TECHNICAL INSTRUCTIONS

Transcription

1 TECHNICAL INSTRUCTIONS Annual Maintenance Kit Instructions For Benchmark 6000 Boilers Kit Number Main Flame Detector P/N Ignitor Rod P/N Compression Nut with Ferrule 3/8 OD P/N Condensate Trap O-Ring P/N Air Filter P/N (2 Each) Latest Update: 06/06/2014 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. VD2: 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 1 of 6

2 1. INTRODUCTION This Technical Instruction Document (TID) provides instructions for performing recommended annual maintenance on Benchmark 6000 Boilers. 2. LIST OF TOOLS The following tools are required to perform the instructions in this bulletin. Flat-head screwdriver or 5/16 nut driver The following wrenches (open-end, box or socket) are used: o 5/8 o 3/4" o 7/8 o 15/16 o 1-1/2 3. MAINTENANCE KIT CONTENTS Table 1: Benchmark 6000 Annual Maintenance Contents Item Part No. Quantity Description MAIN FLAME DETECTOR IGNITOR ROD COMPRESSION NUT WITH FERRULE 3/8 OD AIR FILTER CONDENSATE TRAP O-RING 4. INSTALLATION INSTRUCTIONS WARNING The ignitor rod may be hot, therefore, care should be exercised to avoid burns. It is easier to remove these parts from the unit after the unit has cooled to room temperature. WARNING Remove electrical power before working on the unit. Adhere to all local codes regarding lock-out, tag-out procedures. 4.1 Replacing the Ignitor Rod The instructions in this section replace the following parts: Ignitor Rod p/n Compression Nut With Ferrule p/n VD2: 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 2 of 6

3 1. Set the ON/OFF switch on the control panel, to the OFF position and then disconnect AC power from the unit by turning off power at the breaker. 2. Remove all panels from the front third of the unit, exposing the intake manifold and air filters. 3. Remove the connectors from both pilot flame sight tubes then use a 7/8" wrench to remove both pilot flame sight tubes from the boiler front plate. 4. Disconnect the electrical cable from the pilot burner (see Figure 1). 5. Use a 3/4 wrench to disconnect the gas flex hose from the pilot burner assembly and then remove the elbow from the pilot burner assembly. The hardware attaching the pilot burner assembly to the gas flex hose may differ from the images, but should be removed and retained for later assembly. 6. Use a 1-1/2" wrench to remove the pilot burner assembly from the boiler front plate and set it aside. Boiler Front Plate Main Flame Detector Blower Flange Blower Pilot Flame Sight Tube Connectors Pilot Flame Sight Tube Pilot Burner Assembly Elbow Gas Flex Hose Nipple To Gas Flex Hose Figure 1. Pilot Burner & Flame Detector Mounting Details Pilot Flame Sight Tube 7. Inspect the heating end of the pilot burner assembly for any deterioration or damage. The opening in the heating end was originally 1/2 inch in diameter, but may have expanded during use. It must not be greater than 5/8 inch and be free of debris and carbon build-up. If it cannot be cleaned, or if the opening is larger than 5/8 inch in any direction, you must replace the entire pilot burner assembly (p/n 29700, not included with the kit). Ignitor Rod Compression Nut & Ferrule Figure 2. Pilot Burner Assembly Inspect & clean opening VD2: 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 3 of 6

4 8. Use a 5/8 wrench to unscrew the compression nut holding the ignitor rod in the pilot burner assembly, and then remove the ignitor rod and ferrule and dispose of both. 9. Install the new ignitor rod with compression nut and ferrule, included with the kit, in the pilot burner assembly. Push the ignitor rod all the way into the pilot burner until it stops no further position adjustment is necessary and then tighten the ferrule. 10. Use a 1 1/2" wrench to reinstall the pilot burner assembly on the boiler front plate so that the gas inlet s position in the pilot burner faces away from the blower (matching the position shown in Figure Reinstall the elbow and reattach the gas flex hose to the pilot burner assembly. 12. Reconnect the electrical cable to the pilot burner assembly and both pilot flame sight tubes. 4.2 Replacing the Main Flame Detector The instructions in this section replace the following part: Main Flame Detector p/n Disconnect the flame detector lead wire. 2. Use a 15/16 wrench to remove the flame detector from the blower flange and discard it. 3. Loosen the adjustment nut on the new main flame detector, included with the kit, and then slide it until it is 5.25 inches from the end of the ceramic insulator next to the electrical connector, as shown below, and then tighten the adjustment nut. Do NOT over-tighten the adjustment nut, as this could crack the ceramic Detector Rod Ceramic Insulator Adjustment Nut 5.25 Electrical Connector Figure 2. Main Flame Detector 4. Use a 15/16 wrench to install the new flame detector into the blower flange (see Figure 1). 5. Reconnect the main flame detector lead wire. 4.3 Replacing the Air Filter The instructions in this section replace the following part: Air Filters (2) p/n VD2: 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 4 of 6

5 1. Use a flat-tip screwdriver or 5/16 nut driver to loosen the clamp securing the air filter to the inlet flange of the air/fuel valve, then remove the filter and clamp. Repeat with the second air filter. Air Filter Clamps (2) Air Filters (2) Figure 3. Air Filter Replacement 2. Install two new air filters, included with the kit, on the inlet flange of the air fuel valve 3. Tighten the clamps with a flat-tip screwdriver or 5/16 nut driver. 4.4 Replacing the Condensate Trap O-Ring The instructions below replace the condensate trap O-ring (p/n 84017), located under the condensate trap s cover. The condensate trap is attached to the exhaust manifold s condensate drain pipe. Figure 4. Condensate Trap 1. Disconnect the external condensate trap from the exhaust manifold by loosening the thumb screw on the trap inlet shown in Figure Remove the connection on the outlet side of the condensate trap. 3. Remove the cover from the condensate trap, secured with four (4) thumbscrews. 4. Replace the O-ring from under the cover and replace it with the new condensate trap O-ring, included with the kit. 5. Remove the float and float guide from the condensate trap. 6. Thoroughly clean the trap and float, and inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap. VD2: 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 5 of 6

6 7. Reassemble all piping and hose connections to the condensate trap outlet, then reconnect the trap to the exhaust manifold drain by tightening the thumbscrew on the trap inlet. 3/4" NPT Port Condensate Trap Cover Thumb Screws (4) Thumb Screw Condensate Trap O-Ring INLET Adapter Opening O-Rings (2) Float Guide Float 3/4" NPT Port OUTLET Figure 5. External Condensate Trap 4.5 Putting the Unit Back in Service 1. Reconnect AC power to the unit. 2. Set the ON/OFF switch on the control panel to the On position. 3. Check your work prior to reinstalling the panels, including checking that all connections are tight and do not leak. 4. Replace all panels removed in section 4.1. Change Log Date Description Changed By 10/25/2013 Rev A: Initial release Chris Blair 06/06/2014 Rev B: Replaced Main Flame Rod p/n with p/n 65150, modified Adjustment Nut position to 5.25 in step 3 of section 4.2 (reference PIR 1029) Chris Blair AERCO International, Inc., 2014 VD2: 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 6 of 6