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Aerco BENCHMARK 6000 User Manual

Natural gas modulating & condensing hot water boiler
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Natural Gas Modulating &
Condensing Hot Water Boiler
Applicable to Serial Numbers:
N-14-0172 and Above
Latest Update: 03/20/14
OMM-0086_0D
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
03/20/14

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  • Page 1 Installation, Operation and Maintenance Condensing Hot Water Boiler BENCHMARK 6000 Applicable to Serial Numbers: Gas-Fired Boiler N-14-0172 and Above Latest Update: 03/20/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 1 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 2 Disclaimer 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

    2.13 DUCTED COMBUSTION AIR ..........................34 2.14 SEQUENCING VALVE INSTALLATION ........................34 CHAPTER 3. OPERATION ........................37 3.1 INTRODUCTION ..............................37 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 3 of 210 Ph.: 800-526-0288 GF-133...
  • Page 4 6.7 FLAME FAULT TESTs ............................82 6.8 AIR FLOW FAULT TESTS ............................83 6.8.1 Blower Proof Switch Test ..........................84 6.8.2 Blocked Inlet Switch Test ..........................85 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 5 APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ..................163 APPENDIX E – BOILER DEFAULT SETTINGS ......................167 APPENDIX F – CLEARANCE DRAWINGS ........................169 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 5 of 210 Ph.: 800-526-0288...
  • Page 6 APPENDIX L: RECOMMENDED SPARES ........................201 APPENDIX M – LONG TERM BLOWER STORAGE ..................... 203 APPENDIX N – ULTRA-LOW NOx CALIBRATION ....................... 205 LIMITED WARRANTY ..........................209 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 7: Foreword

    FORWARD FOREWORD The AERCO Benchmark (BMK) 6000 MBH 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 British Thermal Unit. A unit of energy approximately equal to the heat required to raise 1 pound of water 1° F. Combustion Control Panel C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Carbon Monoxide...
  • Page 9 A standard for serial, half-duplex (HDX) transmission of data based on (or EIA-485) the RS-485 Standard RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 9 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 10 Volts, Direct Current Vacuum Fluorescent Display, or Variable Frequency Drive Watt W.C. Water Column µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 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

    MANUAL GAS SHUT-OFF VALVE VALVE OPEN VALVE CLOSED Figure 1-1: Manual Gas Shutoff Valve AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14...

  • Page 13: Prolonged Shutdown

    Chapter 6 of this manual be performed to verify all system- operating parameters. 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 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_0D 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. If the Tip-N-Tell indicator is tripped, do not sign for the 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” above the floor. See Condensate Neutralizer Tank Instructions TID-0074 for details.

  • Page 18: Setting The Unit

    WHEN LIFTING OR MOVING THE BOILER: DO NOT ATTEMPT TO MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER. A SPREADER BAR IS REQUIRED FOR ALL VERTICAL LIFTS. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 19: Supply And Return Piping

    The physical location of the supply and return piping connections are shown in Figure 2-4. Refer to Appendix F, Drawing AP-A-901 for additional dimensional data. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 19 of 210 Ph.: 800-526-0288...

  • Page 20: Pressure Relief Valve & Pressure/Temperature Indicator Installation

    INSTALLATION 2.6.1 Pressure Relief Valve Installation Depending on the pressure required, the Benchmark 6000 is supplied with either a single 2” or two (2) 1¼“ ASME rated Pressure Relief Valves. The pressure rating for the relief valve must be specified on the sales order. Available pressure ratings range from 30 psi to 160 psi, depending on pressure vessel maximum rated pressure.

  • Page 21: Pressure/Temperature Gauge Installation

    It must be installed so that the sensing bulb is inserted into the hot water outlet flow from the boiler. Refer to Figure 2-5B for sample installations. Figure 2-5B: Pressure/Temperature Gauge Installation Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D 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

    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 NEVER USE MATCHES, CANDLES, FLAMES OR OTHER...

  • Page 24: Gas Supply Specifications

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

  • Page 25: Ac Electrical Power Wiring

    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_0D 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 There is a diagram of the connection functions on the cover of the I/O Box as well. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • 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: Combustion Air Terminal

    “to view only” input that can be seen in the operating menu. The sensor is an AERCO BALCO wire sensor Part No. 12449. A resistance chart for this sensor is provided in APPENDIX C. This sensor is an active part of the combustion control system and must be operational for accurate air/fuel mixing control.

  • Page 31: Rs485 Comm 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 The RS-232 communication terminals (TxD, RxD) permit a laptop computer or other suitable terminal to be connected to the boiler.

  • Page 32: Fault Relay Terminals

    2.11 FLUE GAS VENT INSTALLATION The AERCO Gas Fired Venting and Combustion Air Guide, GF-2050 must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification. Because the unit is capable of discharging low temperature exhaust gases, the flue must be pitched back towards the unit a minimum of 1/4"...

  • Page 33: Combustion Air

    The more common methods of combustion air supply are outlined in the following sections. For combustion air supply from ducting, consult the AERCO GF-2050, Gas Fired Venting and Combustion Air Guide. 2.12.1 Combustion From Outside the Building Air supplied from outside the building must be provided through two permanent openings.

  • 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 8 inch diameter connection at the unit.
  • Page 35 Figure 2-14: Sequencing Valve Installed Remove the jumper wire from the Molex connector and then plug it into the sequencing valve’s connector. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D 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_0D Ph.: 800-526-0288 03/20/14 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_0D Page 37 of 210 Ph.: 800-526-0288...
  • Page 38 This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial-to-USB adaptor for use in modern computer USB ports. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 39 Low Water Level alarm. TEST/RESET Switches Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 39 of 210 Ph.: 800-526-0288...
  • Page 40 20 segment red LED bargraph continuously shows the Air/Fuel Valve VALVE POSITION position in 5% increments from 0 to 100% Bargraph AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14...

  • 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_0D 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_0D Ph.: 800-526-0288...

  • Page 43: Operating Menu

    RS-232 port. A view-only software version display is also provided to indicate the current Control Box software version. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 43 of 210 Ph.: 800-526-0288...

  • Page 44: Configuration 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_0D Ph.: 800-526-0288...
  • Page 45 160°F *NOTE The Bldg Ref Temp and Reset Ratio Menu Items are only displayed when the Outdoor Sensor is set to “Enabled”. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 45 of 210 Ph.: 800-526-0288...

  • Page 46: Tuning Menu

    Warmup Int Gain 0.50 Warmup PID timer 0 sec. 240 sec. 20 sec. Reset Defaults? Yes, No, Are You Sure? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 47: Combustion Cal Menu

    These displayed item groups are displayed in UPPER CASE letters, and are bounded by an asterisk * in order to readily identify them within the item list. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 47 of 210 Ph.: 800-526-0288...
  • Page 48 Boiler Shutdown System Shutdown Shutdown On-Outlet One Boiler Mode On-Avg Temp Temp 1 Blr Threshold Setpoint Setback Disable Enable Disable AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 49 Disabled Enabled Disabled *BST COMM MENU* Comm Address BST Min Addr BST Max Addr SSD Address SSD Poll Control 1000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 49 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 50: Start Sequence

    The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for the downstream SSOV location. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 51 The VALVE POSITION bargraph will show 100%. TO BLOWER STEPPER MOTOR AIR IN Figure 3-4: Air/Fuel Valve In Purge Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 51 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 52 The Optical Pilot Flame Sensor proves the Pilot Flame and the red LED stops blinking and changes to steady ON. e) Ignition relay 1 (R1) closes allowing the main Burner ignition sequence to start. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 210 OMM-0086_0D 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_0D Page 53 of 210 Ph.: 800-526-0288...
  • Page 54 Power through R1 Power through R2 and AUX POC C-NC POC 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_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 55: Start/Stop Levels

    (% of Full BTU/Hr Capacity) 18% (Stop Level) 385,000 15.6 400,000 15.0 540,000 11.1 770,000 1,160,000 1,650,000 2,386,000 3,515,000 4,650,000 100% 6,000,000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 55 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 56 5,860,000 5.45 7.95 5,860,000 5.41 11.5 5,740,000 5.77 5,610,000 6.17 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_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 57 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Figure 3-9: Burner Ignition Sequence Flowchart AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 57 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • 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_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 59: Chapter 4. Initial Start-Up

    Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP CHAPTER 4. INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 6000 MBH boiler consists of the following: • Complete installation (Chapter 2) •...

  • Page 60: Required Tools & Instrumentation

    1/4" NPT PLUG BALL VALVE (Install Manometer here for Combustion Calibration) Figure 4-1: 1/4 Inch Gas Plug Location for Combustion Calibration AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14...

  • Page 61: Accessing The Analyzer Probe Port

    EXHAUST MANIFOLD ANALYZER PROBE PORTS (2) WITH 1/4” PLUG CONDENSATE DRAIN PARTIAL REAR VIEW Figure 4-2: Analyzer Probe Hole Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 61 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 62: Pilot Ignition

    Refer to Figure 4-1 for test port location. The Pilot flame is proven by the AERCO BST Sensors located above and below the Pilot. The boiler has two Pilot Flame Detectors. The AERCO BST is an optical sensor inserted in a viewport.
  • Page 63 7.5” and 8.3” W.C. 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_0D Page 63 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 64 NOx readings exceed the target values shown, increase the O level up to 1% higher than the listed calibration range. Record the increased O value on the Combustion Calibration sheet. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 65 27. Once the oxygen level is within the specified range at 70%, press the ENTER key to store the selected blower output voltage for the 80% valve position. Record all readings on the Combustion Calibration Sheets provided. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 65 of 210 Ph.: 800-526-0288...
  • Page 66 50% down to 14% after making a change to the idle screw (TAC valve). 30. This completes the Natural Gas combustion calibration procedures. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 67: Reassembly After Combustion Calibration

    5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold. Replace the 1/8” 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 OMM-0086_0D Page 67 of 210 Ph.: 800-526-0288...
  • Page 68 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 68 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 69: Chapter 5. Mode Of Operation

    Startup in the Indoor/Outdoor Reset Mode is accomplished as follows: NOTE design engineer typically provides design outdoor temperature and supply header temperature data AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 69 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 70: Constant Setpoint Mode

    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 and their factory defaults, see Appendices A and E.

  • Page 71: Remote Setpoint Modes

    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 and their factory defaults, refer to Appendices A and E.

  • Page 72: Remote Setpoint Startup

    Boiler Mode Direct Drive Remote Signal 4-20mA/1-5V, 0-20mA/0- 5V, or Network Refer to section 3.3 for instructions on changing menu options. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 73: Direct Drive Field Wiring

    485 signaling to the boiler. Installations with 1 to 8 boilers can use BST (see Chapter 10). 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 74: Acs External Field Wiring

    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 75: Combination Control System Field Wiring

    While it is possible to change other temperature-related functions for combination mode, these functions are preset to their factory default values. These default settings work well in most AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 75 of 210 Ph.: 800-526-0288...
  • Page 76 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION 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 Appendix E.

  • Page 77: Chapter 6. Safety Device Testing

    Refer to Figure 6-1A to locate the Low Gas Pressure switch and the proper location to connect the water column manometer or gauge when performing the test. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 77 of 210 Ph.: 800-526-0288...

  • Page 78: Low Gas Pressure Fault Test

    7. Fully open the external gas supply ball valve and press the CLEAR button on the Control Box. 8. The fault message should clear and the FAULT indicator should go off. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 79: High Gas Pressure Fault Test

    4. Start the unit in the Manual mode at a valve position (% open) between 25 and 30%. 5. With the unit running, monitor the gas pressure on the manometer installed in step 2 and record the gas pressure reading. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 79 of 210 Ph.: 800-526-0288...

  • Page 80: Low Water Level Fault Test

    11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message. 12. Set the ON/OFF switch to the ON position. The unit is now ready for operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 81: Water Temperature Fault Test

    ERATURE DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON MANUAL TEMPERATURE LIMIT SWITCH Figure 6-2: Temperature Limit Switch Setting AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 81 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 82: Interlock Tests

    6.7 FLAME FAULT TESTS Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 83: Air Flow Fault Tests

    6.8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-4. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 83 of 210 Ph.: 800-526-0288...

  • Page 84: Blower Proof Switch Test

    Menu, Analog Output menu item and select OFF. 7. The Blower Proof Switch will open and the blower should stop. The unit should shut down and display AIRFLOW FAULT DURING RUN. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 85: Blocked Inlet Switch Test

    100% fire rate. Note that no gas or flame is present in the boiler at this time. 5. Wait for the boiler to ramp up to at least 90% before continuing. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 85 of 210 Ph.: 800-526-0288...
  • Page 86 OUTLET AIR INLET (Combustion Air Duct removed) EXHAUST MANIFOLD REAR FRONT Figure 6-5: Boiler Top View Showing Air Inlet Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 87: 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_0D Page 87 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 88: Purge Switch Open During Purge

    6. 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 88 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14...

  • Page 89: 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_0D Page 89 of 210 Ph.: 800-526-0288...

  • Page 90: Safety Pressure Relief Valve Test

    6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 91: Chapter 7. Maintenance

    Replace Gaskets 7.10 Air Filter (88014) Replace Replace 15 mins. * Only performed after initial 6 month period after initial startup. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 91 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 92: 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 92 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 93: 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_0D Page 93 of 210 Ph.: 800-526-0288...

  • Page 94: O 2 Sensor

    7. Reconnect the sensor lead wire. 8. Reinstall the rear right side panel on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 95: Combustion Calibration & Pilot Regulator Adjustment

    4.0” W.C., then the Pilot pressure regulator must be recalibrated using the instructions provided in section 7.5.2. The Pilot Regulator pressure test is performed as follows: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 95 of 210 Ph.: 800-526-0288...
  • Page 96 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 96 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 97: Pilot Regulator Pressure Calibration

    8. Start the boiler in the MANUAL Mode. Observe the manometer pressure when the Pilot solenoid “clicks” open after purge. The manometer should now provide a reading of 4.9” W.C. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 97 of 210 Ph.: 800-526-0288...

  • Page 98: Safety Device Testing

    CHAPTER 7 – MAINTENANCE 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. 9. Pull out the optical flame scanner and look into the observation port in the front plate.

  • Page 99: Burner Assembly Inspection

    14. Remove the Blower from the Burner by pulling outward. Be careful not to allow it to swing and damage other equipment components. Refer to the exploded view in Figure 7-5. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 99 of 210 Ph.: 800-526-0288...
  • Page 100 PILOT FLAME DETECTORS PILOT BURNER BURNER PLATE BLOWER AIR/FUEL VALVE GAS TRAIN “Y” DUCT AIR FILTERS Figure 7-4a: Burner Assembly Mounting Details AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 101 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_0D Page 101 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 102: 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 102 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 103 Torque bolts to approximately 20 ft-lbs. 16. 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_0D Page 103 of 210 Ph.: 800-526-0288...
  • Page 104 REAR BURNER PLATE O2 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 104 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 105 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_0D Page 105 of 210 Ph.: 800-526-0288...

  • Page 106: 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 106 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 107 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE Front Refractory Replacement Procedure – Continued Figure 7-9: Front Plate Assembly AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 107 of 210 Ph.: 800-526-0288...

  • Page 108: Condensate Drain Trap

    4. Remove the float and float guide from the condensate trap. 5. Remove the O-ring from the trap. AERCO recommends that this O-ring be replaced annually. 6. Thoroughly clean the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap.

  • Page 109: Air Filter Cleaning & Replacement

    BURNER ASSEMBLY BLOWER AIR/FUEL VALVE “Y” 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_0D Page 109 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 110: Shutting The Boiler Down For An Extended Period Of Time

    Appendix M – Long Term Blower Storage. Failure to complete these instructions will void all warranties. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 111: 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 MBH 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 112 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 112 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 113 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_0D Page 113 of 210 Ph.: 800-526-0288...
  • Page 114 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 114 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 115 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_0D Page 115 of 210 Ph.: 800-526-0288...
  • Page 116 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 116 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 117 Replace the refractory at the hottest end plate. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 117 of 210 Ph.: 800-526-0288...
  • Page 118 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 118 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 119 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_0D Page 119 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 120 (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 120 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 121 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_0D Page 121 of 210 Ph.: 800-526-0288 GF-133...
  • Page 122 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 122 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 123 Check pilot assembly for carbon buildup. SSOV FAULT DURING Check scanners sensed pilot flame. IGNITION Check power through ignition relay. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 123 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 124: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 80% Valve Position in Control Box are outdated. are Rev. E or higher. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 125 PILOT BURNER PILOT FLAME DETECTORS (2 EA.) BLOWER TO PILOT GAS LINE Figure 8-2: Pilot Burner & Flame Detector Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 125 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 126 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 126 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 127 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE Figure 8-4: Pilot Assembly Troubleshooting (Sheet 1 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 127 of 210 Ph.: 800-526-0288...
  • Page 128 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE Figure 8-4: Pilot Assembly Troubleshooting (Sheet 2 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 129: Chapter 9. Rs-232 Communication

    (if your computer has more than one) and what speed (baud rate) to use when transferring data. For further configuration options (data bits, stop bits, parity, flow control), you can use the Serial AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 129 of 210 Ph.: 800-526-0288...

  • Page 130: Running A Command On A Remote Machine Using Putty

    Figure 9-2: PuTTY GUI: Basic SSH Options for Running Remote Commands Into the textbox titled, Remote command type the full command line you wish to have executed on the remote machine. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 131: Communication Setup

    At the prompt, enter the valid RS-232 password (jaguar) in lower case letters and press Enter. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices: M = Display next Menu...

  • Page 132: Data Logging

    Descriptions of these data logs are provided in the following sections. The basic procedure for accessing each data log is described in section 9.3 step 10. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 133: Fault Log

    Run, Direct Drive 1/15/02 1:21pm Ignition 1/15/02 1:20pm Off, Switch 1/15/02 12:30pm Run, Manual 1/15/02 11:55am Ignition 1/15/02 11:55am Power-up 1/15/02 11:50am AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 133 of 210 Ph.: 800-526-0288 GF-133 03/20/14...

  • Page 134: Sensor Log

    OPEN OPEN OPEN OPEN 1/15/02 5:16pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:11pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:06pm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 135: Chapter 10. Boiler Sequencing Technology

    A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 9-1 below. Figure 10-1. Simplified BST Block Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 135 of 210 Ph.: 800-526-0288...

  • Page 136: Aerco Bst Quick Start Chart

    Option 7 – 4-20ma Drive AND Modbus Header Complete section 10.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 10.3.8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 137: Bst Implementation Instruction

    10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...

  • Page 138: Option 2 - Constant Setpoint With Modbus Wired Header Sensor

    Step 1: MODbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.

  • Page 139: Option 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor

    Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1 - Direct Wired Header Sensor Wiring 1. On the MASTER Unit, connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...
  • Page 140 When ALL C-More units have been configured: 9. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 141: Option 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor

    Step 1 - Modbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 142 When ALL C-More units have been configured: 13. Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 143: Option 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20Ma Setpoint Drive

    Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor”...

  • Page 144: Option 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive

    Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor” in the I/O Box.

  • Page 145: Option 7 - Remote Setpoint With Modbus Header Sensor And 4-20Ma Setpoint Drive

    Step 1: MODbus Header Sensor 1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 146 When ALL C-More units have been configured: Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 210 OMM-0086_0D Ph.: 800-526-0288...

  • Page 147: Option 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive

    Step 1: MODbus Header Sensor 1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
  • Page 148 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual CHAPTER 10 – BOILER SEQUENCING TECHNOLOGY (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 149: Appendix A - Boiler Menu Item Descriptions

    Displays total run time of unit in hours from 0 to 9,999,999. Fault Log Displays information on the last 20 faults. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 149 of 210 Ph.: 800-526-0288 GF-133...
  • Page 150 Allows selection of KC Boiler, KC Boiler LN, BMK Boiler Std, BMK Blr Std Dual, BMK Boiler LN, BMK Blr LN Dual, KC Water Heater, KC Wtr Heater LN, Innovation WH AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 151 Pump Delay Timer Specifies the amount of time (0 to 30 min.) to keep the pump running after the unit turns off. Default is zero. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 151 of 210 Ph.: 800-526-0288...
  • Page 152 Start Level value. There will not be a one minute delay when firing at the 29% Valve Position level. Setting range is 0 to 25. (Default is 10) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 210 OMM-0086_0D Ph.: 800-526-0288...
  • Page 153 Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature. Span is 40% to 100%, Default is 60%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 153 of 210 Ph.: 800-526-0288...
  • Page 154 Range = 1-240 Default = 20 Reset Defaults? Allows Tuning Menu options to be reset to their Factory Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 155 Permits the Standby Voltage to be set from 0 to 4.00 Volts. Oxygen Level Permits the combustion oxygen level to be displayed (0% to 25%). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 155 of 210 Ph.: 800-526-0288 GF-133...
  • Page 156 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 156 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 157: 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_0D Page 157 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 158 Ignition board. COMM FAULT IGN SWTCH CLOSED The Ignition Position Limit switch on the Air/Fuel Valve closed during purge. DURING PURGE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 159 FLAME SSOV The SSOV switch opened during standby. SWITCH OPEN SSOV FAULT The SSOV switch opened during purge. DURING PURGE AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 159 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 160 _?_ ºF WARNING The O2 level measured by the O2 sensor has exceeded O2 LEVEL HIGH _?_ % AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 161: Appendix C - Sensor Resistance/Voltage Chart

    1185.2 2.41 1209.5 2.43 1234.7 2.45 1260.0 2.47 1285.6 2.50 1311.4 2.52 1337.7 2.54 1364.2 2.56 1391.0 2.58 1418.2 1445.7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 161 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 162 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 163: Appendix D - Indoor/Outdoor Reset Ratio Charts

    -10F -15F -20F Table D-2: Header Temperature for a Building Reference Temperature of 60ºF RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 163 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 164 RESET RATIO Temp Table D-4: Header Temperature for a Building Reference Temperature of 70ºF RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 165 RESET RATIO Temp -10F -15F Table D-6: Header Temperature for a Building Reference Temperature of 80ºF RESET RATIO Temp -10F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 165 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 166 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX D – INDOOR/OUTDORR RATIO CHARTS Table D-7: Header Temperature for a Building Reference Temperature of 90ºF RESET RATIO Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14...

  • Page 167: Appendix E - Boiler Default Settings

    Aux Start On Dly 0 sec Failsafe Mode Shutdown Valve Position 0-10V Analog Output CAUTION: DO NOT Change Lo Fire Timer 2 sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 167 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 168 Hi DB Setpt En Demand Offset Deadband High Deadband Low Tuning Menu Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 169: Appendix F - Clearance Drawings

    Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – CLEARANCE DRAWINGS APPENDIX F – CLEARANCE DRAWINGS Drawing Number: AP-A-901 rev H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 169 of 210 Ph.: 800-526-0288...
  • Page 170 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – CLEARANCE DRAWINGS Drawing Number: SD-A-919 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 171 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – CLEARANCE DRAWINGS Drawing Number: SD-A-928 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 171 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 172 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – CLEARANCE DRAWINGS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 173: Appendix G - Parts List Drawings

    Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 1 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 173 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 174 Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 2 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 175 Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 3 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 175 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 176 Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 4 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 177 AERCO Benchmark 6000 Part List 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 5 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 177 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 178 Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 6 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 179 Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 7 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 179 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 180 Benchmark 6000 Part List AERCO 02/01/2014 International, Inc. Blauvelt, NY 10913 Whole Boiler p/n 28510 (PL-A-178) Sheet 8 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 181 Benchmark 6000 Blower & Burner 07/25/2013 International, Inc. Blauvelt, NY 10913 24328, 24328-2 rev B (AP-A-911) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 181 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 182 AERCO Benchmark 6000 FM Gas Train 07/09/2013 International, Inc. 22172-1 rev C (AP-A-912) Blauvelt, NY 10913 Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 183 AERCO Benchmark 6000 FM Gas Train 07/09/2013 International, Inc. 22172-1 rev C (AP-A-912) Blauvelt, NY 10913 Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 183 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 184 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PART LIST DRAWINGS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 185: Appendix H - Piping Drawings

    Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-921 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 185 of 210 Ph.: 800-526-0288...
  • Page 186 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-922 rev E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 187 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-924 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 187 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 188 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 189: Appendix I: C-More Wiring Diagrams

    The AERCO BST sensor internally switches to neutral when the flame is proven. Drawing Number: 68043 rev B Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 189 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 190 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 190 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 191 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68043 rev B Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 191 of 210 Ph.: 800-526-0288...
  • Page 192 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 193 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68048 rev B Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 193 of 210 Ph.: 800-526-0288...
  • Page 194 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 194 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...
  • Page 195 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68048 rev B Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 195 of 210 Ph.: 800-526-0288...
  • Page 196 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 196 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 197: Appendix J: Recommended Periodic Testing

    Perform a slow drain test in accordance Semi- with ASME Boiler and Pressure Vessel Slow drain test Operator Annually Code, Section IV. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 197 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 198 Pilot Sensor 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_0D Ph.: 800-526-0288 03/20/14 GF-133...

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

    SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure K-1: Benchmark Control Panel Exploded View BENCHMARK CONTROL PANEL EXPLODED VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 199 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 200 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure K-2: Benchmark Control Panel Rear View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 200 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 201: Appendix L: Recommended Spares

    24-month Waterside/Fireside Inspection Kit 58025-12 Table L-3: Optional Spare Parts DESCRIPTION PART NUMBER C-More Control Box 181197 Burner 46038 Sensor 61026 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 201 of 210 Ph.: 800-526-0288 GF-133 03/20/14...
  • Page 202 Benchmark 6000 Boiler Installation, Operation & Maintenance Manual APPENDIX L – C-RECOMMENDED SPARES This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 202 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 203: Appendix M - 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_0D Page 203 of 210 Ph.: 800-526-0288...
  • Page 204 8. MOTOR 9. RISER BLOCKS * 10. RISER BASE * * IF REQUIRED Figure M-1: Benchmark 6000 Blower Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 204 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

  • Page 205: Appendix N - Ultra-Low Nox 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 NOx combustion calibration in section 4.4.
  • Page 206 16. Once the oxygen level is within the specified range at 100%, record the O , NOx 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_0D Ph.: 800-526-0288...
  • Page 207 *NOTE Set the Valve Position at 18% but make adjustments to the Combustion Calibration value designated as 16%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D Page 207 of 210 Ph.: 800-526-0288 GF-133...
  • 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_0D Ph.: 800-526-0288...

  • Page 209: Limited Warranty

    AERCO shall at its option modify, repair or exchange the defective item. AERCO shall have the option of having the item returned, FOB its factory, or to make field replacements at the point of installation. In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges.

  • Page 210: Omm-0086_0D

    PIR-934-33: Modified step 13 in Combustion Calibration regarding defective O Sensor PIR-934-37: Modified Blocked Inlet Switch Test instructions, section 6.8.2. Copyright AERCO International Inc. 2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 210 of 210 OMM-0086_0D Ph.: 800-526-0288 03/20/14 GF-133...

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