Watts AERCO Benchmark BMK5000

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Benchmark with Edge [I]: Operation-Maintenance Manual

OMM-0145_D • GF-218 • 11/2/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 164 of 213

Benchmark 750 – 1000 – Drawing Number: 68090 rev B Sheet 2 of 2

Main Page

Table of Contents2
Foreword5
Section 1. Safety Precautions9
Warnings & Cautions9
Emergency Shutdown10
Prolonged Shutdown10
Important - for Massachusetts Installations11
Section 2. Edge [I] Controller Operation13
Introduction13
Login and Password Entry14
Menu Structure15
Unit Status Menu15
Calibration Menu16
Diagnostics Menu17
Advanced Setup Menu20
Section 3. Start Sequence31
Introduction31
Start Sequence31
Start/Stop Levels39
Start/Stop Levels - Air/Fuel & Energy Input40
Benchmark 750/1000 Air/Fuel Valve Position and Energy Input40
Benchmark 1500 Air/Fuel Valve Position and Energy Input41
Benchmark 2000 Air/Fuel Valve Position and Energy Input42
Benchmark 2500 Air/Fuel Valve Position and Energy Input43
Benchmark 3000 Air/Fuel Valve Position and Energy Input44
Benchmark 4000 Air/Fuel Valve Position and Energy Input45
Benchmark 5000N Air/Fuel Valve Position and Energy Input46
Benchmark 5000 Air/Fuel Valve Position and Energy Input47
Benchmark 6000 Air/Fuel Valve Position and Energy Input48
Section 4. Initial Start-Up49
Initial Start-Up Requirements49
Tools & Instruments for Combustion Calibration50
Required Tools & Instrumentation50
Installing Gas Supply Manometer50
Accessing the Analyzer Probe Port54
Benchmark 5000 & 6000 Pilot Flame Ignition55
Fuel Types and Combustion Calibration55
Combustion Calibration55
NATURAL GAS Manual Combustion Calibration56
PROPANE GAS Combustion Calibration63
Reassembly68
Dual Fuel Switchover69
Over-Temperature Limit Switches69
Digital Alarm Switch Checks and Adjustments71
Section 5. Safety Device Testing73
Testing of Safety Devices73
Low Gas Pressure Test74
Low Gas Pressure Test: BMK750 - 250074
Low Gas Pressure Test: BMK3000 - 6000 Only76
High Gas Pressure Test80
High Gas Pressure Test: BMK750 - 250080
High Gas Pressure Test: BMK3000 - 6000 Only82
Low Water Level Fault Test86
Water Temperature Fault Test87
Interlock Tests88
Remote Interlock Test88
Delayed Interlock Test89
Flame Fault Test90
Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches91
Blower Proof Switch Test91
Blocked Inlet Switch Test93
Ssov Proof of Closure Switch Check94
Purge Switch Open During Purge95
Ignition Switch Open During Ignition97
Safety Pressure Relief Valve Test97
Section 6. Standalone Modes of Operation99
Outdoor Air Reset Mode99
Outdoor Air Temperature Sensor Installation99
Outdoor Reset Mode Startup100
Constant Setpoint Mode101
Remote Setpoint Mode101
Direct Drive Modes102
Aerco Control System (Acs)103
Combination Control System (Ccs)103
Combination Control System Field Wiring104
Combination Control System Setup and Startup104
Section 7. Boiler Sequencing Technology107
Introduction107
Installation Notes108
Bst Quick Start Chart108
Bst Implementation Instruction109
Option 1 Constant Setpoint: Direct Wired Header Temp Sensor109
Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor111
Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Sensor114
Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor117
Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20Ma Setpoint Drive120
Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive (Via Protonode)122
Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4-20Ma Setpoint Drive125
Option 8 Remote Setpoint: Modbus Header Temp Sensor & MODBUS Setpoint Drive Via Protonode128
Section 8. Maintenance131
Maintenance Schedule131
Igniter-Injector - Bmk750 - 5000N132
Pilot Ignition Rod - BMK5000 & 6000134
Flame Detector134
O 2 Sensor135
Air Eductor Air Pump Maintenance - BMK5000 & 6000136
Safety Device Testing137
Burner Inspection137
Condensate Drain Trap140
Air Filter Cleaning and Replacement141
Refractory Replacement - Bmk5000 & 6000 Only141
Shutting Boiler down for Extended Period142
Benchmark 5000/6000 Long Term Blower Storage142
Returning the Boiler to Service after Shutdown144
Recommended Periodic Testing144
Recommended Spares146
Section 9. Troubleshooting147
Introduction147
Additional Faults Without Specific Fault Messages158
Appendix A: Wiring Schematics159
A-2: Benchmark 2500 - 3000 Schematics162
A-3: Benchmark 4000 - 5000N Schematics166
Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 Pm EST213

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