Aerco BENCHMARK 6000 - User Manual

Questions and Answers

L
Lori MahoneySep 6, 2025
What causes low water level error in Aerco Boiler?
- E
  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.
V
Virginia WilliamsSep 7, 2025
How to fix MODBUS COMMFAULT on Aerco BENCHMARK 6000?
- J
  johnsondennisSep 7, 2025
  If your Aerco Boiler is showing a MODBUS COMMFAULT, here's what you can do: * Check network connections. If fault persists, contact qualified service personnel.
K
Katie ColeSep 7, 2025
What causes O2 percentage low in Aerco Boiler?
- S
  Sandra EdwardsSep 8, 2025
  If your Aerco Boiler is showing a low O2 percentage, here's what you can check: * Clean the air filter as described in section 7.9. * Inspect all sections of the inlet air duct for any obstructions. * Measure the gas pressure between the SSOV and the Air/Fuel Valve. It should be 7.9” W.C. ± 0.2” W.C. (2.0 kPa ± 50 Pa). * Check the flue for any foreign material. Measure the pressure at the exhaust manifold and compare it to the pressure map (Figure 8-1). * Check the condensate trap as per section 7.8. * Check the blower rotational speed with a strobe light and compare it to the VFD Hz output: RPM = 57.5 x Hz. * Check the VFD faceplate (available from AERCO after-market) using the VFD manufacturer’s troubleshooting documentation.
D
Dominic BarajasSep 8, 2025
What to do if Aerco BENCHMARK 6000 shows O2 sensor malfunction?
- N
  Nicole WallSep 8, 2025
  If your Aerco Boiler displays an O2 sensor malfunction, and the O2 percentage reading is 24%, check the O2 offset and gain values in the Calibration menu. If they are set to 1.0 and 1024 respectively, replace the O2 sensor.
C
cthomasSep 9, 2025
What causes O2 % out of range in Aerco BENCHMARK 6000 Boiler?
- J
  Jonathan NunezSep 9, 2025
  If your Aerco Boiler displays an 'O2 % Out of Range' error, here's what you should investigate: * Check the combustion calibration and recalibrate the boiler if necessary. * Unblock the inlet air duct and measure the open area for combustion air to the room.
A
Amber Sutton MDSep 10, 2025
What causes outdoor temp sensor fault in Aerco BENCHMARK 6000 Boiler?
- J
  Jennifer JohnsonSep 10, 2025
  If your Aerco Boiler is showing an Outdoor Temp Sensor Fault, here’s what you should check: * Inspect the Outdoor Temperature sensor for loose or broken wiring. * Check the resistance of the sensor to determine if it is within specification. * Ensure that the correct sensor is installed.
J
Janet ScottSep 12, 2025
What causes remote setpt signal fault in Aerco Boiler?
- N
  Natalie BridgesSep 12, 2025
  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.
K
keithperezSep 12, 2025
What causes recirculation pump failure in Aerco Boiler?
- P
  Peggy WeberSep 12, 2025
  If your Aerco Boiler is experiencing a recirculation pump failure, it indicates that the internal recirculation pump has failed and needs to be replaced.

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"