Why is the exhaust temperature high in my Aerco Boiler?
If the Aerco Boiler displays a High Exhaust Temperature, the combustion calibration may be off. Check the combustion calibration using procedures in Chapter 4. If the exhaust temperature exceeds 200°F, it may be caused by a carboned heat exchanger due to incorrect combustion calibration. Calibrate or repair as necessary.
What to do if Aerco BENCHMARK 6000 experiences flame loss during run?
If the Aerco Boiler experiences flame loss during operation, several factors could be responsible. First, inspect the flame detector for wear or cracks in the ceramic and replace if needed. Second, check the gas pressure into and out of the air/fuel valve using a gauge or manometer to ensure it's correct, as a defective regulator can cause this issue. Third, ensure proper combustion calibration; if it's off, recalibrate following the procedures in Chapter 4. Fourth, remove the burner and check for carbon build-up or debris, cleaning and reinstalling it if necessary. Fifth, clear any blockages in the condensate drain. Finally, make sure the main flame detector isn't touching the burner mesh; if it is, straighten or replace it.
What to do if Aerco BENCHMARK 6000 displays Airflow Fault during Run?
If the Aerco Boiler is showing an Airflow Fault during Run, start by checking the combustion blower for signs of excessive heat or current draw that may be tripping thermal or current overload devices. Next, inspect the inlet to the combustion blower, including any ductwork leading up to it, for blockages. Then, remove the air filter and Blocked Inlet switch to inspect for blockages; clean or replace as needed. Finally, verify that 24 VAC is present between each side of the Blocked Inlet switch and ground; replace the switch if 24 VAC is not present at both sides.
What causes flame loss during ignition on Aerco BENCHMARK 6000 Boiler?
If your Aerco Boiler is experiencing flame loss during ignition, consider these steps: * Inspect the flame detector for wear and replace if necessary. * Close the internal gas valve in the unit. Install and arc a spark igniter outside the unit to check for a spark. * If there's no spark, check for 120VAC at the primary side of the ignition transformer during the ignition cycle. * If 120VAC is not present, the IGST Board in the Control Box may be defective. Refer fault to qualified service personnel. * While externally arcing the spark igniter, observe the open/close indicator in the SSOV to ensure it's opening. If the valve doesn't open, check for 120VAC at the valve input terminals. If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qua...
How to resolve Direct Drive Signal Fault on Aerco BENCHMARK 6000 Boiler?
If the Aerco Boiler is showing a Direct Drive Signal Fault, check the I/O Box to ensure the signal is hooked up; hook it up if it's not installed. If it is installed, check the polarity and measure the signal level. Also, check the wiring continuity between the source and the unit. Check the signal at the source to ensure it is isolated. Check the DIP switch on the PMC board to ensure it is set correctly for the type of signal being sent. Check the control signal type set in the Configuration Menu.
How to troubleshoot airflow fault during ignition in Aerco Boiler?
To troubleshoot an airflow fault during ignition in your Aerco Boiler, consider these potential causes: * The blower might have stopped due to thermal or current overload. Inspect the combustion blower for signs of excessive heat or high current drain. * There could be a blockage in the blower inlet or inlet air filter. Inspect the inlet to the combustion blower, including the air filter at the air/fuel valve, for any obstructions. * The blower proof switch might be blocked. Remove the blower proof switch and inspect for blockages, cleaning or replacing it as needed. * A blocked inlet switch might be obstructed. Remove the blocked inlet switch and inspect for blockages; clean or replace if necessary. * The blower proof switch could be defective. Check its continuity with the com...
What causes remote setpt signal fault in Aerco Boiler?
If your Aerco Boiler is showing a 'Remote Setpt Signal Fault', here's what you should check: * Ensure the remote setpoint signal is present by checking the I/O Box to ensure the signal is connected. Connect it if it's not installed. If it is installed, check the polarity and measure the signal level. Also, check the continuity of wiring between the source and the unit. * If using a 4 to 20 mA signal, verify that the signal is isolated at the source. * Check the DIP switch on the PMC board to ensure it's correctly set for the type of signal being sent (voltage or current). Also, check the control signal type set in the Configuration menu.
What causes recirculation pump failure in Aerco Boiler?
If your Aerco Boiler is experiencing a recirculation pump failure, it indicates that the internal recirculation pump has failed and needs to be replaced.
What to do if Aerco Boiler shows airflow fault during purge?
If your Aerco Boiler experiences an airflow fault during purge, here's what you can check: * The blower might not be running or is running too slowly. Start the unit and check the blower solid-state relay for input and output voltage. If the relay is okay, inspect the blower itself. * The blocked inlet switch could be defective. Start the unit, and if the blower runs, turn off the unit and check the blocked inlet switch for continuity. Replace the switch if continuity does not exist. * There may be a blockage in the air filter or blocked inlet switch. Remove the air filter and blocked inlet switch and inspect for any obstructions. Clean or replace as needed. * The blower inlet or inlet ductwork might be blocked. Inspect the inlet to the combustion blower, including any ductwork le...
What causes line voltage out of phase error in Aerco BENCHMARK 6000?
If your Aerco Boiler displays a 'Line Voltage Out of Phase' error, check the following: * Ensure the hot and neutral wires are not switched in the AC Power Box. * Verify the transformer wiring in the AC Power Box against the power box transformer wiring diagram to ensure it's wired correctly.
General safety regulations, warnings, and cautions for installers and operating personnel.
Procedure for emergency shutdown of the boiler in case of overheating or gas supply failure.
Guidance on connecting AC power wiring to the unit, referencing GF-2060.
Details on available voltage configurations and power box terminal blocks.
Information on factory-wired internal control systems and external control features.
Description of the C-More Control Panel, its controls, indicators, and displays.
Overview of the menu structure for setting up and configuring the unit.
Menu for adjusting internal setpoint and other configuration settings.
Menu for performing combustion calibration to optimize efficiency and emissions.
Menu for configuring, operating, and monitoring the Boiler Sequencing Technology system.
Checks pre-purge safety switches and initiates the start sequence.
Requirements for initial boiler start-up, including installation, controls, calibration, and testing.
Necessary tools and instrumentation for performing combustion calibration.
List of tools and instrumentation needed for combustion calibration.
Description of the pilot ignition system and its components.
Procedures for calibrating combustion for low and ultra-low NOx emissions.
Mode based on outside air temperature to adjust supply header temperature.
Mode used for fixed header temperature applications like heat pump loops.
Mode allowing remote control of setpoint via EMS or BAS using current or voltage signals.
Mode where air/fuel valve position is controlled by a remote signal.
Mode for operating multiple boilers efficiently using an AERCO Control System.
System using multiple boilers for space heating and domestic hot water needs.
Importance of periodic safety device testing to ensure proper operation and compliance.
Procedures for testing the low gas pressure fault switch.
Procedures for simulating and testing the high gas pressure fault.
Procedure to simulate and test the low water level fault condition.
Procedure to simulate and test the high water temperature fault.
Tests for the Remote Interlock and Delayed Interlock circuits.
Procedure for testing the Remote Interlock circuit.
Procedure for testing the Delayed Interlock circuit.
Procedures to simulate and test flame fault conditions.
Tests for the Blower Proof Switch and Blocked Inlet Switch.
Procedure for testing the Blower Proof Switch.
Procedure for testing the Blocked Inlet Switch.
Checking the proof of closure (POC) switch circuit for the downstream SSOV.
Checking the purge switch located on the Air/Fuel Valve.
Checking the ignition switch located on the Air/Fuel Valve.
Testing the safety pressure relief valve per ASME code.
Routine maintenance schedule for efficiency and reliability.
Location and maintenance procedure for the pilot burner.
Location and maintenance procedure for the main flame detector.
Checking combustion settings and performing pilot regulator adjustments.
Systematic testing of operating and safety devices.
Troubleshooting faults that do not display specific error messages.
Descriptions of menu items for the Combustion Calibration Menu.
Procedures to calibrate the boiler for ultra-low NOx emissions.
General| Model | BENCHMARK 6000 |
|---|---|
| Type | Condensing Boiler |
| Input BTU/hr | 6, 000, 000 BTU/hr |
| Fuel Type | Natural Gas or Propane |
| Heat Exchanger | Stainless Steel |
| Operating Pressure | 160 psi |
| Input Capacity | 6, 000, 000 BTU/hr |
| Vent Diameter | 6" |
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