Watts Aerco Benchmark Series Operation manual

Operation and Service Manual
Benchmark®Platinum Boilers
With Edge 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 – BMK 750 – 3000
N-19-0100 and above – BMK 5000 & 6000
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Table of Contents
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 BMK 750/1000 Air/Fuel Valve Position and Energy Input ..............................................................................24
3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input......................................................................................25
3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input......................................................................................26
3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input......................................................................................27
3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input......................................................................................28
3.4.6 Benchmark 5000 Air/Fuel Valve Position and Energy Input ...........................................................................29
3.4.7 Benchmark 6000 Air/Fuel Valve Position and Energy Input ...........................................................................30
SECTION 4: INITIAL START-UP ........................................................................31
4.1 INITIAL START-UP REQUIREMENTS.................................................................................................31
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION........................................................32
4.2.1 Required Tools & Instrumentation .................................................................................................................32
4.2.2 Installing Gas Supply Manometer...................................................................................................................32
4.2.3 Accessing the Analyzer Probe Port .................................................................................................................35
4.3 FUEL TYPES AND COMBUSTION CALIBRATION.............................................................................36
4.4 COMBUSTION CALIBRATION.............................................................................................................36
4.4.1 NATURAL GAS Manual Combustion Calibration .............................................................................................37
4.4.2 PROPANE GAS COMBUSTION CALIBRATION ..................................................................................................42
4.5 REASSEMBLY......................................................................................................................................47
4.6 DUAL FUEL SWITCHOVER.................................................................................................................48
4.7 OVER-TEMPERATURE LIMIT SWITCHES.........................................................................................49
4.7.1 Adjusting the Automatic Reset Limit Switch Temperature ............................................................................49
4.7.2 Resetting the Manual Reset Limit Switch .......................................................................................................50
4.7.3 Changing the Readout Between Fahrenheit and Celsius................................................................................50
SECTION 5: SAFETY DEVICE TESTING ..............................................................51
5.1 TESTING OF SAFETY DEVICES.........................................................................................................51
5.2 LOW GAS PRESSURE TEST ..............................................................................................................52
5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500...................................................................................................52
5.2.2 LOW GAS PRESSURE TEST: BMK 3000 – 6000 Only ........................................................................................54
5.3 HIGH GAS PRESSURE TEST .............................................................................................................57
5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500 ..................................................................................................57

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5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 – 6000 Only........................................................................................59
5.4 LOW WATER LEVEL FAULT TEST.....................................................................................................62
5.5 WATER TEMPERATURE FAULT TEST..............................................................................................63
5.6 INTERLOCK TESTS.............................................................................................................................64
5.6.1 Remote Interlock Test.....................................................................................................................................64
5.6.2 Delayed Interlock Test ....................................................................................................................................64
5.7 FLAME FAULT TEST............................................................................................................................65
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES..............................66
5.8.1 Blower Proof Switch Test................................................................................................................................66
5.8.2 Blocked Inlet Switch Test ................................................................................................................................68
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK.................................................................................69
5.10 PURGE SWITCH OPEN DURING PURGE........................................................................................70
5.11 IGNITION SWITCH OPEN DURING IGNITION .................................................................................72
5.12 SAFETY PRESSURE RELIEF VALVE TEST.....................................................................................72
SECTION 6: STANDALONE MODES OF OPERATION .........................................73
6.1 OUTDOOR RESET MODE...................................................................................................................73
6.1.1 Outdoor Air Temperature Sensor Installation ................................................................................................73
6.1.2 Outdoor Reset Mode Startup .........................................................................................................................74
6.2 CONSTANT SETPOINT MODE ...........................................................................................................75
6.3 REMOTE SETPOINT MODE................................................................................................................75
6.4 DIRECT DRIVE MODES.......................................................................................................................76
6.5 AERCO CONTROL SYSTEM (ACS)....................................................................................................77
6.6 COMBINATION CONTROL SYSTEM (CCS).......................................................................................78
6.6.1 Combination Control System Field Wiring......................................................................................................79
6.6.2 Combination Control System Setup and Startup............................................................................................79
SECTION 7: BOILER SEQUENCING TECHNOLOGY ............................................81
7.1 INTRODUCTION...................................................................................................................................81
7.1.1 Installation Notes............................................................................................................................................82
7.2 BST QUICK START CHART ................................................................................................................82
7.3 BST IMPLEMENTATION INSTRUCTION ............................................................................................83
7.3.1 Option 1 Constant Setpoint: Direct Wired Header Sensor .............................................................................83
7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Sensor..........................................................................85
7.3.3 Option 3 Outdoor Reset: Direct Wired Header Sensor & Direct Wired Outdoor Sensor ...............................87
7.3.4 Option 4 Outdoor Reset: Modbus Header Sensor & Modbus Outdoor Sensor..............................................89
7.3.5 Option 5 Remote Setpoint: Direct Wired Header Sensor & 4-20ma Setpoint Drive ......................................91
7.3.6 Option 6 Remote Setpoint: Direct Wired Header Sensor & Modbus Setpoint Drive .....................................93
7.3.7 Option 7 Remote Setpoint: Modbus Header Sensor & 4-20ma Setpoint Drive .............................................95
7.3.8 Option 8 Remote Setpoint: MODBUS Header Sensor & MODBUS Setpoint Drive .........................................97
SECTION 8: MAINTENANCE ............................................................................99
8.1 MAINTENANCE SCHEDULE ...............................................................................................................99
8.2 IGNITER-INJECTOR – BMK 750 - 3000 ............................................................................................100
8.3 PILOT IGNITION ROD – BMK 5000 & 6000 ......................................................................................102
8.4 FLAME DETECTOR ...........................................................................................................................102
8.5 O2SENSOR........................................................................................................................................103
8.5.1 Air Eductor Air Pump Maintenance – BMK 5000 & 6000 ...........................................................................104
8.6 SAFETY DEVICE TESTING...............................................................................................................105
8.7 BURNER INSPECTION......................................................................................................................105
8.8 CONDENSATE DRAIN TRAP ............................................................................................................108

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8.9 AIR FILTER CLEANING AND REPLACEMENT ................................................................................109
8.10 REFRACTORY REPLACEMENT – BMK 5000 & 6000 ONLY .........................................................................109
8.10.1 Rear Refractory Replacement....................................................................................................................110
8.10.2 Front Refractory Replacement ..................................................................................................................112
8.11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD.................................................................113
8.11.1 Benchmark 5000/6000 Long Term Blower Storage....................................................................................113
8.12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN....................................................115
8.13 RECOMMENDED PERIODIC TESTING..........................................................................................116
8.14 RECOMMENDED SPARES .............................................................................................................118
SECTION 9: AERTRIM OPERATION................................................................119
9.1 AERTRIM INTRODUCTION ...............................................................................................................119
9.2 AERTRIM ACTIVATION .....................................................................................................................119
9.3 OPERATION DETAILS.......................................................................................................................120
9.4 AERTRIM O2SENSOR AUTO CALIBRATION ..................................................................................122
9.5 AERTRIM MENU VALUES AND DEFAULTS.....................................................................................123
9.6 AERTRIM MAINTENANCE AND TROUBLESHOOTING...................................................................129
SECTION 10: TROUBLESHOOTING ..................................................................131
10.1 INTRODUCTION...............................................................................................................................131
10.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ................................................143
NOTES: ..................................................................................................145

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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
BMK 750 50,000 (14.6 kW) 750,000 (220 kW) 47,750 (14 kW) 716,250 (210 kW)
BMK 1000 50,000 (14.6 kW) 1,000,000 (293 kW) 48,300 (14.15 kW) 968,000 (284 kW)
BMK 1500 75,000 (22 kW) 1,500,000 (440 kW) 64,500 (18.9 kW) 1,395,000 (409 kW)
BMK 2000 100,000 (29.3 kW) 2,000,000 (586 kW) 86,000 (25.2 kW) 1,860,000 (545 kW)
BMK 2500 167,000 (48.9 kW) 2,500,000 (732 kW) 144,000 (42.2 kW) 2,395,000 (702 kW)
BMK 3000 200,000 (58.6 kW) 3,000,000 (879 kW) 174,000 (51.0 kW) 2,874,000 (842 kW)
BMK 5000 400,000 (117 kW) 5,000,000 (1465 kW) 348,000 (102 kW) 4,750,000 (1392 kW)
BMK 6000 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 BMK 750 – 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 BMK 2500 – 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
oHorizontal Discharge

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These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In
addition, the BMK 750 & 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 m
3
/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)
Edge Controller
A control system developed by AERCO and currently used in all
Benchmark Platinum boilers.

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AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
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 (1 thousandth of an ampere)
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
PMC Board Primary Micro-Controller (PMC) board, contained in the Edge
P/N Part Number

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AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
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 million
th
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 (BMK 750 – 2000) and 208 or 460 VAC (BMK
2500/3000) or 208, 460 or 575 VAC (BMK 5000 & 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 inst
alled 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 can not 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, a
nd 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: 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
1Multi-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
3Temperature 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
7Soft 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 X), 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
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 Benchmark Platinum-
Edge: INSTALLATION Manual (GF-210) must be completed before the initial start-up of
the unit.
•Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK
2500/3000) or 208, 460 or 575 VAC (BMK 5000 & 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 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 Enableposition 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: BMK 750 & 1000 SSOV Location (P/N 22322 shown)
Figure 3-1b: BMK 1500 & 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: BMK 2500: SSOV Location (P/N 22318 shown)
Figure 3-1d: BMK 3000: 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: BMK 5000-6000: SSOV Location
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 bargraph on the Controller’s front face shows 100%.
Figure 3-2a: BMK 750 & 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
- BMK 6000: 10.5” W.C., 2.6 kPa
- BMK 5000: 11.0” W.C., 2.7 kPa
UPSTREAM LOW GAS
PRESSURE SWITCH
- BMK 6000: 8.5” W.C., 2.1 kPa
- BMK 5000: 8.0” W.C., 2.0 kPa

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Start Sequence
Figure 3-2b: BMK 1500 – 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
Figure 3-4a: BMK 750 & 1000 Blower Proof Switch
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 3-4b: BMK 1500 – 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 (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 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