Watts Aerco Benchmark Series User Manual

Benchmark Platinum-Edge: Operation-Service Manual
CONTENTS
OMM-0137_D • GF-211 • 7/16/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 2 of 146
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

Watts Aerco Benchmark Series Specifications

General

Brand	Watts
Model	Aerco Benchmark Series
Category	Boiler
Language	English

Summary

FOREWORD

SECTION 1: SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

General safety advisories and installation compliance requirements.

1.2 EMERGENCY SHUTDOWN

Procedures for immediate shutdown in emergencies.

1.3 PROLONGED SHUTDOWN

Instructions for taking the boiler out of service for extended periods.

1.4 MASSACHUSETTS INSTALLATIONS

Specific installation requirements for Massachusetts.

SECTION 2: EDGE CONTROLLER OPERATION

2.1 INTRODUCTION

Overview of accessing the Edge Controller functionality.

2.2 LOGIN AND PASSWORD ENTRY

Details on accessing the controller with different security levels.

SECTION 3: START SEQUENCE

3.1 INTRODUCTION

Guide to starting the boiler using the Edge Controller.

3.2 START SEQUENCE

Steps involved in the pre-purge and ignition sequence.

3.3 START/STOP LEVELS

Air/Fuel Valve positions for starting and stopping the unit.

3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT

Relationship between Air/Fuel Valve position and energy input.

3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 750/1000.

3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 1500.

3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 2000.

3.4.4 BMK 2500 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 2500.

3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 3000.

3.4.6 Benchmark 5000 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 5000.

3.4.7 Benchmark 6000 Air/Fuel Valve Position and Energy Input

Air/Fuel Valve position vs. energy input for BMK 6000.

SECTION 4: INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

Prerequisites and essential steps for initial boiler startup.

4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION

Necessary tools and instrumentation for performing combustion calibration.

4.3 FUEL TYPES and COMBUSTION CALIBRATION

Information on fuel types and the importance of combustion calibration.

4.4 COMBUSTION CALIBRATION

Procedure for calibrating the boiler's combustion for optimal performance.

4.4.1 NATURAL GAS Manual Combustion Calibration

Step-by-step instructions for natural gas combustion calibration.

4.4.2 PROPANE GAS COMBUSTION CALIBRATION

Step-by-step instructions for propane gas combustion calibration.

4.5 REASSEMBLY

Steps for reassembling the unit after calibration.

4.6 DUAL FUEL SWITCHOVER

Instructions for switching between natural gas and propane fuels.

4.7 OVER-TEMPERATURE LIMIT SWITCHES

Explanation of automatic and manual reset over-temperature limit controls.

4.7.1 Adjusting the Automatic Reset Limit Switch Temperature

Procedure to adjust the automatic reset limit switch temperature.

4.7.2 Resetting the Manual Reset Limit Switch

Procedure to reset the manual reset limit switch after an alarm.

4.7.3 Changing the Readout Between Fahrenheit and Celsius

How to switch temperature display between F and C.

SECTION 5: SAFETY DEVICE TESTING

5.1 TESTING OF SAFETY DEVICES

Importance and general procedures for testing safety devices.

5.2 LOW GAS PRESSURE TEST

Procedure to simulate and test a low gas pressure fault.

5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500

Testing low gas pressure for BMK 750-2500 units.

5.2.2 LOW GAS PRESSURE TEST: BMK 3000 – 6000 Only

Testing low gas pressure for BMK 3000-6000 units.

5.3 HIGH GAS PRESSURE TEST

Procedure to simulate and test a high gas pressure fault.

5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500

Testing high gas pressure for BMK 750-2500 units.

5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 – 6000 Only

Testing high gas pressure for BMK 3000-6000 units.

5.4 LOW WATER LEVEL FAULT TEST

Steps to simulate and test a low water level fault condition.

5.5 WATER TEMPERATURE FAULT TEST

Simulating and testing high water temperature faults.

5.6 INTERLOCK TESTS

Testing various interlock circuits for proper operation.

5.6.1 Remote Interlock Test

Testing the remote interlock circuit.

5.6.2 Delayed Interlock Test

Testing the delayed interlock circuits.

5.7 FLAME FAULT TEST

Simulating and testing flame fault conditions.

5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES

Testing the blower proof and blocked inlet switches.

5.8.1 Blower Proof Switch Test

Procedure to test the blower proof switch.

5.8.2 Blocked Inlet Switch Test

Procedure to test the blocked inlet switch.

5.9 SSOV PROOF OF CLOSURE SWITCH CHECK

Checking the SSOV proof of closure switch functionality.

5.10 PURGE SWITCH OPEN DURING PURGE

Testing the purge switch during the purge cycle.

5.11 IGNITION SWITCH OPEN DURING IGNITION

Testing the ignition switch during the ignition cycle.

5.12 SAFETY PRESSURE RELIEF VALVE TEST

Testing the safety pressure relief valve.

SECTION 6: STANDALONE MODES OF OPERATION

6.1 OUTDOOR RESET MODE

Operation based on outside air temperatures to adjust supply header temperature.

6.1.1 Outdoor Air Temperature Sensor Installation

Mounting and connection instructions for the outdoor air sensor.

6.1.2 Outdoor Reset Mode Startup

Steps to set up and start the unit in Outdoor Reset mode.

6.2 CONSTANT SETPOINT MODE

Mode for maintaining a fixed header temperature.

6.3 REMOTE SETPOINT MODE

Remotely controlling the unit's setpoint via EMS or BAS.

6.4 DIRECT DRIVE MODES

Changing air/fuel valve position via remote signal from EMS or BAS.

6.5 AERCO CONTROL SYSTEM (ACS)

System for operating multiple units efficiently via RS-485 network.

6.6 COMBINATION CONTROL SYSTEM (CCS)

System using multiple boilers for space heating and domestic hot water.

6.6.1 Combination Control System Field Wiring

Wiring instructions for ACS, ACS Relay Box, and I/O Box.

6.6.2 Combination Control System Setup and Startup

Setup and startup procedures for the Combination mode.

SECTION 7: BOILER SEQUENCING TECHNOLOGY

7.1 INTRODUCTION

Overview of the Boiler Sequencing Technology system.

7.1.1 Installation Notes

Notes regarding ProtoNode installation for BST systems.

7.2 BST QUICK START CHART

Chart to select BST installation options and corresponding instructions.

7.3 BST Implementation Instruction

Instructions for implementing BST configurations.

7.3.1 Option 1 Constant Setpoint: Direct Wired Header Sensor

BST Option 1: Direct wired header sensor setup.

7.3.2 Option 2 Constant Setpoint: Modbus Wired Header Sensor

BST Option 2: Modbus wired header sensor setup.

7.3.3 Option 3 Outdoor Reset: Direct Wired Header Sensor & Direct Wired Outdoor Sensor

BST Option 3: Direct wired header and outdoor sensor setup.

7.3.4 Option 4 Outdoor Reset: Modbus Header Sensor & Modbus Outdoor Sensor

BST Option 4: Modbus header and outdoor sensor setup.

7.3.5 Option 5 Remote Setpoint: Direct Wired Header Sensor & 4-20ma Setpoint Drive

BST Option 5: Direct wired header and 4-20mA setpoint drive.

7.3.6 Option 6 Remote Setpoint: Direct Wired Header Sensor & Modbus Setpoint Drive

BST Option 6: Direct wired header and Modbus setpoint drive.

7.3.7 Option 7 Remote Setpoint: Modbus Header Sensor & 4-20ma Setpoint Drive

BST Option 7: Modbus header and 4-20mA setpoint drive.

7.3.8 Option 8 Remote Setpoint: MODBUS Header Sensor & MODBUS Setpoint Drive

BST Option 8: Modbus header and Modbus setpoint drive.

SECTION 8: MAINTENANCE

8.1 MAINTENANCE SCHEDULE

Schedule of recommended routine maintenance tasks and frequencies.

8.2 IGNITER-INJECTOR – BMK 750 - 3000

Maintenance procedures for the igniter-injector assembly.

8.3 PILOT IGNITION ROD – BMK 5000 & 6000

Inspection and replacement of the pilot ignition rod.

8.4 FLAME DETECTOR

Inspection and replacement of the flame detector.

8.5 O2 SENSOR

Cleaning and inspection of the O2 sensor for accuracy.

8.5.1 Air Eductor Air Pump Maintenance – BMK 5000 & 6000

Maintenance and troubleshooting for the air pump in the air eductor assembly.

8.6 SAFETY DEVICE TESTING

Importance of testing safety devices as per codes.

8.7 BURNER INSPECTION

Inspection of the burner assembly for intactness and function.

8.8 CONDENSATE DRAIN TRAP

Inspection and cleaning of the condensate drain trap for proper flow.

8.9 AIR FILTER CLEANING and REPLACEMENT

Maintenance schedule for cleaning or replacing the air filter.

8.10 REFRACTORY REPLACEMENT – BMK 5000 & 6000 ONLY

Replacement of refractory materials in the combustion chamber.

8.10.1 Rear Refractory Replacement

Step-by-step instructions for replacing the rear refractory.

8.10.2 Front Refractory Replacement

Instructions for replacing the front refractory material.

8.11 SHUTTING BOILER DOWN FOR EXTENDED PERIOD

Procedures for taking the boiler out of service for one year or more.

8.11.1 Benchmark 5000/6000 Long Term Blower Storage

Instructions for storing Benchmark 5000/6000 blowers long-term.

8.12 RETURNING THE BOILER TO SERVICE AFTER SHUTDOWN

Procedures for putting the boiler back into service after prolonged shutdown.

8.13 RECOMMENDED PERIODIC TESTING

Recommended schedule and actions for periodic testing of boiler controls and safety devices.

8.14 RECOMMENDED SPARES

List of recommended emergency and optional spare parts.

SECTION 9: AERTRIM OPERATION

9.1 AERtrim INTRODUCTION

Introduction to the AERtrim system for optimizing air-fuel ratios.

9.2 AERtrim ACTIVATION

Instructions for activating the AERtrim function with an activation code.

9.3 OPERATION DETAILS

Details on how the AERtrim system adjusts blower voltage for optimal combustion.

9.4 AERtrim O2 SENSOR AUTO CALIBRATION

Automatic calibration feature to maintain O2 sensor accuracy.

9.5 AERtrim MENU VALUES and DEFAULTS

Default and adjustable menu values for AERtrim settings.

9.6 AERtrim MAINTENANCE and TROUBLESHOOTING

Maintenance and troubleshooting for the AERtrim system, focusing on the O2 sensor.

SECTION 10: TROUBLESHOOTING

10.1 INTRODUCTION

Introduction to isolating and correcting boiler faults.

10.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES

Troubleshooting faults that do not display specific messages.