Aerco BENCHMARK 6000 - User Manual

Questions and Answers

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Lori MahoneySep 6, 2025
What causes low water level error in Aerco Boiler?
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  Elizabeth PrestonSep 6, 2025
  If your Aerco Boiler is showing a 'Low Water Level' error, here's what you should investigate: * Check the system to ensure there is sufficient water level. * Test the water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons. Replace the water level circuitry if it does not respond. * Check the continuity of the probe end to the shell; change the probe if there is no continuity.
C
Charles RobinsonSep 18, 2025
Why is the exhaust temperature high in my Aerco Boiler?
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  Jeff SchroederSep 18, 2025
  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.
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Gina WrightSep 5, 2025
What causes line voltage out of phase error in Aerco BENCHMARK 6000?
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  Paul WintersSep 5, 2025
  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.
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Krista HowardSep 23, 2025
How do I fix the IGN BOARD COMM FAULT on my Aerco BENCHMARK 6000 Boiler?
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  Anne AllenSep 23, 2025
  Press the CLEAR button and restart the Aerco Boiler. If the IGN BOARD COMM FAULT persists, contact qualified Service Personnel.
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Tamara RossSep 23, 2025
What to do for Heat Demand Failure in Aerco Boiler?
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  Michael GreenSep 23, 2025
  If the Aerco Boiler experiences a Heat Demand Failure, press the CLEAR button and restart the unit. If the fault persists, replace the Ignition/Stepper (IGST) Board. Also, if the relay is activated when not in Demand, the relay is defective and you should replace the IGST Board.
R
Randy BradleyNov 27, 2025
How to troubleshoot airflow fault during ignition in Aerco Boiler?
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  brandoncunninghamNov 27, 2025
  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...
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michaelvazquezDec 1, 2025
What causes flame loss during ignition on Aerco BENCHMARK 6000 Boiler?
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  Michelle CoxDec 1, 2025
  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...
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Kevin FarrellAug 27, 2025
Why does Aerco BENCHMARK 6000 show Delayed Interlock Open?
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  kgonzalezAug 28, 2025
  If the Aerco Boiler displays a Delayed Interlock Open error, check to ensure the jumper is properly installed across the delayed interlock terminals in the I/O Box. If there are 2 external wires on these terminals, check to see if an end switch for a proving device (such as a pump, louver, etc.) is tied these interlocks. Ensure that the device and/or its end switch is functional.
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Robert BennettAug 27, 2025
How to fix flame loss during ignition in Aerco BENCHMARK 6000 Boiler?
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  aliciacervantesAug 27, 2025
  If the Aerco Boiler experiences flame loss during ignition, start by removing and inspecting the flame detector for wear, replacing it if necessary. Next, close the internal gas valve and test the spark igniter outside the unit to see if it produces a spark. If there's no spark, check for 120VAC at the primary side of the ignition transformer during the ignition cycle. If 120VAC isn't present, the IGST Board in the Control Box may be defective. 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 isn't present, the IGST board may be defective.
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Victoria OlsenAug 27, 2025
What to do if Aerco BENCHMARK 6000 displays Airflow Fault during Run?
- A
  Amber RamirezAug 27, 2025
  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.

Summary

CHAPTER 1. SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

General safety regulations, warnings, and cautions for installers and operating personnel.

1.2 EMERGENCY SHUTDOWN

Procedure for emergency shutdown of the boiler in case of overheating or gas supply failure.

CHAPTER 2. INSTALLATION

2.9 AC ELECTRICAL POWER WIRING

Guidance on connecting AC power wiring to the unit, referencing GF-2060.

2.9.1 Electrical Power Requirements

Details on available voltage configurations and power box terminal blocks.

2.10 FIELD CONTROL WIRING

Information on factory-wired internal control systems and external control features.

CHAPTER 3. OPERATION

3.2 CONTROL PANEL DESCRIPTION

Description of the C-More Control Panel, its controls, indicators, and displays.

3.3 CONTROL PANEL MENUS

Overview of the menu structure for setting up and configuring the unit.

3.6 CONFIGURATION MENU

Menu for adjusting internal setpoint and other configuration settings.

3.8 COMBUSTION CAL MENU

Menu for performing combustion calibration to optimize efficiency and emissions.

3.9 BST (BOILER SEQUENCING TECHNOLOGY ) MENU

Menu for configuring, operating, and monitoring the Boiler Sequencing Technology system.

3.10 START SEQUENCE

Checks pre-purge safety switches and initiates the start sequence.

CHAPTER 4. INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

Requirements for initial boiler start-up, including installation, controls, calibration, and testing.

4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION

Necessary tools and instrumentation for performing combustion calibration.

4.2.1 Required Tools & Instrumentation

List of tools and instrumentation needed for combustion calibration.

4.3 PILOT IGNITION

Description of the pilot ignition system and its components.

4.4 NATURAL GAS COMBUSTION CALIBRATION

Procedures for calibrating combustion for low and ultra-low NOx emissions.

CHAPTER 5. MODE OF OPERATION

5.2 INDOOR;OUTDOOR RESET MODE

Mode based on outside air temperature to adjust supply header temperature.

5.3 CONSTANT SETPOINT MODE

Mode used for fixed header temperature applications like heat pump loops.

5.4 REMOTE SETPOINT MODES

Mode allowing remote control of setpoint via EMS or BAS using current or voltage signals.

5.5 DIRECT DRIVE MODES

Mode where air/fuel valve position is controlled by a remote signal.

5.6 AERCO CONTROL SYSTEM (ACS)

Mode for operating multiple boilers efficiently using an AERCO Control System.

5.7 COMBINATION CONTROL SYSTEM (CCS)

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

CHAPTER 6. SAFETY DEVICE TESTING

6.1 TESTING OF SAFETY DEVICES

Importance of periodic safety device testing to ensure proper operation and compliance.

6.2 LOW GAS PRESSURE FAULT TESTS

Procedures for testing the low gas pressure fault switch.

6.3 HIGH GAS PRESSURE FAULT TEST

Procedures for simulating and testing the high gas pressure fault.

6.4 LOW WATER LEVEL FAULT TEST

Procedure to simulate and test the low water level fault condition.

6.5 WATER TEMPERATURE FAULT TEST

Procedure to simulate and test the high water temperature fault.

6.6 INTERLOCK TESTS

Tests for the Remote Interlock and Delayed Interlock circuits.

6.6.1 Remote Interlock Test

Procedure for testing the Remote Interlock circuit.

6.6.2 Delayed Interlock Test

Procedure for testing the Delayed Interlock circuit.

6.7 FLAME FAULT TESTS

Procedures to simulate and test flame fault conditions.

6.8 AIR FLOW FAULT TESTS

Tests for the Blower Proof Switch and Blocked Inlet Switch.

6.8.1 Blower Proof Switch Test

Procedure for testing the Blower Proof Switch.

6.8.2 Blocked Inlet Switch Test

Procedure for testing the Blocked Inlet Switch.

6.9 SSOV PROOF OF CLOSURE SWITCH

Checking the proof of closure (POC) switch circuit for the downstream SSOV.

6.10 PURGE SWITCH OPEN DURING PURGE

Checking the purge switch located on the Air/Fuel Valve.

6.11 IGNITION SWITCH OPEN DURING IGNITION

Checking the ignition switch located on the Air/Fuel Valve.

6.12 SAFETY PRESSURE RELIEF VALVE TEST

Testing the safety pressure relief valve per ASME code.

CHAPTER 7. MAINTENANCE

7.1 MAINTENANCE SCHEDULE

Routine maintenance schedule for efficiency and reliability.

7.2 PILOT BURNER

Location and maintenance procedure for the pilot burner.

7.3 MAIN FLAME DETECTOR

Location and maintenance procedure for the main flame detector.

7.4 O2 SENSOR

7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT

Checking combustion settings and performing pilot regulator adjustments.

7.5.1 Pilot Regulator Pressure Testing

7.5.2 Pilot Regulator Pressure Calibration

7.6 SAFETY DEVICE TESTING

Systematic testing of operating and safety devices.

7.7 BURNER ASSEMBLY INSPECTION

7.8 REFRACTORY REMOVAL & REPLACEMENT

7.8.1 Rear Refractory Removal & Replacement

7.8.2 Front Refractory Removal & Replacement

7.9 CONDENSATE DRAIN TRAP

7.10 AIR FILTER CLEANING & REPLACEMENT

CHAPTER 8. TROUBLESHOOTING GUIDE

8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES

Troubleshooting faults that do not display specific error messages.

CHAPTER 9 - RS-232 COMMUNICATION

9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION

9.4.1 Fault Log

9.4.2 Operation Time Log

9.4.3 Sensor Log

CHAPTER 10. BOILER SEQUENCING TECHNOLOGY

10.2 AERCO BST QUICK START CHART

10.3 BST IMPLEMENTATION INSTRUCTION

10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor

10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor

10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor

10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor

10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20 ma Setpoint Drive

10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive

10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20 ma Setpoint Drive

10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS

CONFIGURATION MENU

COMBUSTION CAL MENU

Descriptions of menu items for the Combustion Calibration Menu.

APPENDIX J: RECOMMENDED PERIODIC TESTING

APPENDIX N - ULTRA-LOW NOX CALIBRATION

N-1. ULTRA-LOW NOx COMBUSTION CALIBRATION

Procedures to calibrate the boiler for ultra-low NOx emissions.

Aerco BENCHMARK 6000 Specifications

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"