Aerco BENCHMARK 6000 - User Manual

Questions and Answers

M
Michael JohnsonAug 25, 2025
What to do if Aerco BENCHMARK 6000 experiences flame loss during run?
- L
  laura57Aug 26, 2025
  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.
V
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.
R
Robert BennettAug 27, 2025
How to fix flame loss during ignition in Aerco BENCHMARK 6000 Boiler?
- A
  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.
K
Kevin FarrellAug 27, 2025
Why does Aerco BENCHMARK 6000 show Delayed Interlock Open?
- K
  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.
J
janetcookAug 31, 2025
What causes direct drive signal fault in Aerco BENCHMARK 6000?
- J
  Jodi MooreAug 31, 2025
  If your Aerco Boiler is showing a 'Direct Drive Signal Fault,' here's what to check: * Ensure the direct drive 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 wiring continuity between the source and the unit. * 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.
W
Wayne MendezSep 1, 2025
What causes high exhaust temperature in Aerco BENCHMARK 6000 Boiler?
- R
  Robert JohnsonSep 1, 2025
  If your Aerco Boiler is experiencing high exhaust temperature, here’s what you should investigate: * Check the combustion calibration using the procedures outlined in Chapter 4. * If the exhaust temperature is greater than 200°F, it could be due to a carboned heat exchanger resulting from incorrect combustion calibration. Calibrate or repair as necessary.
M
Morgan ZunigaSep 2, 2025
What causes gas pressure fault (high gas pressure) in Aerco BENCHMARK 6000?
- C
  Cassandra BowersSep 2, 2025
  If your Aerco Boiler is showing a gas pressure fault due to high gas pressure, here's what you should check: * Ensure the gas pressure at the inlet of the SSOV does not exceed 14” W.C. (3.5 kPa). * If the gas supply pressure downstream of the SSOV Actuator cannot be lowered to the range of 2.3” ± 0.4” W.C. (573 Pa ± 100 Pa) using the gas pressure adjustment screw (see section 4.4, step 10), the SSOV Actuator may be defective. * Remove the leads from the High Gas Pressure switch and measure continuity across the common (C) and normally closed (NC) terminals with the unit not firing. Replace the switch if continuity does not exist.
N
Nicholas Warner MDSep 3, 2025
How to fix IGN Board Comm Fault on Aerco Boiler?
- S
  Stacy StoneSep 3, 2025
  If your Aerco Boiler is displaying an IGN Board Comm Fault, try the following: * Press the CLEAR button and restart the unit. If the fault persists, contact qualified service personnel.
G
Gina WrightSep 5, 2025
What causes line voltage out of phase error in Aerco BENCHMARK 6000?
- P
  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.
M
Michael JonesAug 25, 2025
How to fix delayed interlock open on Aerco Boiler?
- M
  michael49Aug 25, 2025
  If your Aerco Boiler experiences a delayed interlock open, here's what you should check: * Ensure the delayed interlock jumper is properly installed across the delayed interlock terminals in the I/O Box. * If there are two external wires on these terminals, check to see if an end switch for a proving device (like a pump or louver) is connected to these interlocks. Make sure the device and its end switch are working correctly. You can temporarily install a jumper to test the interlock.

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"