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AERCO Benchmark BMK5000
Watts AERCO Benchmark BMK5000 User Manual
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Benchmark w
ith Edge [I]:
Operatio
n
-Maintenance M
anual
SECTION 5
–
SA
FETY DEV
ICE TESTING
OMM-0
145_D
•
GF
-218
•
11/2/202
0 Techn
ical Support
•
(800) 52
6-
02
88
•
Mon-Fri, 8 am - 5 p
m EST Page
91
of
213
5.8 AIR
FLOW
FAULT
TESTS
-
BLOWER
PROOF
&
BL
OCKED
INLET
SWITCHES
These tests chec
k the operation o
f the
Blower Proo
f
switch
and Blocked Inle
t
switch shown in
Figure 5-
6a
, 5-
6b
and
5-
6c
.
5.8.1
Blower Proof Sw
itch Test
Figure 5-6a: Blower Proof & Blocked Inlet Switch Locations
–
BMK1500
–
5000N
Figure 5-6b: Blower Proof & Blocked Inlet Switch Locations
–
BMK750 &1000
BLOWER
PROOF
SWITCH
BLOCKED
INLET
SWITCH
SSOV
MANUAL
SHUT-OF
F
VALVE
BLOWER PROOF
SWITCH
BLOCK
ED
INLET SWIT
CH
MANUAL
SHUT-OF
F
VALVE
90
92
Table of Contents
Table of Contents
2
Foreword
5
Section 1. Safety Precautions
9
Warnings & Cautions
9
Emergency Shutdown
10
Prolonged Shutdown
10
Important - for Massachusetts Installations
11
Section 2. Edge [I] Controller Operation
13
Introduction
13
Login and Password Entry
14
Menu Structure
15
Unit Status Menu
15
Calibration Menu
16
Diagnostics Menu
17
Advanced Setup Menu
20
Section 3. Start Sequence
31
Introduction
31
Start Sequence
31
Start/Stop Levels
39
Start/Stop Levels - Air/Fuel & Energy Input
40
Benchmark 750/1000 Air/Fuel Valve Position and Energy Input
40
Benchmark 1500 Air/Fuel Valve Position and Energy Input
41
Benchmark 2000 Air/Fuel Valve Position and Energy Input
42
Benchmark 2500 Air/Fuel Valve Position and Energy Input
43
Benchmark 3000 Air/Fuel Valve Position and Energy Input
44
Benchmark 4000 Air/Fuel Valve Position and Energy Input
45
Benchmark 5000N Air/Fuel Valve Position and Energy Input
46
Benchmark 5000 Air/Fuel Valve Position and Energy Input
47
Benchmark 6000 Air/Fuel Valve Position and Energy Input
48
Section 4. Initial Start-Up
49
Initial Start-Up Requirements
49
Tools & Instruments for Combustion Calibration
50
Required Tools & Instrumentation
50
Installing Gas Supply Manometer
50
Accessing the Analyzer Probe Port
54
Benchmark 5000 & 6000 Pilot Flame Ignition
55
Fuel Types and Combustion Calibration
55
Combustion Calibration
55
NATURAL GAS Manual Combustion Calibration
56
PROPANE GAS Combustion Calibration
63
Reassembly
68
Dual Fuel Switchover
69
Over-Temperature Limit Switches
69
Digital Alarm Switch Checks and Adjustments
71
Section 5. Safety Device Testing
73
Testing of Safety Devices
73
Low Gas Pressure Test
74
Low Gas Pressure Test: BMK750 - 2500
74
Low Gas Pressure Test: BMK3000 - 6000 Only
76
High Gas Pressure Test
80
High Gas Pressure Test: BMK750 - 2500
80
High Gas Pressure Test: BMK3000 - 6000 Only
82
Low Water Level Fault Test
86
Water Temperature Fault Test
87
Interlock Tests
88
Remote Interlock Test
88
Delayed Interlock Test
89
Flame Fault Test
90
Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches
91
Blower Proof Switch Test
91
Blocked Inlet Switch Test
93
Ssov Proof of Closure Switch Check
94
Purge Switch Open During Purge
95
Ignition Switch Open During Ignition
97
Safety Pressure Relief Valve Test
97
Section 6. Standalone Modes of Operation
99
Outdoor Air Reset Mode
99
Outdoor Air Temperature Sensor Installation
99
Outdoor Reset Mode Startup
100
Constant Setpoint Mode
101
Remote Setpoint Mode
101
Direct Drive Modes
102
Aerco Control System (Acs)
103
Combination Control System (Ccs)
103
Combination Control System Field Wiring
104
Combination Control System Setup and Startup
104
Section 7. Boiler Sequencing Technology
107
Introduction
107
Installation Notes
108
Bst Quick Start Chart
108
Bst Implementation Instruction
109
Option 1 Constant Setpoint: Direct Wired Header Temp Sensor
109
Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor
111
Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Sensor
114
Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor
117
Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20Ma Setpoint Drive
120
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 Drive
125
Option 8 Remote Setpoint: Modbus Header Temp Sensor & MODBUS Setpoint Drive Via Protonode
128
Section 8. Maintenance
131
Maintenance Schedule
131
Igniter-Injector - Bmk750 - 5000N
132
Pilot Ignition Rod - BMK5000 & 6000
134
Flame Detector
134
O 2 Sensor
135
Air Eductor Air Pump Maintenance - BMK5000 & 6000
136
Safety Device Testing
137
Burner Inspection
137
Condensate Drain Trap
140
Air Filter Cleaning and Replacement
141
Refractory Replacement - Bmk5000 & 6000 Only
141
Shutting Boiler down for Extended Period
142
Benchmark 5000/6000 Long Term Blower Storage
142
Returning the Boiler to Service after Shutdown
144
Recommended Periodic Testing
144
Recommended Spares
146
Section 9. Troubleshooting
147
Introduction
147
Additional Faults Without Specific Fault Messages
158
Appendix A: Wiring Schematics
159
A-2: Benchmark 2500 - 3000 Schematics
162
A-3: Benchmark 4000 - 5000N Schematics
166
Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 Pm EST
213
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Watts AERCO Benchmark BMK5000 Specifications
General
Brand
Watts
Model
AERCO Benchmark BMK5000
Category
Boiler
Language
English
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