks Fluids under pressure may cause injury to personnel or damage to equipment when released Be sure to shut off...

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: ...oot the boiler The Edge i Controller s front panel consists of a touchscreen display along with a variety of indicators and buttons Figure 2 1 Edge i Controller Front Panel 1 Multi Function Bar shows...

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

Page 15: ...e current Outlet temperature Air Inlet Read Only The current Air Inlet temperature O2 Read Only The Current O2 reading Exhaust Read Only The current Exhaust temperature Main Menu Plant Status BST Mana...

Page 16: ...lower Reading Read Only The unit s actual blower voltage O2 Target Read Only The unit s target O2 in the exhaust O2 Reading Numeric Entry The unit s actual O2 in the exhaust CO Target Read Only The ta...

Page 17: ...ed Valve Position A F Sensitivity Numeric Entry Set Air Fuel Valve sensitivity 1 to 5 Main Menu Calibration Subsystems Spark Monitor Spark Monitor Enabled Disabled Enables Disables the Spark Monitor M...

Page 18: ...Blower 2 3 3 4 Main Menu Diagnostics Subsystems Main Menu Diagnostics Subsystems Air Fuel Valve Stepper Motor Auto Stroke Toggle Initiates A F cycle 0 to 100 to 0 Valve Position In Adjust Manual adju...

Page 19: ...it s DSN 2 address Unit MAC Address Read Only The unit s MAC address Network Status Read Only The unit s current network status Main Menu Diagnostics Comm Network BAS BAS Read Only The Building Automa...

Page 20: ...Ignition Relay Backup Relay Pump Relay DHW Relay Aux Relay V2 Spare 1 Relay Fault Relay Spare 2 Relay Blower Blower High Gas Pressure Low Gas Pressure Draft Pressure Spare Pressure 2 3 4 Advanced Setu...

Page 21: ...Right Display Select Choose Water Outlet or System Header Multi Function Bar Select Choose the Multi Function Bar display Fire Rate or Valve Position Brightness Numeric Entry Adjusts Touchscreen brig...

Page 22: ...cation SH and Unit SH Operating Mode Outdoor Reset OAR Min Outside Temp Numeric Entry The minimum outside air temperature the system will read Unit Application SH and Unit SH Operating Mode Outdoor Re...

Page 23: ...he Modbus point within the Modbus address where the DHW temp sensor resides DHW Temp Sensor Network or BAS DHW Temp Unit Addr Numeric Entry Manager Specify the unit to which the DHW Header Temp Sensor...

Page 24: ...f On Outlet Temp or On Avg Temp If either On option is chosen and BST detect a low flow condition it slowly shuts down one unit at a time in an attempt to raise the Fire Rate of the remaining units Lo...

Page 25: ...Select Choose the signal that closes the valve 0mA 4mA or 20mA Min Valves Open Numeric Entry Specify the minimum number of isolation valves that must stay open at all times including during plant stan...

Page 26: ...enu Advanced Setup Comm Network Communication Failsafe Unit Failsafe Mode Toggle Choose how the unit will operate when either the Manager communication or a Remote Signal is lost Constant Setpt or Shu...

Page 27: ...fall before the unit restarts 0 to 10 F Setpoint Limiting Enable Setback Schedule Enable Disable Enables disables Setback Schedule functionality Setback Setpoint Numeric Entry The Setpoint that will...

Page 28: ...ge during ignition 5 00 to 5 00 Low Fire Timer Numeric Entry Specifies how long to remain in the low fire position after ignition before going to the desired output 2 to 600 sec Ignition Hold Timer Nu...

Page 29: ...Off Delay function 40 to 100 Slow Shutdown Enabled Shutoff Delay Temp Numeric Entry Specifies the number of degrees above setpoint that the outlet temperature can rise without triggering a unit shut d...

Page 30: ...Benchmark with Edge I Operation Maintenance Manual SECTION 2 OPERATION OMM 0145_A99 GF 218 9 18 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 30 of 157 This page intentionally blank...

Page 31: ...thout a 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 A...

Page 32: ...ng of this section The Edge i 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...

Page 33: ...am 5 pm EST Page 33 of 157 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 34: ...lower relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on the Air Fuel Valve Figure 3 2a and 3 2b will rea...

Page 35: ...ion 5 Next the Blower Proof and Blocked Inlet switches close Figure 3 4a and 3 4b On the Ignition Sequence screen the Purging indicator turns grey while purging is underway Figure 3 3 and Purge Timer...

Page 36: ...ion Sequence screen s Spark Cleaning indicator Figure 3 3 turns grey This cycle turns on the ignition transformer to produce a spark with no gas flowing to remove moisture and carbon buildup from the...

Page 37: ...ted 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 whic...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ...57 3 4 6 Benchmark4000 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 CAPA...

Page 46: ...t 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 76...

Page 47: ...y 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 48: ...nchmark with Edge I Operation Maintenance Manual SECTION 3 START SEQUENCE OMM 0145_A99 GF 218 9 18 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 48 of 157 This page intentionally blan...

Page 49: ...tart up 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 f...

Page 50: ...n the upstream side of the SSOV to verify that the gas supply pressure is within the required range of 4 W C and 14 W C Mounted on the downstream side of the SSOV to monitor the gas pressure during th...

Page 51: ...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 52: ...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 53: ...E SWITCH NATURAL GAS INLET TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS PRESSURE SWITCH SSOV LEAK DETECTION BALL VALVE LEAK DETECTION BALL VALVE TO AIR FUEL VALVE HIGH GAS PRESSURE SWITCH MANUAL SH...

Page 54: ...as shown in Figure 4 2 Prepare the port for the combustion analyzer probe as follows Analyzer Probe Port Access Instructions 1 Refer to Figure 4 2 and remove the 1 4 NPT plug from the exhaust manifold...

Page 55: ...Section 4 6 4 4 COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated with either standard combustion NOx emissions of 20 ppm or Ultra Low NOx NOx 9 ppm on the BMK750 to 2000 only at th...

Page 56: ...ary enter a technician level password 6 The first Manual Combustion Calibration screen appears lists the three steps that must be completed before continuing Figure 4 4 First Manual Combustion Calibra...

Page 57: ...n the downstream side of the SSOV is within the required range shown in Table 4 1 If it isn t remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Make...

Page 58: ...8 until the gas pressure is within the range in Table 4 1 and the O2 Reading column to matches the Target column 20 Enter the downstream manometer s gas pressure reading in the Downstream Gas Pressure...

Page 59: ...s in Table 4 3a through 4 3d depending on model The O2 NOx and CO should stay within the ranges shown in these tables TABLE 4 3a NATURAL GAS BMK Final Valve Positions BMK750 1000 750 1000 Valve Positi...

Page 60: ...0 ppm 50 ppm BMK3000 70 5 1 0 2 85 5 4 0 2 20 ppm 100 ppm 50 6 1 0 2 65 5 5 0 2 20 ppm 100 ppm 40 5 0 0 2 45 5 7 0 2 20 ppm 50 ppm 30 6 4 0 2 30 5 6 0 2 20 ppm 50 ppm 14 6 4 0 2 14 6 2 0 2 20 ppm 50 p...

Page 61: ...formed 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 4 4 2 PROPANE GAS COMBUSTION CALIBRA...

Page 62: ...point left image below Method 2 Enable Fine VP Step then manually press the or buttons once per 1 to bring the unit to the desired valve position right image below Figure 4 9 Manual Combustion Calibra...

Page 63: ...2 sensor cannot be made to match the analyzer the sensor may be defective and need to be replaced 18 Compare the O2 value in the Target and Reading columns If they don t match adjust the Blower Voltag...

Page 64: ...e values plus the O2 value on the Combustion Calibration Data Sheet provided with the unit 24 Lower the Valve Position to the next calibration point using the Left arrow key if using Method 1 in step...

Page 65: ...150 ppm 40 40 5 5 0 5 100 ppm 150 ppm 30 30 5 5 0 5 100 ppm 150 ppm 18 18 6 0 1 0 100 ppm 150 ppm BMK6000 70 85 5 5 0 5 100 ppm 150 ppm 50 65 5 5 0 5 100 ppm 150 ppm 40 45 5 5 0 5 100 ppm 150 ppm 30...

Page 66: ...uctions 1 Set the Enable Disable switch in the Disable 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 N...

Page 67: ...al 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...

Page 68: ...adjustable Temperature Limit switch is manually adjustable from 32 F 212 F 0 C 100 C This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the...

Page 69: ...utton Resets the unit after an alarm condition UP Button Increases the displayed temperature DOWN Button Decreases the displayed temperature SET SET Button Used to access and store parameters in the u...

Page 70: ...h the code set at 0 AERCO recommends that you do not change this code 7 Press the SET button again to enter the code The first parameter label SP will appear in the display 8 Using the and arrow keys...

Page 71: ...ng as designed Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTES Manual and...

Page 72: ...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 73: ...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 74: ...arb fitting in that location 4 Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 16 W C 0 4 0 kPa manometer 5 Apply the reading of the manifold pressure taken i...

Page 75: ...a reading of the inlet gas pressure If the inlet pressure is below the minimum calculated in step 5 above then increase the pressure to match the calculated minimum 12 Slowly turn the indicator dial o...

Page 76: ...8 am 5 pm EST Page 76 of 157 LOW Gas Pressure Test Instructions BMK3000 6000 Only Figure 5 2b LOW and HIGH Gas Pressure Test Components BMK4000 Shown NATURAL GAS INLET HIGH GAS PRESSURE SWITCH TO AIR...

Page 77: ...157 LOW Gas Pressure Test Instructions BMK3000 6000 Only Figure 5 2c Low Gas Pressure Switch Locations Test Ports BMK6000 Shown MANUAL SHUT OFF VALVE TO AIR FUEL VALVE NATURAL GAS Low Gas Pressure Tes...

Page 78: ...ile counting the number of turns you make 10 The FAULT indicator should start flashing and the unit should shut down and display a Fault Lockout Gas Pressure Fault message at approximately the value s...

Page 79: ...s Figure 5 3b BMK1500 2000 HIGH Gas Pressure Fault Test SSOV GAS INLET TO AIR FUEL VALVE HIGH GAS PRESSURE BALL VALVE 1 4 NTP PLUG Install manometer here for High Gas Pressure Test MANUAL SHUT OFF VAL...

Page 80: ...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 81: ...lowed 11 Slowly turn the indicator dial on the High Gas Pressure switch until the unit shuts down due to a gas pressure fault This is the setpoint 12 Press the RESET button on the High Gas Pressure sw...

Page 82: ...Mon Fri 8 am 5 pm EST Page 82 of 157 HIGH Gas Pressure Test Instructions BMK3000 6000 ONLY Figure 5 2b LOW and HIGH Gas Pressure Test Components BMK4000 Shown TO AIR FUEL VALVE SSOV MANUAL SHUT OFF VA...

Page 83: ...Switch Locations Test Ports BMK6000 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 manomet...

Page 84: ...icator flashes 5 On the Controller go to Main Menu Diagnostics Manual Mode 6 Enable the Manual Run control 7 Raise the valve position above 30 using the Plus and Minus controls 8 Set the Controller s...

Page 85: ...tch the displayed OUTLET TEMPERATURE 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 the Upper...

Page 86: ...d closed However they may be utilized in the field as a remote stop and start an emergency cut off or to prove that a device such as a pump gas booster or louver is operational 5 6 1 Remote Interlock...

Page 87: ...hen enable the Manual Run control 3 Set the valve position between 25 and 30 using the Plus and Minus controls 4 If there is a jumper across the DELAYED INTL K IN terminals remove one side of the jump...

Page 88: ...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 89: ...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 90: ...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 91: ...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 Mode and then put the unit in Manual M...

Page 92: ...sition 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 Di...

Page 93: ...it 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 R...

Page 94: ...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 95: ...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...

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Page 97: ...ation 6 1 OUTDOOR AIR RESET MODE The Outdoor Air Reset operating mode is based on outside air temperatures As the outside air temperature decreases the supply header temperature will increase and vice...

Page 98: ...the total outside air temperature span which will be used for Setpoint control OAR Min Outside Temp The minimum outside temperature the system can read it is tied to the OAR Max Setpoint For example i...

Page 99: ...Press SH Operating Mode and choose Constant Setpt 3 Press SH Setpoint and choose the desired setpoint 6 3 REMOTE SETPOINT MODE The unit s setpoint can be remotely controlled by an Energy Management Sy...

Page 100: ...Automation System BAS The Direct Drive mode can be driven by a current or voltage signal The default setting for the Direct Drive mode is 4 20 mA 1 5 VDC With this setting a 4 to 20 mA signal sent by...

Page 101: ...lers via Modbus RS 485 network communication For ACS programming operation and Header Sensor installation details see the ACS Operations Guide OMM 081 GF 131 For operation via an RS 485 Modbus network...

Page 102: ...n boilers that are divided up into Building Priority BLDG PRIORITY boilers and Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and using two hydronic isolat...

Page 103: ...Setup BST Cascade Cascade Configuration Unit Mode Off 2 On the Controller go to Main Menu Advanced Setup Unit Application Configuration 3 Press SH Operating Mode and choose Combination 4 Press the Rem...

Page 104: ...hmark with Edge I Operation Maintenance Manual SECTION 6 MODES OF OPERATION OMM 0145_A99 GF 218 9 18 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 104 of 157 This page intentionally b...

Page 105: ...other units on the network are defined as Client units The Manager monitors the system Header Temperature and also monitors all Client unit s status information efficiently controlling all units in or...

Page 106: ...r e Once the installation is working properly as a BST system install the ProtoNode device f Make sure that the Modbus load and bias resistors are properly configured for the system to operate with th...

Page 107: ...either o P N 61047 BALCO if connecting directly to I O board o P N 61060 PT1000 if connecting to Modbus Transmitter 7 3 1 Option 1 Constant Setpoint Direct Wired Header Temp Sensor OPTION 1 Instructi...

Page 108: ...nager only 1 Go to Main Menu Advanced Setup BST Cascade set the Parameters to the Values in each menu listed in the table below Menu Screen Name Parameters Values Cascade Configuration Auto Manager Tr...

Page 109: ...le 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 jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity...

Page 110: ...n Name Parameters Values Cascade Configuration Auto Manager Transfer Enabled This is available on the Manager unit only Auto failover Type C More Backup Manager Address Enter the designated backup uni...

Page 111: ...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 to be observed Ground the shi...

Page 112: ...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 113: ...I O Board of any Boiler unit using shielded pair 18 22 AWG cable 2 Connect the Header Temp Sensor P N 61040 to pins 2 and 3 of the Modbus Transmitter using shielded pair 18 22 AWG cable 3 Install a ju...

Page 114: ...ONFIGURATION Using the Modbus Transmitter provides gives the plant the ability to use the Backup manager feature This allows the any of the client units to become a Backup manager if the manager unit...

Page 115: ...OPTION 4 Instructions Outdoor Reset Modbus Header Temp Sensor Modbus Outdoor Temp Sensor Outdoor Temp Sensor Network Sensor Comm Address 240 Outdoor Temp Point 15 Plant Setpoint Header temperature re...

Page 116: ...2 Ground the shield to any SHLD terminal on the I O Board NOTES The Header Temp Sensor must be installed between 2 and 10 feet 0 61 and 3 1m downstream of the last boiler in the plant s supply water...

Page 117: ...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 menu in the table...

Page 118: ...s 2 and 3 of the Modbus Transmitter using Shielded pair 18 22 AWG cable 4 On the Modbus Transmitter install a jumper wire between pins 1 and 2 NOTES Polarity must be observed for the RS485 connections...

Page 119: ...be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 3 OPTION 6 CONFIGURATION On All Boiler 1 Go to Main Menu Advanced...

Page 120: ...to pins 2 and 3 of the Modbus Transmitter units using Shielded pair 18 22 AWG cable 3 On the Modbus Transmitter install a jumper wire between pins 1 and 2 NOTES Polarity must be observed for the RS485...

Page 121: ...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 menu in the table...

Page 122: ...s Transmitter using shielded pair 18 22 AWG cable 3 Install a jumper wire between pins 1 and 2 of the Modbus Transmitter NOTES Polarity must be observed for the RS485 connections Connect the shield to...

Page 123: ...t units to become a Backup manager if the manager unit is not communicating 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 ta...

Page 124: ...with Edge I Operation Maintenance Manual SECTION 7 BOILER SEQUENCING TECHNOLOGY OMM 0145_A99 GF 218 9 18 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 124 of 157 This page intentiona...

Page 125: ...njector BMK750 3000 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 Inspect I...

Page 126: ...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 127: ...1500 3000 Figure 8 1c Igniter Injector Flame Detector BMK2500 3000 Figure 8 1d Igniter Injector Orientation BMK2500 3000 Shown BLOWER PLENUM IGNITER INJECTOR ASSEMBLY FLAME DETECTOR FLAME OBSERVATION...

Page 128: ...1 and all BMK5000 6000 24 Month Maintenance Kits Figure 8 2a Pilot Burner Main Pilot Flame Detector Figure 8 2b Pilot Burner Pilot Ignition Rod Cross Section 8 4 FLAME DETECTOR The BMK750 4000 Flame D...

Page 129: ...0 24 Month Maintenance Kits 8 5 O2 SENSOR The Lean Oxygen Sensor P N 61026 should be cleaned and inspected every 12 months It is not included in any of the 12 or 24 month maintenance kits On BMK750 30...

Page 130: ...O2 Sensor Cover on the unit s back panel see Figure 8 3b above It includes an air pump which draws an air sample from the combustion chamber past the O2 Sensor ensuring its accuracy The air pump conta...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 5...

Page 140: ...e a Use a Megger each month to ensure that integrity of the winding insulation has been maintained Record the Megger readings Immediately investigate any significant drop in insulation resistance b DO...

Page 141: ...wed Placing the Boiler Back in Service After A Prolonged Shutdown Instructions 1 Review installation requirements included in Section 2 of the Benchmark 750 6000 with Edge i Install Startup Manual OMM...

Page 142: ...commended specifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Tech Verify factory settings Annually Service Tech Check with combustion calibration test equ...

Page 143: ...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 T...

Page 144: ...r Regulator 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 27...

Page 145: ...c When a fault occurs in the unit proceed as follows to isolate and correct the fault Fault Correction Instructions 1 Observe the fault messages displayed on the Edge i Controller 2 Refer to the Fault...

Page 146: ...ng or the resistance reading is greater than zero ohms replace the switch 6 Defective Blocked Inlet switch 6 Turn off unit and check the continuity of the Blocked Inlet switch If there is an erratic r...

Page 147: ...and ground If 24 VAC is not present refer fault to qualified service personnel 6 PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT DURING IGNITION apply for this fault 6 See CORRECTIVE ACTIONS for AIRFLO...

Page 148: ...nal is not isolated floating 2 Check signal at source to ensure it is isolated 3 Edge i Controller signal type selection switches not set for correct signal type voltage or current 3 Check DIP switch...

Page 149: ...d restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Relay is activated when not in Demand 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATU RE 1 Poor combustion ca...

Page 150: ...curring faster than units can respond 6 If the system is a variable flow system monitor system flow changes to ensure that the rate of flow change is not faster than what the units can respond to HIGH...

Page 151: ...be in the Air Fuel Valve or the Controller Refer fault to qualified service personnel 2 Defective Ignition switch 2 If the Air Fuel Valve does rotate to the ignition position check the ignition posit...

Page 152: ...he Low Water TEST and RESET buttons on the Controller s front panel Replace water level circuitry if it does not respond 3 Defective water level probe 3 Check continuity of probe end to the shell chan...

Page 153: ...switch is wired correctly correct wire numbers on the normally open terminals 4 Defective Power Supply Board or fuse 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power...

Page 154: ...or Actuator 3 Ensure Flame Detector is in good condition and is not tilted inward toward burner head SSOV FAULT DURING PURGE See SSOV SWITCH OPEN SSOV FAULT DURING RUN SSOV switch closed for 15 second...

Page 155: ...TIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 9 2 to troubleshoot faults which may occur without a specific fault message being displayed TABLE 9 2 Boiler Troubleshooting with No Fault...

Page 156: ...OMM 0145_A99 GF 218 9 18 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 156 of 157 downstream SSOV Actuator Figure 9 1 SSOV Actuator with Gas Pressure Adjustment SKP25 BRASS HEX HEAD R...

Page 157: ...Manual OMM 0145_A99 GF 218 9 18 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 157 of 157 Change Log Date Description Changed By 9 18 2019 Rev A Initial release internal reference DIR...

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