Watts Aerco BMK 750 Operation manual

Other documents for this product include:
OMM-0144, GF-217 Installation and Startup Manual
OMM-0146, GF-219 Reference Manual
TAG-0019, GF-2070 Boiler Application Design Guide
TAG-0022, GF-2050 Vent-Combustion Air Design Guide
TAG-0047, GF-2030 Benchmark Gas Guide
TAG-0048, GF-2060 Benchmark Power Design Guide
Applies to serial numbers:
G-19-0001 and above –BMK750 –4000
N-19-0001 and above –BMK5000 & 6000
Operations and Service Manual
Benchmark®Boilers
with Edge [i] Controller
Natural Gas, Propane Gas and Dual
Fuel Modulating & Condensing Boilers
Models 750 through 6000
OMM-0145_A99 •GF-218 •9/18/2019

Benchmark with Edge [I]: Operation-Maintenance Manual
CONTENTS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 2of 157
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 [I] CONTROLLER OPERATION ..............................................13
2.1 INTRODUCTION...................................................................................................................................13
2.2 LOGIN AND PASSWORD ENTRY.......................................................................................................14
2.3 MENU STRUCTURE ............................................................................................................................15
2.3.1 Unit Status Menu ...........................................................................................................................................15
2.3.2 Calibration Menu ...........................................................................................................................................16
2.3.3 Diagnostics Menu...........................................................................................................................................17
2.3.4 Advanced Setup Menu...................................................................................................................................20
SECTION 3. START SEQUENCE ........................................................................31
3.1 INTRODUCTION...................................................................................................................................31
3.2 START SEQUENCE .............................................................................................................................31
3.3 START/STOP LEVELS.........................................................................................................................39
3.4 START/STOP LEVELS –AIR/FUEL & ENERGY INPUT.....................................................................40
3.4.1 BMK750/1000 Air/Fuel Valve Position and Energy Input ..............................................................................40
3.4.2 BMK1500 Air/Fuel Valve Position and Energy Input......................................................................................41
3.4.3 BMK2000 Air/Fuel Valve Position and Energy Input......................................................................................42
3.4.4 BMK2500 Air/Fuel Valve Position and Energy Input......................................................................................43
3.4.5 BMK3000 Air/Fuel Valve Position and Energy Input......................................................................................44
3.4.6 Benchmark4000 Air/Fuel Valve Position and Energy Input ...........................................................................45
3.4.7 Benchmark5000 Air/Fuel Valve Position and Energy Input ...........................................................................46
3.4.8 Benchmark6000 Air/Fuel Valve Position and Energy Input ...........................................................................47
SECTION 4. INITIAL START-UP ........................................................................49
4.1 INITIAL START-UP REQUIREMENTS.................................................................................................49
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION........................................................50
4.2.1 Required Tools & Instrumentation ................................................................................................................50
4.2.2 Installing Gas Supply Manometer ..................................................................................................................50
4.2.3 Accessing the Analyzer Probe Port ................................................................................................................54
4.3 FUEL TYPES AND COMBUSTION CALIBRATION.............................................................................55
4.4 COMBUSTION CALIBRATION.............................................................................................................55
4.4.1 NATURAL GAS Manual Combustion Calibration ............................................................................................56
4.4.2 PROPANE GAS COMBUSTION CALIBRATION..................................................................................................61
4.5 REASSEMBLY......................................................................................................................................66
4.6 DUAL FUEL SWITCHOVER.................................................................................................................67
4.7 OVER-TEMPERATURE LIMIT SWITCHES.........................................................................................68
4.7.1 Digital Alarm Switch Checks and Adjustments...............................................................................................69
SECTION 5. SAFETY DEVICE TESTING ..............................................................71
5.1 TESTING OF SAFETY DEVICES.........................................................................................................71

Benchmark with Edge [I]: Operation-Maintenance Manual
CONTENTS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 3of 157
5.2 LOW GAS PRESSURE TEST ..............................................................................................................72
5.2.1 LOW GAS PRESSURE TEST: BMK750 –2500...................................................................................................72
5.2.2 LOW GAS PRESSURE TEST: BMK3000 –6000 Only ........................................................................................74
5.3 HIGH GAS PRESSURE TEST .............................................................................................................78
5.3.1 HIGH GAS PRESSURE TEST: BMK750 –2500 ..................................................................................................78
5.3.2 HIGH GAS PRESSURE TEST: BMK3000 –6000 Only........................................................................................80
5.4 LOW WATER LEVEL FAULT TEST.....................................................................................................84
5.5 WATER TEMPERATURE FAULT TEST..............................................................................................85
5.6 INTERLOCK TESTS.............................................................................................................................86
5.6.1 Remote Interlock Test....................................................................................................................................86
5.6.2 Delayed Interlock Test ...................................................................................................................................87
5.7 FLAME FAULT TEST............................................................................................................................88
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES..............................89
5.8.1 Blower Proof Switch Test ...............................................................................................................................89
5.8.2 Blocked Inlet Switch Test ...............................................................................................................................91
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK.................................................................................92
5.10 PURGE SWITCH OPEN DURING PURGE........................................................................................93
5.11 IGNITION SWITCH OPEN DURING IGNITION .................................................................................95
5.12 SAFETY PRESSURE RELIEF VALVE TEST.....................................................................................95
SECTION 6. STANDALONE MODES OF OPERATION .........................................97
6.1 OUTDOOR AIR RESET MODE............................................................................................................97
6.1.1 Outdoor Air Temperature Sensor Installation ...............................................................................................97
6.1.2 Outdoor Reset Mode Startup ........................................................................................................................98
6.2 CONSTANT SETPOINT MODE ...........................................................................................................99
6.3 REMOTE SETPOINT MODE................................................................................................................99
6.4 DIRECT DRIVE MODES.....................................................................................................................100
6.5 AERCO CONTROL SYSTEM (ACS)..................................................................................................101
6.6 COMBINATION CONTROL SYSTEM (CCS).....................................................................................101
6.6.1 Combination Control System Field Wiring ...................................................................................................102
6.6.2 Combination Control System Setup and Startup .........................................................................................102
SECTION 7. BOILER SEQUENCING TECHNOLOGY ..........................................105
7.1 INTRODUCTION.................................................................................................................................105
7.1.1 Installation Notes..........................................................................................................................................106
7.2 BST QUICK START CHART ..............................................................................................................106
7.3 BST IMPLEMENTATION INSTRUCTION ..........................................................................................107
7.3.1 Option 1 Constant Setpoint: Direct Wired Header Temp Sensor ................................................................107
7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Temp Sensor .............................................................109
7.3.3 Option 3 Outdoor Reset: Direct Wired Header Temp Sensor & Direct Wired Outdoor Sensor ..................111
7.3.4 Option 4 Outdoor Reset: Modbus Header Temp Sensor & Modbus Outdoor Temp Sensor.......................113
7.3.5 Option 5 Remote Setpoint: Direct Wired Header Temp Sensor & 4-20ma Setpoint Drive .........................116
7.3.6 Option 6 Remote Setpoint: Direct Wired Header Temp Sensor & Modbus Setpoint Drive ........................118
7.3.7 Option 7 Remote Setpoint: Modbus Header Temp Sensor & 4-20ma Setpoint Drive.................................120
7.3.8 Option 8 Remote Setpoint: MODBUS Header Temp Sensor & MODBUS Setpoint Drive ............................122
SECTION 8. MAINTENANCE ..........................................................................125
8.1 MAINTENANCE SCHEDULE .............................................................................................................125
8.2 IGNITER-INJECTOR –BMK750 - 4000.............................................................................................126
8.3 PILOT IGNITION ROD –BMK5000 & 6000 .......................................................................................128
8.4 FLAME DETECTOR ...........................................................................................................................128
8.5 O2SENSOR129

Benchmark with Edge [I]: Operation-Maintenance Manual
CONTENTS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 4of 157
8.5.1 Air Eductor Air Pump Maintenance –BMK5000 & 6000 ............................................................................130
8.6 SAFETY DEVICE TESTING...............................................................................................................131
8.7 BURNER INSPECTION......................................................................................................................131
8.8 CONDENSATE DRAIN TRAP ............................................................................................................134
8.9 AIR FILTER CLEANING AND REPLACEMENT ................................................................................135
8.10 REFRACTORY REPLACEMENT –BMK5000 & 6000 ONLY..........................................................................135
8.10.1 Rear Refractory Replacement....................................................................................................................136
8.10.2 Front Refractory Replacement ..................................................................................................................138
8.11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD.................................................................139
8.11.1 Benchmark 5000/6000 Long Term Blower Storage...................................................................................139
8.12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN....................................................141
8.13 RECOMMENDED PERIODIC TESTING..........................................................................................142
8.14 RECOMMENDED SPARES .............................................................................................................144
SECTION 9. TROUBLESHOOTING ..................................................................145
9.1 INTRODUCTION.................................................................................................................................145
9.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ..................................................155

Benchmark with Edge [I]: Operation-Maintenance Manual
FORWARD
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 5of 157
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.
IMPORTANT!
Unless otherwise specified:
•All descriptions in this document apply to the Benchmark Series of boiler.
•All measurements apply to both natural gas and propane models.
The Benchmark models operate within the input and output ranges listed below.
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
oHorizontal Discharge
Please consult the Benchmark Venting and Combustion Air Design Guide (TAG-0022, GF-
2050) for a list of allowable and preferred vent materials.

Benchmark with Edge [I]: Operation-Maintenance Manual
FORWARD
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 6of 157
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)
Edge [i] Controller
A control system developed by AERCO and currently used in all
Benchmark 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)

Benchmark with Edge [I]: Operation-Maintenance Manual
FORWARD
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 7of 157
AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
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 [i] 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 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
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)

Benchmark with Edge [I]: Operation-Maintenance Manual
FORWARD
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 8of 157
AERCO Technical Terminology Meanings
TERMINOLOGY
MEANING
P&T
Pressure and Temperature
ProtoNode
Hardware interface between BAS and a boiler
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)

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 1: SAFETY PRECAUTIONS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 9of 157
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), 208 or 480 VAC (BMK2500 –4000),
or 208, 480 or 575 VAC (BMK5000 & 6000) and 24 volts AC may be used in this
equipment. On international units, the voltage can be 220V to 240V single phase.
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.

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 1: SAFETY PRECAUTIONS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 10 of 157
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

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 1: SAFETY PRECAUTIONS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 11 of 157
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)

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 1: SAFETY PRECAUTIONS
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 12 of 157
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)]…………………

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 13 of 157
SECTION 2. EDGE [I] CONTROLLER OPERATION
2.1 INTRODUCTION
This section provides a brief outline of how to gain access to Benchmark Boiler’s Edge [i]
Controller functionality. Full instructions for using the Edge [i] Controller to setup, configure and
operate a Benchmark Boiler are included in the Edge [i] Controller Manual, OMM-0141, GF-213-
B
The Edge [i] Controller is shown below. This panel contains all of the controls, indicators and
displays necessary to operate, adjust and troubleshoot the boiler.
The Edge [i] Controller’s front panel consists of a touchscreen display along with a variety of
indicators and buttons.
Figure 2-1 Edge [i] Controller Front Panel
1
Multi-Function Bar, shows 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 [i] 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

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 14 of 157
2.2 Login and Password Entry
The Edge [i] 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 [i] 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 [i] Controller Main Menu
NOTE:
Full instructions for using the Edge [i] Controller are in the Edge [i] Controller Manual (OMM-
0141, GF-213-B).

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 15 of 157
2.3 MENU STRUCTURE
The Main Menu give you access to all Edge [i] Controller user functionality. There are four major
divisions within the menu structure.
Figure 3.3: The Edge [i] Controller Main Menu
2.3.1 Unit Status Menu
The Unit Status menu contains the following sections and parameters. Unlike other Edge
menus, navigation starts at the Unit Status screen and proceeds from there by scrolling right.
Main Menu →Unit Status
Target Fire Rate
Read Only
The target Fire Rate (0% to 100%).
Current Fire Rate
Read Only
The current Fire Rate (0% to 100%).
Flame Strength
Read Only
The current Flame Strength (0% to 100%).
Inlet Temp
Read Only
The current Inlet Water temperature
Setpoint
Read Only
The unit’s current Setpoint.
Outlet
Read Only
The current Outlet temperature.
Air Inlet
Read Only
The current Air Inlet temperature.
O2
Read Only
The Current O2reading.
Exhaust
Read Only
The current Exhaust temperature.
Main Menu →Plant Status –BST Manager Only
Outside Temp
Read Only
The reading of the outside temperature meter
SH/Other Setpoint
Read Only
The BST cascade’s current Setpoint.
SH/Other Supply
Read Only
The supply temperature reading.
Inlet Temp
Read Only
The inlet temperature reading.
Units Available
Read Only
The number of units in the BST cascade.
Units Firing
Read Only
The number of units in the BST cascade firing.
Units Online
Read Only
The number of units in the BST cascade online.
SH/Other Fire Rate
Read Only
The fire rate for the BST cascade.
Main Menu →BST Cascade Status –BST Manager Only
SH/Other Fire Rate
Read Only
The fire rate for the BST cascade.
Units Online
Read Only
The number of units in the BST cascade online.
SH/Other Setpoint
Read Only
The BST cascade’s current Setpoint.
Units Available
Read Only
The number of units in the BST cascade available.
Sh/Other Supply
Read Only
The supply temperature reading.

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 16 of 157
Units Firing
Read Only
The number of units firing in the BST cascade.
Main Menu →Isolation Valve Status –BST Manager Only
Min # Valves Open
Read Only
The number of isolation valves designated as “always
open.”
Main Menu →Runtime Statistics
Average Cycles Per Hour
Read Only
The unit’s average number of cycles per hour.
Run Hours
Read Only
The number of hours the unit has run since startup.
Cycle Count
Read Only
The number of cycles during unit run hours.
Main Menu →Unit Event History
Event
Read Only
Lists the unit’s warning and fault events.
Main Menu →Plant Event History
Event
Read Only
Lists the plant’s warning and fault events.
2.3.2 Calibration Menu
The Calibration menu contains the following sections and parameters:
Main Menu →Calibration →Manual Combustion
NOx Requirement
Select
Select the unit’s NOx requirement: None, <= 20 or <= 9
PPM.
Valve Position - Target
Read Only
The unit’s target Valve Position.
Valve Position - Reading
Read Only
The unit’s actual Valve Position.
Blower - Target
Read Only
Target blower voltage for current Valve Position.
Blower - Reading
Read Only
The unit’s actual blower voltage.
O2% - Target
Read Only
The unit’s target O2% in the exhaust.
O2% - Reading
Numeric Entry
The unit’s actual O2% in the exhaust.
CO - Target
Read Only
The target CO amount in the exhaust, in ppm.
CO - Reading
Numeric Entry
The actual CO amount in the exhaust, in ppm.
NOx - Target
Read Only
The target NOx amount in the exhaust, in ppm
NOx - Reading
Numeric Entry
The actual NOx amount in the exhaust, in ppm.
Flame Strength - Reading
Numeric Entry
The unit’s Flame Strength, from Multimeter
Air Temperature - Reading
Read Only
The current air temperature.
Downstream Gas pressure
Numeric Entry
Appears only when fire rate = 100%.
Blower Voltage
Adjust
Adjust as needed to match targets to actual readings.
2.3.2.1 Main Menu → Calibration → Input/Output
Main Menu →Calibration →Input/Output →Temperature Sensors
Sensor
Select
Select: Feed Forward, Exhaust, Outside Temp, Air
Inlet, Lower Inlet, Outlet.
Offset
Numeric Entry
Optional offset applied to current Sensor
Current Reading
Read Only
Current sensor’s current reading. (Flow In Adj & Flow
Rate removed).
Main Menu →Calibration →Input/Output →O2 Sensor
O2 Offset
Numeric Entry
A correction value to selected input, if needed.
O2
Read Only
The Current O2reading.
Auto Calibrate Now
Yes/No
Initiates Auto Calibration
Auto Calibrate Status
Read Only
Displays current Auto Calibration status.
Calibration Frequency
Select
Select: Never, Monthly, Weekly, Daily.

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 17 of 157
Time
Numeric Entry
Specify Auto Calibrate time of day (Calibration
Frequency = Daily).
Main Menu →Calibration →Input/Output →Analog Inputs
Analog Name
Select
Select: Flow or Remote Analog In.
Offset
Numeric Entry
A correction value to selected input, if needed.
Current Reading
Read Only
Current reading of selected input.
Main Menu →Calibration →Input/Output →Analog Outputs
Analog Name
Read Only
Displays the name Analog Output.
Level
Numeric Entry
Set the output’s level (0.00 to 20.00 mA)
Offset
Numeric Entry
A correction value to the analog output, if needed (-2.00 to
2.00).
Feedback
Read Only
Displays feedback from Analog Output.
2.3.2.2 Main Menu → Calibration → Subsystems
Main Menu →Calibration →Subsystems →Air Fuel Valve
Valve Position
Manual Adjust
Set to desired Valve Position.
A/F Sensitivity
Numeric Entry
Set Air/Fuel Valve sensitivity (1% to 5%)
Main Menu →Calibration →Subsystems →Spark Monitor
Spark Monitor
Enabled/Disabled
Enables/Disables the Spark Monitor.
Min Spark
Numeric Entry
Minimum spark. (0.00 to 0.29 amps)
Max Spark
Numeric Entry
Maximum spark. (0.30 to 2.50 amps)
2.3.2.3 Main Menu → Calibration → Combustion Summary
Main Menu →Calibration →Combustion Summary
Valve Position
Read Only
Displays combustion calibration valve steps.
O2
Read Only
Displays combustion calibration O2 results.
NOx
Read Only
Displays combustion calibration NOx results.
CO
Read Only
Displays combustion calibration CO results.
Flame Strength
Read Only
Displays combustion calibration flame strength.
2.3.3 Diagnostics Menu
The Diagnostics menu contains the following sections:
2.3.3.1 Main Menu → Diagnostics → Manual Run
Main Menu →Diagnostics →Manual Run
Manual Mode
Enable/Disable
Enables/disables running in Manual Mode.
Fire Rate
Adjust
Manual fire rate adjustment, 0 to 100%.
O2
Read Only
The percentage of O2 in the unit’s exhaust.
Flame Strength
Read Only
The flame strength sensed in the burner, 0 to 100%.

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 18 of 157
2.3.3.2 Main Menu → Diagnostics → Front Panel
Main Menu →Diagnostics →Front Panel
Touchscreen Display Test
On/Off
Starts the Touchscreen Display Test.
Touchscreen Test
On/Off
Starts the Touchscreen Test.
Status Light Test
On/Off
Starts the Status Light Test.
Keypad and Switch Test
On/Off
Starts the Keypad and Switch Test.
2.3.3.3 Main Menu → Diagnostics → Analog Outputs and Relays
Main Menu →Diagnostics →Analog Outputs and Relays →Relays
Ignition Relay
Enable/Disable
Enables/Disables the Ignition Relay.
Blower Relay
Enable/Disable
Enables/Disables the Blower Relay.
Pump Relay
Enable/Disable
Enables/Disables the Pump Relay.
Aux Relay
Enable/Disable
Enables/Disables the Aux Relay.
Fault Relay
Enable/Disable
Enables/Disables the Fault Relay.
Main Menu →Diagnostics →Analog Outputs and Relays →Analog Outputs
Valve
Read/Adjust
Adjustable display of the A/F valve Position.
Blower
Read/Adjust
Adjustable display of the Blower.
2.3.3.4 Main Menu → Diagnostics → Subsystems
Main Menu →Diagnostics →Subsystems →Air Fuel Valve Stepper Motor
Auto Stroke
Toggle
Initiates A/F cycle, 0 to 100 to 0%
Valve Position In
Adjust
Manual adjustment of A/F Valve 0 to 100%.
Main Menu →Diagnostics →Subsystems →Blower
Profile
Select
Select the profile to run (default = Profile 1).
Profile Run
Enable/Disable
Enables running the selected profile.
Blower
Numeric Entry
Manually adjust the Blower’s voltage.
Main Menu →Diagnostics →Subsystems →Ignition
Ignition Spark
Enable/Disable
Enables testing the unit’s ignition spark.
Spark Current
Read Only
The current Spark Current.
2.3.3.5 Main Menu → Diagnostics → System
Main Menu →Diagnostics →System →Pre-Start Up
Pre-Start Up Mode
Enable/Disable
Enables Pre-Start Up Mode, a test of various system
components without firing the unit.
Valve Position Out
Read Only
The current A/F valve position.
Blower (voltage)
Read Only
The current Blower voltage.
Blower (RPM)
Read Only
The current Blower RPM.
Spark Current
Read Only
The current Spark Current.
Flame Strength
Read Only
The current flame strength.
Gas pressure
Read Only
The current gas pressure.
Main Menu →Diagnostics →System →Versions
Serial Number
Read Only
The unit’s serial number.
Software Version
Read Only
The Controller’s software version.

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 19 of 157
Engineering Version
Read Only
The Controller’s Engineering software version.
Graphic Data Version
Read Only
The Controller’s graphic version.
Display Version
Read Only
The Controller’s display version.
I/O Board Version
Read Only
The I/O board version.
Touch Version
Read Only
The touch screen version.
Bluetooth Version
Read Only
The Bluetooth version.
Framework Version
Read Only
The Framework version.
Bootloader version
Read Only
The Bootloader version.
Display BL Version
Read Only
Display Bootloader version.
I/O PCB BL Version
Read Only
I/O Board PCB Bootloader version.
2.3.3.6 Main Menu → Diagnostics → Comm & Network
Main Menu →Diagnostics →Comm & Network →IP Network
Unit IP Address
Read Only
The unit’s IP address.
Subnet Mask
Read Only
The unit’s subnet mask address.
Gateway IP Address
Read Only
The unit’s gateway IP address.
DSN 1
Read Only
The unit’s DSN 1 address.
DSN 2
Read Only
The unit’s DSN 2 address.
Unit MAC Address
Read Only
The unit’s MAC address.
Network Status
Read Only
The unit’s current network status.
Main Menu →Diagnostics →Comm & Network →BAS
BAS
Read Only
The Building Automation System protocol.
Communication
Address
Read Only
The unit’s BAS address.
Device Instance
Read Only
The unit’s Device Instance within BAS.
Unit IP Address
Read Only
The unit’s IP address on the network.
Unit MAC Address
Read Only
The unit’s MAC address within BAS.
Last Command
Received
Read Only
The last command received by the unit.
BAS IP
Read Only
If Security is enabled, this is the IP of the BAS system
that the unit can only communicate with.
Network Status
Read Only
The unit’s BAS network’s current status.
Main Menu →Diagnostics →Comm & Network →onAER
Unit IP Address
Read Only
The unit’s IP address.
Upload Time
Read Only
Frequency at which the unit transmits data to onAER
Test Setup
Enable
Initiates test o onAER functionality.
Test Heartbeat
Enable
Initiates test of the onAER heartbeat.
Main Menu →Diagnostics →Comm & Network →USB Storage
Status
Read Only
Status of the USB device.
Serial Number
Read Only
The serial number of the USB device.
Size
Read Only
The size of the USB device.
Available Space
Read Only
The amount of free space on the USB device.

Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 2: OPERATION
OMM-0145_A99 •GF-218 •9/18/2019 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 20 of 157
2.3.3.7 Main Menu → Diagnostics → Input/Output Summary
Main Menu →Diagnostics →Input/Output Summary
This screen is a read-only display of the following unit and/or BST cascade parameters:
Air Inlet:
Supply Header:
Exhaust:
Return Header:
Outlet:
Outside Temp:
Lower Inlet:
Supply Loop 2:
Upper Inlet:
Return Loop 2:
DHW Temp :
RTD Spare 1:
Feed Forward:
RTD Spare 2:
O2:
Spare Aout2:
Spare Aout1:
Spare Aout3:
Cascade Valve:
Blower:
BLR V.S. Pump:
DHW V.S. Pump:
Flow:
CO/Analog In:
Air Pump:
Cas Vlv Fdbk:
Remote Ain:
Spare Ain1:
Spare Ain2:
Spare Ain3:
Blower Relay:
Swing Valve 1 Relay:
Ignition Relay:
Backup Relay:
Pump Relay:
DHW Relay:
Aux Relay:
V2/Spare 1 Relay:
Fault Relay:
Spare 2 Relay:
Blower
Blower
High Gas Pressure:
Low Gas Pressure:
Draft Pressure
Spare Pressure:
2.3.4 Advanced Setup Menu
The Advanced Setup menu contains the following sections:
Main Menu →Advanced Setup →Access
Password
Numeric Entry
Enter 159 or your password, then press Save.
2.3.4.1 Main Menu → Advanced Setup → Unit
Main Menu →Advanced Setup →Unit →Unit Settings
Unit Serial #
Entry
The unit’s factory-set serial number. Do NOT change except
when replacing the Controller.
Unit Type
Enter
Displays unit’s product and model. Do NOT change except
when replacing the Controller.
Unit Size
Select
Displays the unit’s sizes. Do NOT change except when
replacing the Edge Controller.
Date
Numeric Entry
Allows you to set the current date.
Time Format
Toggle
Choose the 12 Hour or 24-Hour time format.
Time
Numeric Entry
Allows you to set the current time.