AER BENCHMARK 6000 User manual

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

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Page 2of 210 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0086_0D
03/20/14 Ph.: 800-526-0288 GF-133
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
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. AERCO International is not liable for errors appearing in this manual. Nor for
incidental or consequential damages occurring in connection with the furnishing,
performance, or use of this material.

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
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GF-133 Ph.: 800-526-0288 03/20/14
TABLE OF CONTENTS
FOREWORD..........................................................................................................................................7
CHAPTER 1. SAFETY PRECAUTIONS................................................................................................ 11
1.1 WARNINGS & CAUTIONS .....................................................................................................................................11
1.2 EMERGENCY SHUTDOWN....................................................................................................................................12
1.3 PROLONGED SHUTDOWN ...................................................................................................................................13
1.4 MASSACHUSETTS INSTALLATIONS ...............................................................................................13
CHAPTER 2. INSTALLATION............................................................................................................... 15
2.1 INTRODUCTION ...................................................................................................................................................15
2.2 RECEIVING THE UNIT ...........................................................................................................................................15
2.3 MOVING & UNPACKING THE UNIT ......................................................................................................................15
2.4 SITE PREPARATION ..............................................................................................................................................16
2.4.1 Installation Clearances .................................................................................................................................16
2.4.2 Setting the Unit ............................................................................................................................................18
2.5 SUPPLY AND RETURN PIPING ..............................................................................................................................19
2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR INSTALLATION............................................20
2.6.1 Pressure Relief Valve Installation .................................................................................................................20
2.6.2 Pressure/Temperature Gauge Installation ...................................................................................................21
2.7 CONDENSATE DRAIN & PIPING............................................................................................................................22
2.8 GAS SUPPLY PIPING .............................................................................................................................................23
2.8.1 Gas Supply Specifications .............................................................................................................................24
2.8.2 Manual Gas Shutoff Valve ............................................................................................................................24
2.8.3 External Gas Supply Regulator .....................................................................................................................24
2.8.3.1 Massachusetts Installations Only ..........................................................................................................24
2.8.3.2 All Installations (Except Massachusetts) ...............................................................................................24
2.9 AC ELECTRICAL POWER WIRING..........................................................................................................................25
2.9.1 Electrical Power Requirements ....................................................................................................................27
2.10 FIELD CONTROL WIRING....................................................................................................................................27
2.10.1 OUTDOOR AIR IN Terminal.........................................................................................................................29
2.10.2 COMBUSTION AIR Terminal .......................................................................................................................30
2.10.3 O2SENSOR Terminals .................................................................................................................................30
2.10.4 SPARK SIGNAL Terminals ............................................................................................................................30
2.10.5 ANALOG IN Terminals.................................................................................................................................30
2.10.6 B.M.S. (PWM) IN Terminals ........................................................................................................................30
2.10.7 SHIELD Terminals........................................................................................................................................30
2.10.8 ANALOG OUT Terminals .............................................................................................................................30
2.10.9 RS485 Comm Terminals..............................................................................................................................31
2.10.10 RS232 Comm Terminals............................................................................................................................31
2.10.11 VFD/BLOWER Terminals ...........................................................................................................................31
2.10.12 Interlock Terminals...................................................................................................................................31
2.10.12.1 Remote Interlock In (OUT & IN).........................................................................................................31
2.10.12.2 Delayed Interlock In (OUT & IN) ........................................................................................................31
2.10.13 FAULT RELAY Terminals ............................................................................................................................32
2.10.14 AUX.RELAY Terminals ...............................................................................................................................32
2.11 FLUE GAS VENT INSTALLATION .........................................................................................................................32
2.12 COMBUSTION AIR..............................................................................................................................................33
2.12.1 Combustion From Outside the Building .....................................................................................................33
2.12.2 Combustion Air from Inside the Building ...................................................................................................33
2.13 DUCTED COMBUSTION AIR ...............................................................................................................................34
2.14 SEQUENCING VALVE INSTALLATION..................................................................................................................34
CHAPTER 3. OPERATION.................................................................................................................... 37
3.1 INTRODUCTION ...................................................................................................................................................37

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3.2 CONTROL PANEL DESCRIPTION ...........................................................................................................................37
3.3 CONTROL PANEL MENUS.....................................................................................................................................41
3.3.1 Menu Processing Procedure.........................................................................................................................41
3.4 OPERATING MENU ..............................................................................................................................................43
3.5 SETUP MENU .......................................................................................................................................................43
3.6 CONFIGURATION MENU......................................................................................................................................44
3.7 TUNING MENU ....................................................................................................................................................46
3.8 COMBUSTION CAL MENU....................................................................................................................................47
3.9 BST (Boiler Sequencing Technology ) Menu ........................................................................................................47
3.10 START SEQUENCE ..............................................................................................................................................50
3.11 START/STOP LEVELS...........................................................................................................................................55
CHAPTER 4. INITIAL START-UP.......................................................................................................... 59
4.1 INITIAL START-UP REQUIREMENTS......................................................................................................................59
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION ...................................................................59
4.2.1 Required Tools & Instrumentation...............................................................................................................60
4.2.2 Installing Gas Supply Manometer.................................................................................................................60
4.2.3 Accessing the Analyzer Probe Port ...............................................................................................................61
4.3 PILOT IGNITION ...................................................................................................................................................62
4.4 NATURAL GAS COMBUSTION CALIBRATION .......................................................................................................62
4.5 REASSEMBLY AFTER COMBUSTION CALIBRATION ..............................................................................................67
CHAPTER 5. MODE OF OPERATION.................................................................................................. 69
5.1 INTRODUCTION ...................................................................................................................................................69
5.2 INDOOR/OUTDOOR RESET MODE .......................................................................................................................69
5.2.1 Reset Ratio....................................................................................................................................................69
5.2.2 Building Reference Temperature .................................................................................................................69
5.2.3 Outdoor Air Temperature Sensor Installation ..............................................................................................69
5.2.4 Indoor/Outdoor Reset Mode Startup...........................................................................................................69
5.3 CONSTANT SETPOINT MODE...............................................................................................................................70
5.3.1 Setting the Setpoint......................................................................................................................................70
5.4 REMOTE SETPOINT MODES .................................................................................................................................71
5.4.1 Remote Setpoint Field Wiring ......................................................................................................................71
5.4.2 Remote Setpoint Startup..............................................................................................................................72
5.5 DIRECT DRIVE MODES .........................................................................................................................................72
5.5.1 Direct Drive Field Wiring...............................................................................................................................73
5.5.2 Direct Drive Startup ......................................................................................................................................73
5.6 AERCO CONTROL SYSTEM (ACS)..........................................................................................................................73
5.6.1 ACS External Field Wiring .............................................................................................................................74
5.6.2 ACS Setup and Startup..................................................................................................................................74
5.7 COMBINATION CONTROL SYSTEM (CCS).............................................................................................................74
5.7.1 Combination Control System Field Wiring ...................................................................................................75
5.7.2 Combination Control System Setup and Startup..........................................................................................75
CHAPTER 6. SAFETY DEVICE TESTING............................................................................................ 77
6.1 TESTING OF SAFETY DEVICES...............................................................................................................................77
6.2 LOW GAS PRESSURE FAULT TESTs .......................................................................................................................77
6.3 HIGH GAS PRESSURE FAULT TEST ........................................................................................................................79
6.4 LOW WATER LEVEL FAULT TEST ..........................................................................................................................80
6.5 WATER TEMPERATURE FAULT TEST ....................................................................................................................81
6.6 INTERLOCK TESTS ................................................................................................................................................82
6.6.1 Remote Interlock Test ..................................................................................................................................82
6.6.2 Delayed Interlock Test ..................................................................................................................................82
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

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
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6.9 SSOV PROOF OF CLOSURE SWITCH .....................................................................................................................87
6.10 PURGE SWITCH OPEN DURING PURGE..............................................................................................................88
6.11 IGNITION SWITCH OPEN DURING IGNITION......................................................................................................89
6.12 SAFETY PRESSURE RELIEF VALVE TEST...............................................................................................................90
CHAPTER 7. MAINTENANCE............................................................................................................... 91
7.1 MAINTENANCE SCHEDULE ..................................................................................................................................91
7.2 PILOT BURNER .....................................................................................................................................................92
7.3 MAIN FLAME DETECTOR......................................................................................................................................93
7.4 O2SENSOR ...........................................................................................................................................................94
7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT......................................................................95
7.5.1 Pilot Regulator Pressure Testing...................................................................................................................95
7.5.2 Pilot Regulator Pressure Calibration.............................................................................................................97
7.6 SAFETY DEVICE TESTING ......................................................................................................................................98
7.7 BURNER ASSEMBLY INSPECTION .........................................................................................................................99
7.8 REFRACTORY REMOVAL & REPLACEMENT ........................................................................................................102
7.8.1 Rear Refractory Removal & Replacement ..................................................................................................102
7.8.2 Front Refractory Removal & Replacement.................................................................................................106
7.9 CONDENSATE DRAIN TRAP................................................................................................................................108
7.10 AIR FILTER CLEANING & REPLACEMENT..........................................................................................................109
7.11 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME .............................................................110
7.12 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ..................................................110
CHAPTER 8. TROUBLESHOOTING GUIDE...................................................................................... 111
8.1 INTRODUCTION .................................................................................................................................................111
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ............................................................................124
CHAPTER 9. RS-232 COMMUNICATION........................................................................................... 129
9.1 INTRODUCTION .................................................................................................................................................129
9.1.1 Aquiring the PuTTY Application..................................................................................................................129
9.1.2 Logging on to a Remote Machine Using PuTTY ..........................................................................................129
9.1.3 Running a Command on a Remote Machine Using PuTTY .........................................................................130
9.2 RS-232 COMMUNICATION SETUP .....................................................................................................................131
9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION...............................................................................131
9.4 DATA LOGGING..................................................................................................................................................132
9.4.1 Fault Log .....................................................................................................................................................133
9.4.2 Operation Time Log ....................................................................................................................................133
9.4.3 Sensor Log ..................................................................................................................................................134
CHAPTER 10. BOILER SEQUENCING TECHNOLOGY...................................................................... 135
10.1 INTRODUCTION ...............................................................................................................................................135
10.2 AERCO BST Quick Start Chart ..........................................................................................................................136
10.3 BST Implementation Instruction......................................................................................................................137
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor ............................................................137
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor.........................................................138
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor .....139
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ......................141
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ...............143
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive.............144
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive........................145
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive .....................147
APPENDIX A – BOILER MENU ITEM DESCRIPTIONS .................................................................................................149
APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES ........................................................................................157
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART............................................................................................161
APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ......................................................................................163
APPENDIX E – BOILER DEFAULT SETTINGS ..............................................................................................................167
APPENDIX F – CLEARANCE DRAWINGS....................................................................................................................169

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
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APPENDIX G – PARTS LIST DRAWINGS ....................................................................................................................173
APPENDIX H – PIPING DRAWINGS...........................................................................................................................185
APPENDIX I: C-MORE WIRING DIAGRAMS..............................................................................................................189
APPENDIX J: RECOMMENDED PERIODIC TESTING..................................................................................................197
APPENDIX K – C-MORE CONTROL PANEL VIEWS.....................................................................................................199
APPENDIX L: RECOMMENDED SPARES ...................................................................................................................201
APPENDIX M – LONG TERM BLOWER STORAGE .....................................................................................................203
APPENDIX N – ULTRA-LOW NOx CALIBRATION .......................................................................................................205
LIMITED WARRANTY ............................................................................................................................. 209

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
FORWARD
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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. The
maximum turn down ratio for the BMK 6000 is 15:1. This BMK model provides extremely high
efficiency and makes it ideally suited for modern low temperature, as well as, conventional
heating systems.
The Benchmark Model BMK 6000 operates within the following input and output ranges:
Benchmark Model Input Range (BTU/hr.) Output Range (BTU/hr.)
Minimum
Maximum
Minimum
Maximum
BMK 6000 400,000 6,000,000 372,000 5,580,000
The output of the boiler is a function of the unit’s firing rate (valve position) and return water
temperature.
When installed and operated in accordance with this Instruction Manual, the BMK 6000 MBH
Boiler complies with the NOx emission standards outlined in:
•South Coast Air Quality Management District (SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements, the BMK 6000 offer the maximum venting
flexibility with minimum installation space requirements. These Boilers are Category II, III and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:
•Conventional, Vertical
•Conventional, Sidewall
•Conventional, Direct Vent, Vertical
•Sealed, Direct Vent, Horizontal
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.
IMPORTANT
Unless otherwise specified, all descriptions and procedures provided in this
Installation, Operation & Maintenance Manual apply to the Benchmark 6000
MBH boiler.

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
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Phrases, Abbreviations and Acronyms
Phrase, Abbreviation
or Acronym Meaning
A (Amp) Ampere
ACS AERCO Control System, AERCO’s boiler management system
ADDR Address
AGND Analog Ground
ALRM Alarm
ASME American Society of Mechanical Engineers
AUX Auxiliary
BAS
Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate
Symbol rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BMK Benchmark series boilers
BLDG (Bldg)
Building
BST AERCO on-board Boiler Management Technology
BTU British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound of water 1° F.
CCP
Combustion Control Panel
C-More Controller
(or Control Box)
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CO Carbon Monoxide
COMM (Comm)
Communication
Cal. Calibration
CNTL Control
DBB Double Block and Bleed. Used to define boiler gas trains containing 2
Safety Shutoff Valves (SSOVs) and a solenoid operated vent valve.
Also known as IRI gas trains(see below)
DIP Dual In-Line Package
EMS Energy Management System; often used interchangeably with BAS
FM Factory Mutual. Used to define boiler gas trains.
GND Ground
HDR Header
HX Heat Exchanger
Hz Hertz (Cycles Per Second)
I.D.
Inside Diameter
IGN Ignition
IGST Board Ignition/Stepper Board contained in C-More Control Box

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Phrases, Abbreviations and Acronyms - Continued
Phrase, Abbreviation
or Acronym
Meaning
INTLK (INTL’K) Interlock
I/O Input/Output
I/O Box Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
IP Internet Protocol
IRI Industrial Risk Insurers. A now discontinued code u
sed to define gas
trains containing two SSOVs and a solenoid operated vent valve.
ISO Isolated
LED Light Emitting Diode
LN Low NOx
MA (mA) Milliampere (1 thousand
th
of an ampere)
MAX (Max) Maximum
MIN (Min) Minimum
Modbus® A serial, half-
duplex data transmission protocol developed by AEG
Modicon
NC (N.C.) Normally Closed
NO (N.O.) Normally Open
NOx Nitrogen Oxide
NPT National Pipe Thread
O2 Oxygen
O.D. Outside Diameter
PMC Board A Primary Micro-Controller (PMC) board is contained in the C-More
Control Box used on all Benchmark units.
PPM Parts Per Million
PTP Point-to-Point (usually over RS-232 networks)
PWM Pulse Width Modulation
REF (Ref) Reference
RES. Resistive
RS232
(or EIA-232) A standard for serial, full-duplex (FDX) transmission of data based on the RS-232 Standard
RS422
(or EIA-422) A standard for serial, full-duplex (FDX) transmission of data based on the RS-422 Standard
RS485
(or EIA-485) A standard for serial, half-duplex (HDX) transmission of data based on the RS-485 Standard
RTN (Rtn) Return
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield

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Phrases, Abbreviations and Acronyms - Continued
Phrase, Abbreviation
or Acronym
Meaning
SSOV Safety Shut Off Valve
TEMP (Temp) Temperature
Terminating Resistor A resistor placed at each end of a daisy-chain or multi-drop network in
order to prevent reflections that may cause invalid data in the
communication
VAC Volts, Alternating Current
VDC Volts, Direct Current
VFD Vacuum Fluorescent Display, or Variable Frequency Drive
W Watt
W.C. Water Column
µA
Micro amp (1 millionth of an ampere)

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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CHAPTER 1. SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. 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. Where applicable, the equipment
shall be installed in accordance with the current Installation Code for Gas Burning Appliances
and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should
be carefully followed in all cases. Authorities having jurisdiction should be consulted before
installations are made.
See pages 14 and 15 for important information regarding installation of units within the
Commonwealth of Massachusetts.
IMPORTANT
This Instruction Manual is an integral part of the product and must be
maintained in legible condition. It must be given to the user by the installer
and kept in a safe place for future reference.
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE
UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.
THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A
POSITIVE PRESSURE AND THEREFORE MUST BE COMPLETELY
SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO
LIVING SPACES.
ELECTRICAL VOLTAGES UP TO 480 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE COVER ON THE UNIT’S POWER BOX
(LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
WARNING
WARNING
WARNING
WARNING
WARNING

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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A THREE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNIT. THE SWITCH MUST BE INSTALLED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY
DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO UNIT
SHEET METAL ENCLOSURES.
Many soaps used for gas pipe leak testing are corrosive to metals. The
piping must be rinsed thoroughly with clean water after leak checks have
been completed.
DO NOT use this boiler if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
NOTE
The Installer must identify and indicate the location of the
emergency shutdown manual gas valve to operating personnel.
Figure 1-1: Manual Gas Shutoff Valve
WARNING
CAUTION
CAUTION
MANUAL GAS SHUT-OFF VALVE
VALVE OPEN VALVE CLOSED

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in 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.
1.4 MASSACHUSETTS INSTALLATIONS
Boiler installations within the Commonwealth of Massachusetts must conform to the following
requirements:
•Boiler must be installed by a plumber or a gas fitter who is licensed within the
Commonwealth of Massachusetts.
•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. Contact your AERCO representative for details.
•The vent termination must be located a minimum of 4 feet above grade level. If side-wall
venting is used, the installation must conform to the following requirements extracted from
248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building
or structure used in whole or in part for residential purposes, including those owned or operated
by the Commonwealth and where the side wall exhaust vent termination is less than seven (7)
feet above finished grade in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satisfied:
•INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal vented gas fueled equipment. It
shall be the responsibility of the property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a
crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a battery
operated carbon monoxide detector with an alarm shall be installed.
1. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
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2. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior
of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust
vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign
shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS".
3. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in
the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room
or structure separate from the dwelling, building or structure used in whole or in part for
residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall horizontally vented gas equipment
provides a venting system design or venting system components with the equipment, the
instructions provided by the manufacturer for installation of the equipment and the venting
system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system
components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT
PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the flue gases, but identifies "special
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of the
installation.
____________________________________________________________________________
[End of Extracted Information From 248 CMR 5.08 (2)]

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
OMM-0086_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 15 of 210
GF-133 Ph.: 800-526-0288 03/20/14
CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
the AERCO Benchmark Model BMK 6000 Boiler.
2.2 RECEIVING THE UNIT
Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for the
BMK 6000 Model is approximately 3500 pounds. The unit must be moved with the proper rigging
equipment for safety and to avoid equipment damage. The unit should be completely inspected
for evidence of shipping damage and shipment completeness at the time of receipt from the
carrier and before the bill of lading is signed.
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. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 MOVING & UNPACKING THE UNIT
While packaged in the shipping container, the unit can be moved using a forklift.
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either factory installed on the
unit or packed separately with the unit:
•Pressure/Temperature Gauge
•ASME Pressure Relief Valve
•Condensate Drain Trap (part no. 24060)
•2” Gas Supply Shutoff Valve
When optional accessories are ordered, they may be packed with the unit, factory installed on
the unit, or packed and shipped in a separate container. Any standard or optional accessories
shipped loose should be identified and stored in a safe place until ready for installation or use.

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
Page 16 of 210 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0086_0D
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Figure 2-1: Benchmark 6000 Mounted on Shipping Skid
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark Boiler includes:
•Access to AC Input Power at 208 VAC, Three-Phase, 60 Hz @ 30 Amps
OR 460 VAC, Three-Phase, 60 Hz @ 20 Amps
•Access to Natural Gas line at a minimum pressure of 14 inches W.C. with the unit in
operation (approximately 20” W.C. static).
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. Minimum acceptable clearances required are as follows:
•Front : 36 inches (914 mm)
•Sides: 24 inches (610 mm)
•Rear: 24 inches (610 mm)
•Top: 18 inches (457 mm)
All gas piping, water piping and electrical conduit or cable must be arranged so that they do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
SHIPPING SKID

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
OMM-0086_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 17 of 210
GF-133 Ph.: 800-526-0288 03/20/14
IMPORTANT
Ensure that adequate clearance exists at the rear of the unit to permit
installation and service maintenance of the AERCO Condensate Trap. Refer
to section 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.
Figure 2-2: Benchmark Boiler Model 6000 Clearances
Housekeeping pad
should not extend
under the condensate
assembly
4” – 8”
4” MINIMUM

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
Page 18 of 210 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0086_0D
03/20/14 Ph.: 800-526-0288 GF-133
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.
FOR MASSACHUSSETTS ONLY
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter who is licensed within the Commonwealth of Massachusetts. In
addition, the installation must comply with all requirements specified in
Chapter 1 (Safety Precautions), pages 14 and 15.
2.4.2 Setting the Unit
The unit must be installed on a concrete housekeeping pad, a minimum of 4 inches and a
maximum of 8 inches thick, to ensure proper condensate drainage (see NOTE below).
NOTE
When using the AERCO Condensate Neutralizer Tank for proper
condensate drainage, the Neutralizer Tank must be stored in a pit,
OR the boiler and AERCO Condensate Trap must be elevated
higher than 4” above the floor. Ensure that the condensate
assembly is not positioned above the housekeeping pad during
installation so as not to interference with condensate piping. See
Condensate Tank Instructions TID-0074 for details.
Two (2) lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-3.
Cut the cardboard at marked locations to provide access to the lifting tabs.
Remove the four (4) lag screws securing the unit to the shipping skid, and, if still in place,
remove the front Top Panel. Lift the unit off the shipping skid and position it on the concrete
Housekeeping Pad (required) in the desired location.
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.
WARNING
WARNING

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
OMM-0086_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 19 of 210
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Figure 2-3: Boiler Lifting Provisions
If anchoring the unit, refer to the dimensional drawings in Appendix F for anchor locations.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient
space for piping connections and future service/maintenance requirements must also be taken
into consideration. All piping must include ample provisions for expansion.
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.
2.5 SUPPLY AND RETURN PIPING
The Benchmark Boiler utilizes 6” flanged fittings for the water system supply and return piping
connections. 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.
LIFTING TABS
NOTE:
Remove the two top panels
to access the lifting tabs.

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
Page 20 of 210 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0086_0D
03/20/14 Ph.: 800-526-0288 GF-133
Figure 2-4: Supply and Return Locations
2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR
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. Each pressure relief valve is furnished as a kit
(92102-Tab) which consists of the relief valve for the pressure rating specified on the Sales
Order. The appropriate size reducing bushing and nipple are also included in the kit. The
pressure relief valves, nipples and bushings are connected to 45º street elbows already installed
on the heat exchanger of the boiler. The relief valves are installed on the top of the boiler as
shown in Figure 2-5A. A suitable pipe joint compound should be used on all threaded
connections. Any excess should be wiped off to avoid getting any joint compound into the valve
body. Each relief valve must be piped to within 12 inches of the floor to prevent injury in the
event of a discharge. The discharge piping must be full size, without reduction. No valves, or size
reductions are allowed in the discharge line. In multiple unit installations the discharge lines must
not be manifolded together. Each must be individually run to a suitable discharge location.
6” WATER OUTLET
AIR INLET
6” WATER INLET
2” GAS INLET
EXHAUST
MANIFOLD
CONDENSATE
DRAIN