Aerco BENCHMARK 6000 User Manual
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Aerco BENCHMARK 6000 User Manual

Natural gas and propane modulating & condensing hot water boiler
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Natural Gas and Propane
Modulating & Condensing
Hot Water Boiler
Applicable to Serial Numbers:
N-15-0428 and Above
Latest Update: 10/15/2015
OMM-0086_0F
GF-133
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
USER MANUAL
Installation, Operation and Maintenance
BENCHMARK 6000
Gas-Fired Boiler
Page 1 of 210
10/15/2015

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  • Page 1 BENCHMARK 6000 Modulating & Condensing Hot Water Boiler Gas-Fired Boiler Applicable to Serial Numbers: N-15-0428 and Above Latest Update: 10/15/2015 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 1 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    CHAPTER 3. OPERATION ........................37 3.1 INTRODUCTION ..............................37 3.2 CONTROL PANEL DESCRIPTION ........................... 37 3.3 CONTROL PANEL MENUS ............................. 41 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 3 of 210 Ph.: 800-526-0288 GF-133...
  • Page 4 6.7 FLAME FAULT TESTS ............................85 6.8 AIR FLOW FAULT TESTS ............................86 6.8.1 Blower Proof Switch Test ..........................87 6.8.2 Blocked Inlet Switch Test ..........................87 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 5 APPENDIX F – PARTS LIST DRAWINGS ........................171 APPENDIX G – PIPING DRAWINGS ........................... 181 APPENDIX H: C-MORE WIRING DIAGRAMS ......................185 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 5 of 210 Ph.: 800-526-0288...
  • Page 6 APPENDIX K: RECOMMENDED SPARES ........................201 APPENDIX L – LONG TERM BLOWER STORAGE ....................... 203 APPENDIX M – ULTRA-LOW NO CALIBRATION ....................... 205 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 7: Foreword

    FORWARD FOREWORD The AERCO Benchmark (BMK) 6000 MBH (1758 kW) boiler is a modulating and condensing unit. It represents a true industry advancement that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
  • Page 8 (1 BTU/hr = 0.293 W) Combination Control Panel Combination Control System C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Cubic Feet per Hour (1 CFH = 0.028 m...
  • Page 9 AERCO’s on-line remote monitoring system Printed Circuit Board PMC Board Primary Micro-Controller (PMC) board, contained in the C-More Part Number Proof of Closure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 9 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 10 W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 11: Chapter 1. Safety Precautions

    In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers.

  • Page 12: Emergency Shutdown

    Chapter 6 of this manual should be performed to verify that all system-operating parameters are correct. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream of the unit. The installer must identify the emergency shut-off device.

  • Page 13: Massachusetts Installations

    • Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap. • AERCO provides an optional external CO Detector, part number 58092. It can be installed and configured to simply sound an alarm or to shut down the boiler(s) if CO concentrations rise above a configurable threshold.
  • Page 14 ____________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 15: Chapter 2. Installation

    NOTE AERCO is not responsible for lost or damaged freight. Each unit has a Tip- N-Tell indicator on the outside of the shipping container. This indicates if the unit has been turned on its side during shipment.

  • Page 16: Site Preparation

    2.4.1 Installation Clearances The Benchmark Model 6000 boiler dimensions and minimum acceptable clearances are shown in Figure 2-2. The minimum clearance dimensions, required by AERCO, are listed below. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements.
  • Page 17 2.7 for Condensate Trap installation details. When using the AERCO Condensate Neutralizer Tank for condensate drainage, the tank must be installed in a pit, OR the boiler and AERCO Condensate Trap must be elevated higher than 4” (10.2 cm) above the floor.

  • Page 18: Setting The Unit

    All holes are flush with the bottom surface of the frame. • All dimensions shown are in inches [millimeters] Figure 2-2b. Benchmark 6000 Anchor Bolt Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 19 If installing a Combination Control Panel (CCP) system, it is important to identify the Combination Mode boilers in advance and place them in the proper physical location. Refer to Chapter 5 for information on Combination Mode boilers. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 19 of 210 Ph.: 800-526-0288...

  • Page 20: Supply And Return Piping

    INSTALLATION 2.6.1 Pressure Relief Valve Installation Depending on the pressure required, the Benchmark 6000 is supplied with one or more ASME rated Pressure Relief Valves. All pressure relief valves supplied with the boiler must be installed to meet code and safety requirements. The pressure rating for the relief valve must be specified on the sales order.

  • Page 21: Pressure/Temperature Gauge Installation

    CORRECT LOCATION Typically located 6” to 18” (15.2 to 45.7 cm) from the boiler outlet connection Figure 2-5B: Pressure/Temperature Gauge Installation Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 21 of 210 Ph.: 800-526-0288...

  • Page 22: Condensate Drain & Piping

    • The base of the condensate trap must be supported to ensure that it is level (horizontal). • The trap must be removable for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port.

  • Page 23: Gas Supply Piping

    HOUSKEEPING PAD MUST NOT EXTEND UNDER THE CONDENSATE ASSEMBLY. Figure 2-7: Sample Condensate Trap Installation 2.8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING!

  • Page 24: Gas Supply Specifications

    Benchmark 6000 units contain a 2 inch NPT NATURAL GAS inlet connection on the back of the unit as shown in Figure 2-4.

  • Page 25: All Installations (Except Massachusetts)

    Figure 2-8: Manual Gas Shut-Off Valve Location 2.9 AC ELECTRICAL POWER WIRING The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to connecting any AC power wiring to the unit. External AC power connections are made to the unit inside the Power Box on the front of the unit.
  • Page 26 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 27: Electrical Power Requirements

    National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code. For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF- 2060). 2.10 FIELD CONTROL WIRING Each unit is fully wired from the factory with an internal operating control system.
  • Page 28 Figure 2-12a: Input/Output (I/O) Box Location TERMINAL STRIPS I/O PCB BOARD Figure 2-12b: Input/Output (I/O) Box Interior AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 29: Outdoor Air In Terminal

    Figure 2-13: I/O Box Terminal Strips 2.10.1 OUTDOOR AIR IN Terminal An OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO P/N GM-123525) as required primarily for the INDOOR/OUTDOOR RESET mode of operation. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature.

  • Page 30: Air Temp Sensor Terminal

    The Valve Feedback signal is connected to the “Valve Fdbk” terminals and is used to confirm that the valve has properly opened or closed. If the Valve Feedback signal does not AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 30 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 31: Shield Terminals

    2.10.9 RS485 Comm Terminals The RS-485 communication terminals (+, GND, & -) are used when the boiler plant is being controlled by an Energy Management System (EMS) or AERCO ACS (formerly BMS/BMS-II) using Modbus (RS-485) communication. 2.10.10 RS232 Comm Terminals As of Firmware version 4.0 and above, these terminals are used only by factory-trained...

  • Page 32: Interlock Terminals

    • In conjunction with the optional external sequencing valve (see section 2.14 and Chapter 9 – BST), a component of AERCO’s on-board Boiler Sequencing Technology (BST) solution. By default a cable of the boiler’s wiring harness is connected to these terminals. If BST is implemented, the other end of that cable is connected to the sequencing valve.

  • Page 33: Flue Gas Vent Installation

    For combustion air supply from ducting, see section 2.13 below and consult the AERCO GF- 2050, Gas Fired Venting and Combustion Air Guide. Air must be supplied to the unit(s) through two permanent openings. These two openings must have a free area of not less than one square inch (6.45 cm...

  • Page 34: Ducted Combustion Air

    In a ducted combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run. See the AERCO Benchmark Venting and Combustion Air Guide, GF-2050. When using the unit in a ducted combustion air configuration, each unit must have a minimum 14 inch (35.56 cm) diameter...
  • Page 35 Figure 2-15: Sequencing Isolation Valve Installed Remove the jumper wire from the Molex connector and then plug it into the sequencing isolation valve’s connector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 35 of 210 Ph.: 800-526-0288...
  • Page 36 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 37: Chapter 3. Operation

    These operating controls, indicators and displays are listed and described in Table 3- 1. Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this Chapter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 37 of 210 Ph.: 800-526-0288...
  • Page 38 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Figure 3-1: Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 39 Low Water Level alarm. TEST/RESET Pressing RESET resets the water level monitor circuit. switches Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 39 of 210 Ph.: 800-526-0288 GF-133...
  • Page 40 20 segment red LED bargraph continuously shows the Air/Fuel VALVE POSITION Valve position in 5% increments from 0 to 100% Bargraph AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 41: Control Panel Menus

    The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 41 of 210 Ph.: 800-526-0288...
  • Page 42 Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 43: Operating Menu

    Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration menu (Table 3-4). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 43 of 210 Ph.: 800-526-0288...

  • Page 44: Setup Menu

    The Configuration menu settings shown in Table 3-4 are Factory- Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 45 30 min. 0 min. Aux Start On Dly 0 sec. 120 sec. 0 sec. Failsafe Mode Shutdown or Constant Setpt Shutdown AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 45 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 46 Outdoor Sensor menu item is set to Enabled. CAUTION DO NOT change the Analog Output menu item from its default setting (Valve Position 0-10V). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 47: Tuning Menu

    Set Stdby Volt 4.00 V 0/2.00 V Oxygen Level Variable * If values fall outside this range, contact the AERCO factory. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 47 of 210 Ph.: 800-526-0288 GF-133...

  • Page 48: Bst (Boiler Sequencing Technology) Menu

    Constant Setpoint Constant Setpt Setpoint Reset Head Temp Source Network FFWD Temp FFWD Temp Header Temp Addr Header Temp Point AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 49 BST Setpt Lo Limit 220°F (104.4°C) 195°F (90.6°C) BST Prop Band 1°F (-17.2°C) 120°F (48.9°C) 100°F (37.8°C) BST Intgral Gain 0.00 2.00 0.50 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 49 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 50: Start Sequence

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 51 The Air/Fuel Valve rotates to the full-open purge position and closes purge position switch. The dial on the Air/Fuel Valve (see Figure 3-4) will read 100 to indicate that it is full-open (100%). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 51 of 210 Ph.: 800-526-0288...
  • Page 52 Figure 3-5: Blower Proof Switch NOTE A Function Timing Chart for the BMK6000 Proved Pilot Control System is provided in Figure 3-7, below. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 53 Once the demand for heat has been satisfied, the C-More Controller will turn off the SSOV gas valves. The blower relay will be deactivated and the Air/Fuel Valve will be closed. STANDBY will be displayed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 53 of 210 Ph.: 800-526-0288...
  • Page 54 Power through R2 and AUX Proof of Closure C-NC Proof of Closure C-NO Figure 3-7: Timing Chart For Proved Pilot System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 55: Start/Stop Levels

    11.5 (2.87 kW) 7.5 (1.87 kW) 5,740,000 (1682 kW) 5.77 11 (2.74 kW) 7.1 (1.77 kW) 5,610,000 (1644 kW) 6.17 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 55 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 56 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Figure 3-8: Relationship Between Air/Fuel Valve Position and Energy Input AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 57 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Figure 3-9: Burner Ignition Sequence Flow Chart AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 57 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 58 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 59: Chapter 4. Initial Start-Up

    Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start-up requirements. An AERCO Gas Fired Startup Sheet, included with each Benchmark unit, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO via e-mail at: STARTUP@AERCO.COM. WARNING! DO NOT ATTEMPT TO DRY FIRE THE UNIT.

  • Page 60: Required Tools & Instrumentation

    Install manometer here for HIGH GAS PRESSURE Combustion Calibration. SWITCH (10.5” W.C., 2.6 kPa) Figure 4-1: Port Location for Combustion Calibration AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 61: Accessing The Analyzer Probe Port

    ANALYZER PROBE PORTS WITH 1/4” PLUGS 1 IN FRONT 2 IN REAR PARTIAL RIGHT SIDE VIEW Figure 4-2: Analyzer Probe Hole Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 61 of 210 Ph.: 800-526-0288 GF-133...

  • Page 62: Pilot Ignition

    CHAPTER 4 – INITIAL START-UP 4.3 PILOT IGNITION The Benchmark 6000 boiler is equipped with an interrupted pilot ignition system. The pilot is ignited by a spark discharge within the Pilot Burner inside the combustion chamber. The input of the Pilot flame is approximately 18,000 BTU/hr. (5.3 kW). The Pilot Burner flame will stay ignited until the main Burner flame has stabilized and FLAME PROVEN appears in the C-More Controller display.
  • Page 63 6.3 and 6.4. BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). Figure 4-3: Gas Pressure Adjustment Screw Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 63 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 64 6817 and then press the ENTER key. 19. Press the MENU key on the front panel of the C-MORE until COMBUSTION CAL MENU appears on the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 65 1% higher than the listed calibration range shown in the table. Record the increased O value on the Combustion Calibration sheet. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 65 of 210 Ph.: 800-526-0288...
  • Page 66 50% down to 18% after making a change to the idle screw (TAC valve). 30. This completes the Natural Gas combustion calibration procedures. TAC VALVE IDLE SCREW Figure 4-4: TAC Valve Adjust (Idle Screw) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 67: Reassembly After Combustion Calibration

    If desired, the Over- Temperature Alarm can be checked or adjusted using the procedure in section 4.5.1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 67 of 210 Ph.: 800-526-0288...

  • Page 68: Over-Temperature Alarm Switch Checks And Adjustments

    Increases the displayed temperature. DOWN Button Decreases the displayed temperature. SET Button Used to access and store parameters in the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...
  • Page 69 To calibrate the offset (P1), press and hold the SET button for 8 seconds on the Over- Temperature Alarm switch. Access code value 0 should appear in the display. The switch comes from the factory with the code set at 0. AERCO recommends that you do not change this code.
  • Page 70 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 71: Chapter 5. Mode Of Operation

    I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is provided on the cover of the I/O Box. Refer to Chapter 2, section 2.9.1 for additional wiring information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 71 of 210 Ph.: 800-526-0288...

  • Page 72: Indoor/Outdoor Reset Mode Startup

    The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted. For descriptions of temperature-related functions, see Appendix A;...

  • Page 73: Setting The Setpoint

    DIP switch adjustment must be made on the PMC Board located in the Control Panel Assembly. Refer to GF-112, Appendix D for DIP switch settings, or contact your local AERCO representative for details. In order to enable the REMOTE SETPOINT mode, the following menu setting must be made in...

  • Page 74: Remote Setpoint Field Wiring

    While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions, see Appendix A.

  • Page 75: Direct Drive Field Wiring

    DIP switch adjustment must be made on the PMC Board located in the Control Box Assembly. Refer to Appendix D of the C-More Control Panel OMM, GF-112, for DIP switch settings, or contact your local AERCO representative for details.

  • Page 76: Aerco Control System (Acs)

    485 signaling to the boiler. Installations with 1 to 8 boilers can use BST (see Chapter 9). The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible.

  • Page 77: Combination Control System (Ccs)

    Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay...

  • Page 78: Combination Control System Field Wiring

    These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Chapter 3.

  • Page 79: Chapter 6. Safety Device Testing

    Electrical voltages in this system may include 575, 208 or 460, 120 and 24 volts AC. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 79 of 210 Ph.: 800-526-0288...

  • Page 80: Low Gas Pressure Fault Tests

    12. Press the CLEAR button on the Control Panel to clear the fault. 13. The fault message should clear and the FAULT indicator should go off. The unit should now restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 81 10.5” W.C. (2.66 kPa) 8.5” W.C. (2.1 kPa) Gas Pressure test Figure 6-1: Low & High Gas Pressure Switch Locations & Test Point Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 81 of 210 Ph.: 800-526-0288...

  • Page 82: High Gas Pressure Fault Test

    3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may be opened to aid in draining. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 83: Water Temperature Fault Test

    4. Reset the adjustable Over-Temperature switch to its original setting. 5. The unit should start once the adjustable Temperature Limit switch setting is above the actual outlet water temperature. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 83 of 210 Ph.: 800-526-0288...

  • Page 84: Interlock Tests

    4. The unit should shut down and display INTERLOCK OPEN. 5. Once the interlock connection is reconnected, the INTERLOCK OPEN message should automatically clear and the unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 85: Delayed Interlock Test

    11. Open the valve previously closed in step 8. 12. Press the CLEAR button. The unit should restart and fire. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 85 of 210 Ph.: 800-526-0288...

  • Page 86: Air Flow Fault Tests

    OFF VALVE HEX SCREWS HOLDING WYE-DUCT TO A/F VALVE (1 OF 3) Figure 6-4: Blower Proof Switch & Blocked Inlet Switch Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 87: Blower Proof Switch Test

    DO NOT ALLOW ANYTHING TO BE PULLED INTO THE BLOWER. Do not wear anything that could get caught and pull you into the blower. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 87 of 210 Ph.: 800-526-0288...
  • Page 88 9. Remove the jumper wires installed in step 2 and replace the black connector boot on the Flame Detector. 10. Press the CLEAR button. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 89: Ssov Proof Of Closure Switch

    11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. ACTUATOR COVER SCREW SSOV ACTUATOR COVER Figure 6-6: Downstream SSOV Actuator Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 89 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 90: Purge Switch Open During Purge

    7. Replace the wire on the Purge switch and depress the CLEAR button. The unit should restart. AIR/FUEL VALVE COVER (ROTATE CCW TO REMOVE) Figure 6-7: Air/Fuel Valve Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 91: Ignition Switch Open During Ignition

    6. The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION. 7. Replace the wire on the Ignition switch and press the CLEAR button. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 91 of 210 Ph.: 800-526-0288...

  • Page 92: Safety Pressure Relief Valve Test

    Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI, Appendix 1, Part V Safety Relief Valve Test (Water Boiler). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 93: Chapter 7. Maintenance

    Test Replace & Test 7.13 15 min. Probe Capacitor * Only performed after initial 6 month period after initial startup. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 93 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 94: Pilot Burner

    6. Remove one of the two Pilot Flame Detectors to provide clearance for Pilot Burner removal. 7. Using a 1-1/2” open end wrench, loosen and remove the Pilot Burner from the Burner Plate. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 95: Main Flame Detector

    Flame Detector on the Blower Flange. 7. Reconnect the Main Flame Detector lead wire. 8. Replace the front panel on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 95 of 210 Ph.: 800-526-0288...

  • Page 96: O 2 Sensor

    7. Reconnect the sensor lead wire. 8. Reinstall the left-rear access panel on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 97 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE SENSOR GAS SUCTION LINE TO EXHAUST MANIFOLD EXHAUST MANIFOLD Figure 7-2: O Sensor Mounting Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 97 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 98: Combustion Calibration & Pilot Regulator Adjustment

    AUTO mode. 12. If the Pilot Regulator is NOT within specifications, proceed to section 7.5.2 and perform the Pilot Regulator Pressure Calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 99: Pilot Regulator Pressure Calibration

    9. Pull one of the Pilot Flame Detectors out (see Figure 7-1) and look into the observation port in the front plate. You should see the orange glow of the Pilot flame during the ignition trial period (see NOTE below). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 99 of 210 Ph.: 800-526-0288...

  • Page 100: Safety Device Testing

    Pilot Regulator Pressure Calibration Procedure – Continued NOTE If you DO NOT see the orange glow, contact AERCO technical support to ascertain the problem. If you DO see it, proceed to the next step. 10. If the manometer reading is less than 4.6” W.C. (1.1 kPa), increase the regulator setting by rotating the adjustment screw clockwise (CW).

  • Page 101: Burner Assembly Inspection

    19. Loosen and remove the eight (8) 3/8” hex nuts and washers from the Blower Flange where it is attached to the Burner Plate (see Figures 7-4a & 7-4b). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 101 of 210 Ph.: 800-526-0288...
  • Page 102 PILOT FLAME DETECTORS BLOWER PILOT BURNER AIR/FUEL VALVE WYE-DUCT GAS TRAIN FILTERS Figure 7-4a: Burner Assembly Mounting Details – Right-Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 103 BURNER GASKET (P/N 81159) 3/8” HEX NUTS/WASHERS (8 EA.) O-RING AIR/FUEL VALVE BURNER BLOWER FLANGE BLOWER Figure 7-5: Burner Assembly – Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 103 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 104: Refractory Removal & Replacement

    5. Remove the O sensor and the 1/4” stainless steel tube from the rear plate. 6. Disconnect the wires from the thermal switch on the rear plate. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 105 Torque bolts to approximately 20 ft-lbs (27.1 Nm). 17. To avoid exhaust leaks, ensure that a uniform seal is established when reconnecting the flue system to the boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 105 of 210 Ph.: 800-526-0288...
  • Page 106 THERMAL SWITCH REAR BURNER PLATE SENSOR GAS SUCTION LINE FROM EXHAUST MANIFOLD Figure 7-7: Partial Rear View Showing Rear Burner Plate AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 107 When servicing the heat exchanger and burner assemblies. At high temperatures, ceramic fibers can be converted to crystaline silica fibers which have been identified as carcinogenic when inhaled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 107 of 210 Ph.: 800-526-0288...

  • Page 108: Front Refractory Removal & Replacement

    30% fire rate must be performed to drive off organic binders. These organic binders are not hazardous materials, however they may emit an odor similar to burning wood. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 109 BOILER SHELL BURNER SHIELD BURNER GASKET BURNER ASSEMBLY FRONT PLATE BURNER GASKET Figure 7-9b: Front Plate Assembly – Cut-Away View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 109 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 110: Condensate Drain Trap

    (P/N 84017) INLET Float 3/4" NPT Port O-Rings OUTLET CROSS-SECTION EXPLODED VIEW Figure 7-10: External Condensate Trap: Cross-Section & Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 111: Air Filter Cleaning & Replacement

    BURNER ASSEMBLY BLOWER AIR/FUEL VALVE WYE-DUCT GAS TRAIN AIR FILTER CLAMPS AIR FILTERS Figure 7-11: Air Filter Location and Removal AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 111 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 112: Low Water Cutoff (Lwco) Capacitor Integrity Test

    Serious personal injury or death may occur if this warning is not observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 113 Ohmmeter 19-Pin Shell Harness Cable Connector LWCO Probe Assembly Connector Figure 7-14: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 113 of 210 Ph.: 800-526-0288 GF-133...

  • Page 114: Low Water Cutoff (Lwco) - Standard C-More Test

    6. Open the drain valve and drain all water from the unit. 7. Refer to Appendix L for maintenance of blower during shut down. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 115: Placing The Boiler Back In Service After A Prolonged Shutdown

    I/O board’s Spark Signal terminals, red wire to the positive (+) terminal and black to negative (-). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 115 of 210 Ph.: 800-526-0288...
  • Page 116 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 117: Chapter 8. Troubleshooting Guide

    This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 6000 boiler. The troubleshooting procedures contained herein are presented in tabular form on the following pages. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action.
  • Page 118 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 119 13. Wrong 0-10V output selection on the 13. Check the Analog Out option on the C-More Configuration control box. menu. Valve Position 0-10V should be selected. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 119 of 210 Ph.: 800-526-0288...
  • Page 120 Verify that 24 VAC is present between each side of the switch and ground. If 24 VAC is not present at both sides, replace switch. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 121 120VAC at the valve input terminals. If Chapter.. 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 121 of 210 Ph.: 800-526-0288...
  • Page 122 F, check HIGH EXHAUST Carboned heat exchanger due to combustion calibration. Calibrate or repair as necessary. TEMPERATURE incorrect combustion calibration AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 123 Replace the refractory at the hottest end plate. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 123 of 210 Ph.: 800-526-0288...
  • Page 124 4. Defective IGST Board 4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 125 Unit not seeing information from Check network connections. If fault persists, contact MODBUS COMMFAULT Modbus network qualified Service Personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 125 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 126 (correct wire numbers on the normally open terminals). Switch wired incorrectly. If the switch is wired correctly, replace the switch. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 127 Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. RECIRC PUMP FAILURE 1. Internal recirculation pump failed. 1. Replace recirculation pump. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 127 of 210 Ph.: 800-526-0288 GF-133...
  • Page 128 Normally this measurement should be near zero or no more than a few millivolts. Hot and Neutral reversed at SSOV. Check SSOV power wiring. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 129 Check scanners sensed pilot flame. SSOV FAULT DURING IGNITION Check power through ignition relay. Scanners close neutral side of relay coil. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 129 of 210 Ph.: 800-526-0288 GF-133...

  • Page 130: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 70% Valve Position in Control Box are outdated. are Rev. E or higher. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 131 (8.5” W.C., 2.1 kPa) HIGH GAS PRESSURE SWITCH (10.5” W.C.,2.6 kPa ) Figure 8-1: Gas Train Component and Pilot Gas Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 131 of 210 Ph.: 800-526-0288 GF-133...
  • Page 132 BRASS HEX HEAD (Remove to access the Gas Pressure Adjustment Screw). COVER SCREW Figure 8-3: SSOV Actuator With Gas Pressure Adjustment (SKP25) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 133 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE Continued on Sheet 2 Figure 8-4: Pilot Assembly Troubleshooting Flow Chart (Sheet 1 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 133 of 210 Ph.: 800-526-0288...
  • Page 134 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE Continued from Sheet 1 Figure 8-4: Pilot Assembly Troubleshooting Flow Chart (Sheet 2 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 135: Chapter 9. Boiler Sequencing Technology

    A simplified block diagram of multiple boilers connected to a BST is shown in Figure 9-1 below. Figure 9-1: Simplified BST Block Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 135 of 210 Ph.: 800-526-0288...

  • Page 136: Installation Notes

    ProtoNode installed. Set the BST system for desired mode of operation (SETPOINT mode). Test the system completely with the ProtoNode installed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 137: Aerco Bst Quick Start Chart

    Option 7 – 4-20ma Drive AND Modbus Header Complete section 9.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 9.3.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 137 of 210 Ph.: 800-526-0288...

  • Page 138: Bst Implementation Instruction

    When ALL C-More units have been configured: 7. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 139: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    When ALL C-More units have been configured: 9. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 139 of 210 Ph.: 800-526-0288...

  • Page 140: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    The outdoor sensor may be wired up to 200 feet (61m) from the boiler. Temp Sensor PN 123525 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 141 When ALL C-More units have been configured: 9. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 141 of 210 Ph.: 800-526-0288...

  • Page 142: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    The sensor must be shielded from direct sunlight as well as impingement by the elements. The outdoor sensor may be wired up to 200 feet (61m) from the boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 143 When ALL C-More units have been configured: 13. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 143 of 210 Ph.: 800-526-0288...

  • Page 144: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be observed. • The ground for the shield is at the driver signal source. I/O Box AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...
  • Page 145 When ALL C-More units have been configured: 8. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 145 of 210 Ph.: 800-526-0288...

  • Page 146: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Header Temp Sensor I/O Box Step 2: Remote Setpoint with Network 1. Configure and Connect the SSD Device (ProtoNode) per the AERCO Manual (GF129). Step 3: Configure ALL C-More Units On ALL boilers: 1. Go to the Configuration menu item and set the BST Menu item to Enabled.

  • Page 147: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Unit’s I/O Box. Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be observed. • The ground for the shield is at the driver signal source. I/O Box AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 147 of 210 Ph.: 800-526-0288 GF-133...
  • Page 148 When ALL C-More units have been configured: 10. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 149: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Temp Sensor PN 24410 Modbus Transmitter I/O Box Step 2: Remote Setpoint with Network 1. Configure and Connect the SSD Device (ProtoNode) per the AERCO Manual (GF129). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 149 of 210 Ph.: 800-526-0288...
  • Page 150 When ALL C-More units have been configured: 10. Go to the Boiler Sequencing Menu item of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 151: Appendix A - Boiler Menu Item Descriptions

    Displays the total number of run cycles. Run Hours Displays total run time of unit in hours. Fault Log Displays information on the last 20 faults. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 151 of 210 Ph.: 800-526-0288 GF-133...

  • Page 152: Table A-2: Setup Menu Item Descriptions

    4-digit serial # on the Code Plate, e.g., G-12-1234. Software Version Identifies the current software version of the control box. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 210 OMM-0086_0F Ph.: 800-526-0288...

  • Page 153: Table A-3: Configuration Menu Item Descriptions

    Specifies the amount of time, up to 30 minutes, to keep the Pump Delay Timer pump running after the unit turns off. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 153 of 210 Ph.: 800-526-0288...
  • Page 154 Valve Position in reaches the Start Level value. There will not be a one minute delay when firing at the 29% Valve Position level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 155 Sets the Fire Rate above which a boiler will trigger the Slow Slow Sht Threshold Shutdown feature. BST Menu When set to Enabled, the BST menu options appear. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 155 of 210 Ph.: 800-526-0288 GF-133...

  • Page 156: Table A-4: Tuning Menu Item Descriptions

    Range = 0 - 240 seconds Default = 20 seconds Reset Defaults? Allows Tuning menu options to be reset to their Factory Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 157: Table A-5: Combustion Calibration Menu Item Descriptions

    Permits the Standby Voltage to be set from 0 to 4.00 Volts. Permits the combustion oxygen level to be displayed (0% to Oxygen Level 25%). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 157 of 210 Ph.: 800-526-0288...
  • Page 158 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU DESCRIPTIONS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 159: Appendix B - Startup, Status & Display Messages

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 159 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 160 The Ignition Position Limit switch on the Air/Fuel Valve opened during ignition. DURING IGNITION INTERLOCK OPEN The Remote Interlock is open. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...
  • Page 161 Factory menu. WARNING O LEVEL The O level measured by the O sensor has exceeded HIGH 9.0 % AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 161 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 162 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 163: Appendix C - Sensor Resistance/Voltage Chart

    1260.0 2.47 87.8 1285.6 2.50 93.3 1311.4 2.52 98.9 1337.7 2.54 104.4 1364.2 2.56 1391.0 2.58 115.6 1418.2 121.1 1445.7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 163 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 164 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 165: Appendix D - Indoor/Outdoor Reset Ratio Charts

    RESET RATIO Air Temp °F °C 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 -26.1 -28.9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 165 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 166 Air Temp °F °C 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 -26.1 -28.9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 167 Air Temp °F °C 26.7 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 -20.6 -23.3 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 167 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 168 Air Temp °F °C 32.2 29.4 26.7 23.9 21.1 18.3 15.6 12.8 10.0 -1.1 -3.9 -6.7 -9.4 -12.2 -15.0 -17.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 169: Appendix E - Clearance Drawings

    Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX E – CLEARANCE DRAWINGS APPENDIX E – CLEARANCE DRAWINGS Drawing Number: AP-A-901 rev L AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 169 of 210 Ph.: 800-526-0288...
  • Page 170 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX E – CLEARANCE DRAWINGS Drawing Number: SD-A-919 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 171: Appendix F - Parts List Drawings

     Not shown on drawing Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 1 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 171 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 172 FLAME DETECTOR REPLACEMENT KIT Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 2 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 173 CROSS-SECTION Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 3 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 173 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 174 Burner part list is shown on pages below Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 4 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 175 APPENDIX F – PART LIST DRAWINGS AERCO Benchmark 6000 Part List 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 5 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 175 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 176 FRONT VIEW Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 6 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 177 POWER I/O BOX – COVER REMOVED Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 7 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 177 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 178 Benchmark 6000 Part List AERCO 01/15/2015 International, Inc. Blauvelt, NY 10913 Whole Boiler P/N 28510 Sheet 8 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 179 575V BURNER ASSEMBLY – BLOWER P/N 65166 AERCO Benchmark 6000 Blower & Burner 04/16/2015 International, Inc. Blauvelt, NY 10913 24328 rev E Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 179 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 180 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – PART LIST DRAWINGS Benchmark 6000 FM Gas Train – P/N 22222 rev B Item Part # Description Item Part # Description MAXITROL REGULATOR W/ 2-6" 123542 FLANGE 2" 125# 2"NPT...

  • Page 181: Appendix G - Piping Drawings

    Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIXGH – PIPING DRAWINGS APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-921 rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 181 of 210 Ph.: 800-526-0288...
  • Page 182 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-922 rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 183 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIXGH – PIPING DRAWINGS Drawing Number: SD-A-924 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 183 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 184 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 185: Appendix H: C-More Wiring Diagrams

    Drawing Number: 68043 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 185 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 186 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 187 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68043 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 187 of 210 Ph.: 800-526-0288...
  • Page 188 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 189 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68048 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 189 of 210 Ph.: 800-526-0288...
  • Page 190 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 190 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 191 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68048 rev C Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 191 of 210 Ph.: 800-526-0288...
  • Page 192 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 193 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68076 rev B Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 193 of 210 Ph.: 800-526-0288...
  • Page 194 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 194 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...
  • Page 195 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68076 rev B Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 195 of 210 Ph.: 800-526-0288...
  • Page 196 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 196 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 197: Omm-0086_0F

    Perform a slow drain test in accordance Semi- Slow drain test Operator with ASME Boiler and Pressure Vessel Annually Code, Section IV. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 197 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 198 Pilot Flame Detector Operator Red LED should be on when operating Annually Pilot View Port Monthly Operator Turn off boiler first. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 198 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 199: Appendix J - C-More Control Panel Views

    PUSH BUTTON P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure J-1 – Benchmark Control Panel - Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 199 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 200 CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure J-2 – Benchmark Control Panel - Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 200 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015...

  • Page 201: Appendix K: Recommended Spares

    DESCRIPTION PART NUMBER C-More Control Box 69186‐1 123449 Temperature Sensor, 1‐1/2" Lean Oxygen Sensor 61026 Over Temp‐Auto Reset Switch 123966 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 201 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...
  • Page 202 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX K – RECOMMENDED SPARES This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 202 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 203: Appendix L - Long Term Blower Storage

    Rotate wheel a minimum of 10 full revolutions to keep the motor bearing grease from separating and drying out. THIS STEP IS CRITICAL. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 203 of 210 Ph.: 800-526-0288...
  • Page 204 8. MOTOR 9. RISER BLOCKS * 10. RISER BASE * * IF REQUIRED Figure L-1: Benchmark 6000 Blower Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 204 of 210 OMM-0086_0F Ph.: 800-526-0288 10/15/2015 GF-133...

  • Page 205: Appendix M - Ultra-Low No Calibration

    Factory Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation. Prior to performing the procedure in this Appendix, the boiler must be set up as described in Chapter 4, section 4.1 through the low NO...
  • Page 206 16. Once the oxygen level is within the specified range at 100%, record the O , NO and CO readings on the Combustion Calibration Data Sheets provided with the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 206 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 207 ), nitrogen oxide (NO ) and carbon monoxide (CO) should remain within the same limits for all valve positions as shown in the following table. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 207 of 210 Ph.: 800-526-0288...
  • Page 208 5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold. Replace the 1/4” NPT plug in the manifold. 6. Replace all previously removed sheet metal enclosures on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 208 of 210 OMM-0086_0F Ph.: 800-526-0288...
  • Page 209 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0F Page 209 of 210 Ph.: 800-526-0288 GF-133 10/15/2015...

  • Page 210: Omm-0086_0F

    A023: Replace flame rod 65150 with 65182 934-145: Warranty pages removed. Warranty information for all BMK units is now included in a new stand-alone document, All Benchmark Limited Warranty, posted on the AERCO web site. 934-150: Clarified references to & function of spark monitor (p/n 61034) (or AC current transducer) in section 2.10.4, added new section 7.14 Spark Monitor 934-155: Added...

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