Watts AERCO Benchmark OMM-0136 Operation manual

Operation and Service Manual
Benchmark®Platinum 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-19-0300 and above –BMK750 –4000
N-19-0100 and above –BMK5000 & 6000
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Table of Contents
TABLE OF CONTENTS...........................................................................................2
FOREWORD ......................................................................................................5
SECTION 1: SAFETY PRECAUTIONS ...................................................................9
1.1 WARNINGS & CAUTIONS .....................................................................................................................9
1.2 EMERGENCY SHUTDOWN.................................................................................................................10
1.3 PROLONGED SHUTDOWN.................................................................................................................10
1.4 IMPORTANT –FOR MASSACHUSETTS INSTALLATIONS...............................................................11
SECTION 2: EDGE CONTROLLER OPERATION ..................................................13
2.1 INTRODUCTION...................................................................................................................................13
2.2 LOGIN AND PASSWORD ENTRY.......................................................................................................14
SECTION 3: START SEQUENCE ........................................................................15
3.1 INTRODUCTION...................................................................................................................................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.......................................................................................25
3.4.3 BMK2000 Air/Fuel Valve Position and Energy Input.......................................................................................26
3.4.4 BMK2500 Air/Fuel Valve Position and Energy Input.......................................................................................27
3.4.5 BMK3000 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 Valve Position and Energy Input ...........................................................................31
SECTION 4: INITIAL START-UP ........................................................................33
4.1 INITIAL START-UP REQUIREMENTS.................................................................................................33
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION........................................................34
4.2.1 Required Tools & Instrumentation .................................................................................................................34
4.2.2 Installing Gas Supply Manometer...................................................................................................................34
4.2.3 Accessing the Analyzer Probe Port .................................................................................................................38
4.3 FUEL TYPES AND COMBUSTION CALIBRATION.............................................................................38
4.4 COMBUSTION CALIBRATION.............................................................................................................38
4.4.1 NATURAL GAS Manual Combustion Calibration .............................................................................................39
4.4.2 PROPANE GAS COMBUSTION CALIBRATION ..................................................................................................45
4.5 REASSEMBLY......................................................................................................................................50
4.6 DUAL FUEL SWITCHOVER.................................................................................................................52
4.7 OVER-TEMPERATURE LIMIT SWITCHES.........................................................................................53
4.7.1 Adjusting the Automatic Reset Limit Switch Temperature ............................................................................53
4.7.2 Resetting the Manual Reset Limit Switch .......................................................................................................54
4.7.3 Changing the Readout Between Fahrenheit and Celsius................................................................................54
SECTION 5: SAFETY DEVICE TESTING ..............................................................55
5.1 TESTING OF SAFETY DEVICES.........................................................................................................55
5.2 LOW GAS PRESSURE TEST ..............................................................................................................56
5.2.1 LOW GAS PRESSURE TEST: BMK750 –2500 ...................................................................................................56

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5.2.2 LOW GAS PRESSURE TEST: BMK3000 –6000 Only .........................................................................................58
5.3 HIGH GAS PRESSURE TEST .............................................................................................................62
5.3.1 HIGH GAS PRESSURE TEST: BMK750 –2500...................................................................................................62
5.3.2 HIGH GAS PRESSURE TEST: BMK3000 –6000 Only ........................................................................................64
5.4 LOW WATER LEVEL FAULT TEST.....................................................................................................68
5.5 WATER TEMPERATURE FAULT TEST..............................................................................................69
5.6 INTERLOCK TESTS.............................................................................................................................70
5.6.1 Remote Interlock Test.....................................................................................................................................70
5.6.2 Delayed Interlock Test ....................................................................................................................................70
5.7 FLAME FAULT TEST............................................................................................................................71
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES..............................72
5.8.1 Blower Proof Switch Test................................................................................................................................72
5.8.2 Blocked Inlet Switch Test................................................................................................................................74
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK.................................................................................75
5.10 PURGE SWITCH OPEN DURING PURGE........................................................................................76
5.11 IGNITION SWITCH OPEN DURING IGNITION .................................................................................78
5.12 SAFETY PRESSURE RELIEF VALVE TEST.....................................................................................78
SECTION 6: STANDALONE MODES OF OPERATION .........................................79
6.1 OUTDOOR RESET MODE...................................................................................................................79
6.1.1 Outdoor Air Temperature Sensor Installation ................................................................................................79
6.1.2 Outdoor Reset Mode Startup .........................................................................................................................80
6.2 CONSTANT SETPOINT MODE ...........................................................................................................81
6.3 REMOTE SETPOINT MODE................................................................................................................81
6.4 DIRECT 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: BOILER SEQUENCING TECHNOLOGY ............................................87
7.1 INTRODUCTION...................................................................................................................................87
7.1.1 Installation Notes............................................................................................................................................88
7.2 BST QUICK START CHART ................................................................................................................88
7.3 BST IMPLEMENTATION INSTRUCTION ............................................................................................89
7.3.1 Option 1 Constant Setpoint: Direct Wired Header Temp Sensor ...................................................................89
7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor................................................................91
7.3.3 Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Temp Sensor ...........93
7.3.4 Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor .........................95
7.3.5 Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20ma Setpoint Drive ............................97
7.3.6 Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive ...........................99
7.3.7 Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4-20ma Setpoint Drive .................................101
7.3.8 Option 8 Remote Setpoint: MODBUS Header Temp Sensor & MODBUS Setpoint Drive .............................103
SECTION 8: MAINTENANCE ..........................................................................105
8.1 MAINTENANCE SCHEDULE .............................................................................................................105
8.2 IGNITER-INJECTOR –BMK750 - 4000.............................................................................................106
8.3 PILOT IGNITION ROD –BMK5000 & 6000 .......................................................................................108
8.4 FLAME DETECTOR ...........................................................................................................................108
8.5 O2SENSOR109
8.5.1 Air Eductor Air Pump Maintenance –BMK5000 & 6000 ............................................................................110

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8.6 SAFETY DEVICE TESTING...............................................................................................................111
8.7 BURNER INSPECTION......................................................................................................................111
8.8 CONDENSATE DRAIN TRAP ............................................................................................................114
8.9 AIR FILTER CLEANING AND REPLACEMENT ................................................................................115
8.10 REFRACTORY REPLACEMENT –BMK5000 & 6000 ONLY..........................................................................115
8.10.1 Rear Refractory Replacement....................................................................................................................116
8.10.2 Front Refractory Replacement ..................................................................................................................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 TESTING..........................................................................................122
8.14 RECOMMENDED SPARES .............................................................................................................124
SECTION 9: AERTRIM OPERATION................................................................125
9.1 AERTRIM INTRODUCTION...............................................................................................................125
9.2 AERTRIM ACTIVATION .....................................................................................................................126
9.3 OPERATION DETAILS.......................................................................................................................126
9.4 AERTRIM O2SENSOR AUTO CALIBRATION ..................................................................................128
9.5 AERTRIM MENU VALUES AND DEFAULTS.....................................................................................128
9.6 AERTRIM MAINTENANCE AND TROUBLESHOOTING...................................................................136
SECTION 10: TROUBLESHOOTING ..................................................................139
10.1 INTRODUCTION...............................................................................................................................139
10.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ................................................150
NOTES: ..................................................................................................152

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FOREWORD
The AERCO Benchmark (BMK) 750 through 6000 natural gas and propane fueled boilers are
modulating and condensing units. They represent a true industry advance that meets the needs
of today's energy and environmental concerns. Designed for application in any closed loop
hydronic system, the Benchmark's modulating capability relates energy input directly to
fluctuating system loads. These BMK models provide extremely high efficiency operation and
are ideally suited for modern low temperature, as well as, conventional heating systems.
The Benchmark models operate within the following input and output ranges:
IMPORTANT!
Unless otherwise specified:
•All descriptions provided in this document apply to the Benchmark Platinum Series of boiler.
•All measurements apply to both natural gas and propane models, unless otherwise
specified.
Benchmark Boiler Intake and Output Ranges
MODEL
INPUT RANGE (BTU/HR.)
OUTPUT RANGE (BTU/HR.)
MINIMUM
MAXIMUM
MINIMUM
MAXIMUM
BMK750
50,000 (14.6 kW)
750,000 (220 kW)
47,750 (14 kW)
716,250 (210 kW)
BMK1000
50,000 (14.6 kW)
1,000,000 (293 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 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 (51.0 kW)
2,874,000 (842 kW)
BMK4000
267,000 (78.2 kW)
4,000,000 (1172 kW)
232,000 (68.0 kW)
3,800,000 (1113 kW)
BMK5000
400,000 (117 kW)
5,000,000 (1465 kW)
348,000 (102 kW)
4,750,000 (1392 kW)
BMK6000
400,000 (117 kW)
6,000,000 (1758 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 Coast Air Quality
Management District (SCAQMD), Rule 1146.2. In addition, the BMK2500 –6000 comply with
the Bay Area Air Quality Management District regulation 9, Rule 7.
Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting
flexibility with minimum installation space requirements. These boilers are Category II and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:
•Room Combustion Air:
oVertical Discharge
oHorizontal Discharge
•Ducted Combustion Air:
oVertical Discharge

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oHorizontal Discharge
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In
addition, the BMK750 & 1000 models are also approved for PVC and CPVC, vent systems
(excluding the state of Massachusetts).
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.
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
Symbol rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal 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 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)
CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
CNTL
Control
CPU
Central Processing Unit
DBB
Double Block and Bleed, a gas trains 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)

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AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
Edge Controller
A control system developed by AERCO and currently used in all
Benchmark Platinum boilers.
EMS
Energy Management System; often used interchangeably with BAS
FM
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)
HP
Horse Power
HX
Heat Exchanger
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 currently used on Benchmark boilers
IP
Internet Protocol
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)
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
O2
Oxygen
O.D.
Outside Diameter
OMM, O&M
Operation and Maintenance Manual
onAER
AERCO’s on-line remote monitoring system
PCB
Printed Circuit Board

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AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
PMC Board
Primary Micro-Controller (PMC) board, contained in the Edge
P/N
Part Number
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
PVC
Poly Vinyl Chloride, a common synthetic plastic
PWM
Pulse Width Modulation
REF (Ref)
Reference
RES.
Resistive
RS232
(or EIA-232)
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 (Rtn)
Return
SETPT (Setpt)
Setpoint Temperature
SHLD (Shld)
Shield
SPDT
Single Pole Double Throw, a type of switch
SSOV
Safety Shut Off Valve
TEMP (Temp)
Temperature
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network
in order 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
UL
A business that tests and validates products
VAC
Volts, Alternating Current
VDC
Volts, Direct Current
VFD
Variable Frequency Drive
VPS
Valve Proving System
W
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
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
See section 1.4 for important information regarding installation of units within the
Commonwealth of Massachusetts.
IMPORTANT!
This manual is an integral part of the product and must be maintained in legible condition. It
must be given to the user by the installer and kept in a safe 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 when
released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully
decrease all trapped pressures to zero before performing maintenance.
•Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
•The exhaust vent pipe of the unit operates under a positive pressure and therefore must
be completely sealed to prevent leakage of combustion products into living spaces.
•Electrical voltages up to 120 VAC (BMK750 –2000) and 208 or 460 VAC (BMK2500 -
4000) or 208, 460 or 575 VAC (BMK5000 & 6000) and 24 volts AC may be used in this
equipment. Therefore, the cover on the unit’s power box (located behind the front panel
door) must be installed at all times, 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 safely disconnect electrical service. Do not affix switch
to unit sheet metal enclosures.
CAUTION!
•Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
•DO NOT use this boiler if any part has been under water. Call a qualified service technician
to inspect and replace any part that has been under water.

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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:
The Installer must identify and indicate the location of the emergency shutdown manual gas
valve to operating personnel.
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,
provide a manually operated remote shutdown switch or circuit breaker marked for easy
identification at 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, provide
an emergency shutdown switch in the control room that is hard-wired to immediately shut
off the fuel upon activation.
1.3 PROLONGED SHUTDOWN
If there is an emergency, turn off the electrical power supply to the boiler and close the manual
gas valve 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 of time, such as a year or more, complete
the instructions in Section 8.11: Shutting Boiler Down for Extended Period.
When returning a unit to service after a prolonged shutdown, it is recommended that the
instructions in Section 4: Initial Startup Procedures and Section 5: Safety Device Testing be
performed to verify that all system-operating parameters are correct.
.
VALVE
OPEN
VALVE
CLOSED

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1.4 IMPORTANT –FOR MASSACHUSETTS INSTALLATIONS
Requirements for Massachusetts Installations
Boiler Installations within the Commonwealth of Massachusetts must conform to
the following requirements:
•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
side-wall 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. In the event that the side wall horizontally vented gas fueled equipment 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)

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Requirements for Massachusetts Installations
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.
(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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SECTION 2: OPERATION
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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 setup, configure and
operate a Benchmark Boiler are included in the Edge Controller Manual.
NOTE: The Edge Controller Manual is document number OMM-0139, GF-213.
The Edge Controller is shown below. This panel contains all of 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 with a variety of
indicators and buttons.
Figure 2-1 Edge Controller Front Panel
1
Multi-Function Bar, shows either:
•Fire Rate
•Valve Position
2
Parameter Indicator for both temperature
read-outs:
•LEFT: Inlet or Setpoint temperature
•RIGHT: Outlet or System Header
temperature
3
Temperature scale indicator: Fahrenheit
or Celsius
4
Configurable temperature read-outs (2):
•LEFT: Inlet or Setpoint
temperature
•RIGHT: Outlet or System Header
temperature
5
Operation Mode Indicators (2):
•LEFT: Demand or Manual
•RIGHT: Manager or Client (BST
only)
6
Edge Controller Touchscreen
7
Soft Keys
8
onAER Indicator Light
9
Ready Light
10
Enable/Disable Switch
11
Low Water Level Buttons (2):
•TEST: Initiates Low Water test
•RESET: Resets unit after Low Water
test
1
2
3
6
7
10
11
4
5
9
8

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2.2 Login and Password Entry
The Edge Controller has multiple levels of password protection.
Level
Password
Description
1
No password
The default. Many parameters are visible but “Read Only.”
2
159
Allows routine maintenance to be performed. Appropriate for AERCO
Trained technicians (ATT).
A higher-level password is reserved 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 the number keypad to enter the password (each number appears as a *), 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 Main Menu appears. All Edge
functionality is accessed through one of the six Main Menu items.
Figure 2-3: Edge Controller Main Menu
NOTE:
Full instructions for using the Edge Controller are in the Edge Controller Manual (GF-213).

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SECTION 3 - START SEQUENCE
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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 trained
personnel. Operation prior to initial startup by factory trained personnel may void the equipment
warranty. In addition, the following WARNINGS and CAUTIONS must be observed at all times.
WARNING!
•All of the installation procedures in Section 2: Installation of the BenchmarkPlatinum-Edge:
INSTALLATION Manual (GF-210) must be completed before the initial start-up of the unit.
•Electrical voltages up to 120 VAC (BMK750 –2000) and 208 or 460 VAC (BMK2500 -
4000) or 208, 460 or 575 VAC (BMK5000 & 6000) and 24 volts AC may be used in this
equipment. It must be serviced only by factory certified service technicians.
•Do not attempt to dry fire the unit. Starting the unit without 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 AERCO factory trained personnel.
Operation prior to initial startup by factory trained personnel may void the equipment
warranty. In addition, the following WARNINGS and CAUTIONS must be observed at all
times.
3.2 START SEQUENCE
When the Edge Controller Enable/Disable switch is set to the Enable position, it checks all pre-
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 Proof switches are not checked prior to starting
the pre-purge.
If all of the above switches are closed, the READY light (above the Enable/Disable switch) will
light when the switch is in the Enable position and the unit will be in the STANDBY mode.
NOTE:
If any of the Pre-Purge safety device switches are open, or the required conditions are not
observed throughout the start sequence, appropriate fault messages will be displayed.
When there is a demand for heat, the following events occur:

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Start Sequence
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 screens and
demonstrates (or highlights) which switches are not met. SSOV locations are shown in
Figure 3-1a through 3-1d.
Figure 3-1a: BMK750 & 1000 SSOV Location (P/N 22322 shown)
Figure 3-1b: BMK1500 & 2000 SSOV Location (P/N 22314 shown)
TO
AIR/FUEL
VALVE
MANUAL
SHUT-OFF
VALVE
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
SSOV
SSOV
TO AIR/FUEL
VALVE
MANUAL
SHUT-OFF VALVE
NATURAL
GAS INLET
NATURAL
GAS INLET
LOW GAS
PRESSURE
SWITCH

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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
PRESSURE
SWITCH
SSOV
SSOV
TO
AIR/FUEL
VALVE
NATURAL
GAS INLET
HIGH GAS PRESSURE
SWITCH
MANUAL
SHUT-OFF VALVE
LOW GAS
PRESSURE
SWITCH
NATURAL
GAS INLET

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Start Sequence
Figure 3-1e: BMK5000-6000: SSOV Location –BMK6000 Shown
3. The Auxiliary Delay occurs for a configurable length of time and the Delayed Interlocks are
closed.
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 and closes purge position
switch. The dial on the Air/Fuel Valve (Figure 3-2a and 3-2b) will read 100 to indicate
that it is full-open (100%).
c. The Fire Rate bar graph on the Controller’s front face shows 100%.
Figure 3-2a: BMK750 & 1000 Air/Fuel Valve in Purge Position
STEPPER MOTOR
TO
BLOWER
AIR INLET
100
UPSTREAM
SSOV
TO AIR/FUEL
VALVE
GAS INLET
MANUAL SHUT-
OFF VALVE
DOWNSTREAM
SSOV WITH
POC
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

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Start Sequence
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 is underway
(Figure 3-3) and Purge Timer displays the purge cycle’s elapsed time in seconds.
Figure 3-3: Ignition Sequence Screen –Purging
TO BLOWER
STEPPER
MOTOR
AIR IN
PURGE
VALVE POSITION
DIAL AT 100%
BLOWER PROOF SWITCH
BLOCKED INLET SWITCH

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Start Sequence
Figure 3-4a: BMK750 & 1000 Blower Proof Switch
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 to indicate that
the valve is in the low fire position.
b) The Spark Cleaning cycle begins (default duration = 7 sec.) and the Ignition Sequence
screen’s Spark Cleaning indicator(Figure3-3)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 spark element. For the duration of this cycle, the Controller displays the
Cleaning Igniter status message.
c) Following the Spark Cleaning cycle, power is applied to the gas Safety Shut-off Valve
(SSOV). When the SSOV indicates the Gas Valve is OPEN (POC) and the Ignition
Sequence screen’s Ignition indicator (Figure 3-3) turns grey.
d) If no spark is present 3 seconds into the ignition trial, the Controller aborts the Ignition
Cycle and shuts down the boiler. Refer to Section 10: Troubleshooting in this guide for
guidance if this occurs.
AIR/FUEL VALVE
OUTLET TO BLOWER
BLOCKED
INLET
SWITCH
BLOWER
PROOF
SWITCH
AIR/FUEL VALVE
INLET FROM GAS
TRAIN