TECHNICAL INSTRUCTIONS

Transcription

1 TECHNICAL INSTRUCTIONS 24 Month Maintenance Kit Instructions For Benchmark Boilers Maintenance Kit # Flame Detector P/N Ignitor- Injector P/N Exhaust Manifold Seal P/N Burner Gasket P/N Release Gasket P/N Lower Release Gasket P/N LWCO Capacitor Kit P/N Flame Detector Gasket P/N Condensate Trap O-Ring P/N Condensate Trap Orifice Gasket P/N Air Filter P/N Blower Gasket P/N Created 04/03/2014 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. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 1 of 12

2 1. INTRODUCTION This Technical Instruction Document (TID) provides instructions for performing recommended 24 month maintenance on Benchmark 2500 and Benchmark 3000 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 Phillips head screwdriver #2 6mm Allen wrench Torque wrench The following wrenches (open-end, box or socket) are used: o 3/8 o 7/16 o 1/2 o 9/16 o 1 3. MAINTENANCE KIT CONTENTS Table 1: Contents of Benchmark Month Maintenance Item Part No. Quantity Description IGNITOR-INJECTOR AIR FILTER FLAME DETECTOR FLAME DETECTOR GASKET CONDENSATE TRAP ORIFICE GASKET CONDENSATE TRAP O-RING BLOWER GASKET EXHAUST MANIFOLD SEAL LWCO / CAPACITOR ASSEMBLY KIT BURNER GASKET BURNER RELEASE GASKET LOWER RELEASE GASKET 4. INSTALLATION INSTRUCTIONS WARNING Remove electrical power before working on the unit. Adhere to all local codes regarding lock-out, tag-out procedures. WARNING Various components may be hot, therefore care must be exercised to avoid burns. It is suggested that you allow the unit to cool to room temperature before starting these instructions. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 2 of 12

3 4.1 Replacing the Blower and Burner Gaskets The instructions in this section replace the blower gasket (p/n 81157) and burner gasket (p/n 81180). In addition, these instructions also remove the ignitor-injector (p/n 58023), flame detector (p/n 66034) and flame detector gasket (p/n 81048) from the boiler; they are replaced in sections 4.2 and 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. Shut off the gas supply valve to the unit. 3. Remove the panels from the top and sides of the unit, exposing the intake manifold and blower. 4. Disconnect the electrical cable from the ignitor. Blower Gasket Blower Plenum Staged Ignition Solenoid O2 Sensor Burner Plate Flame Detector & Gasket Ignitor-Injector Burner Gasket Figure 1. Gasket, Ignitor-Injector & Flame Detector Locations 5. Use a 7/16 wrench to disconnect the compression nut securing the igniter-injector s gas injector tube to the elbow of the staged ignition assembly and then disconnect the staged ignition solenoid from the igniter-injector. Discard the old compression nut. Staged Ignition Solenoid Ignitor-Injector Elbow Compression Nut Indexing Washers (0-3 as needed) Flame Detector Figure 2. Ignitor-Injector Disassembly 6. Use a 1" wrench to remove the ignitor-injector from the blower plenum and discard it. 7. Disconnect the flame detector lead wire and then remove the two (2) Phillip head screws securing the flame detector to the blower plenum (Figure 3). These screws will be used during reassembly, in section /06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 3 of 12

4 8. Remove the flame detector and gasket from the blower plenum and discard them. Flame Detector Gasket Flame Detector Figure 3. Flame Detector Replacement NOTE The next two steps will remove the blower plenum from between the burner and the blower, HOWEVER, once the plenum is removed, the entire weight of the gas train and blower will be borne by one U-bolt that attaches the gas train to the rails. It is therefore necessary devise a way to support the weight of the blower and blower motor until the plenum is reinstalled. This can be a hoist, a jack, or a piece of lumber cut to size. As an alternative, a special bracket, P/N 23176, may be ordered from AERCO and permanently installed so that the blower is supported during future maintenance procedures. Contact AERCO for details. 9. Use a 3/8 wrench to remove the eight (8) hex nuts and washers securing the blower plenum to the burner plate. Hex Nuts (8) Burner Top Plenum Figure 4. Blower Plenum Fasteners 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 4 of 12

5 10. Use a 5/16 wrench and 6mm Allen wrench to remove the four (4) hex nuts and washers securing the blower plenum to the blower (left image), and use a 3/8 wrench to remove the two (2) hex bolts and washers securing the plenum to the plenum rail bracket (right image). Plenum Plenum Rail Bracket Nuts (4) Hex Bolts (2) Blower Figure 5. Blower Plenum Removal 11. Move the staged ignition solenoid off to the side and then lift the blower plenum off the unit. The burner gasket and blower gasket are now accessible. Burner Gasket(s) Plenum Blower Gasket Figure 6. Burner Gasket Removal NOTE Some units may have a single burner gasket while others may have three. In both cases, you must install all three burner gaskets included with the kit, the release gasket, burner gasket and lower release gasket. 12. Remove the existing burner gasket(s) CAUTION! If the old gasket cannot be removed easily, it may be scraped off, but MUST be removed entirely and without damage to the top surface of the burner. Do NOT use metal tools for scraping as this may leave scratches. Use a vacuum cleaner to remove any remaining pieces or particles. Ensure that NO particles of the old gasket fall into the burner cavity. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 5 of 12

6 13. Replace the burner gasket(s) with the three (3) new gaskets included with the kit, in the order shown below. You must ensure that the Lower Release Gasket (P/N 81185), which features tabs, is placed first, in the lowest position Release Gasket Burner Gasket Lower Release Gasket Figure 7. Burner Gasket Installation 14. Replace the existing blower gasket with the new blower gasket included with the kit. 15. Replace the blower plenum and secure it to the burner plate with eight (8) nuts and washers removed during disassembly. Tighten to 30 to 35 ft-lbs. of torque, using a criss-cross tightening pattern (tighten one, then tighten its opposite) to ensure an even seal. 16. Loosen both hex bolts holding the plenum rail bracket to the rails (see Figure 5), then secure the blower plenum to the plenum rail bracket with two (2) hex bolts and washers removed during disassembly. Once that is complete, tighten both plenum rail bracket hex bolts. 17. Secure the blower plenum to the blower with the four (4) nuts and washers removed in step 9. Torque the bolts to 70 in/lbs. 4.2 Replacing the Ignitor-Injector The instructions below install the new ignitor-injector (p/n 58023), including compression nut and indexing washers. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 6 of 12

7 1. Use a 1" wrench to install the new ignitor-injector, included with the kit, onto the blower plenum. Use zero to three indexing washers, as needed, so that the igniter-injector s gas injector tube is positioned within the 120 angle range shown below. Torque the ignitor-injector to in-lbs. DO NOT over tighten. Figure 8. Ignitor-Injector Orientation (viewed from above looking down) 2. Connect the igniter-injector s gas injector tube to the elbow of the staged ignition solenoid with the new compression nut, included with the kit. 3. Reconnect the igniter-injector cable. 4.3 Replacing the Flame Detector and Flame Detector Gasket The instructions below replace the flame detector (p/n 66034) and flame detector gasket (p/n 81048). 1. Install the new flame detector and flame detector gasket, included with the kit, fastening them with the #10-32 Phillips head screws removed during disassembly (see Figure 3). 2. Reconnect the flame detector lead wire. 4.4 Replacing the Air Filter The instructions in this section replace the air filter (p/n 88014). 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. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 7 of 12

8 2. Remove the filter and clamp and dispose of them. Air/Fuel Valve Air Filter Hose Clamp Manual shut-off valve Gas Train Air Filter Figure 9. Air Filter Replacement 3. Install the new air filter and clamp, included with the kit, and tighten the clamp with a flat-tip screwdriver or 5/16 nut driver. 4.5 Replacing the Exhaust Manifold Seal The instructions below replace the exhaust manifold seal (p/n 84040), located between the exhaust manifold and the bottom of the heat exchanger. 1. Place a piece of cardboard or other soft material under the exhaust manifold. This will protect the base of the unit when the exhaust manifold is lowered and slid out from under the heat exchangers. 2. Disconnect the exhaust manifold from the condensate drain in the rear of the unit. 3. Disconnect the condensate trap from its outlet and then remove the condensate trap. 4. Disconnect the exhaust manifold from the exhaust vent. 5. Use a 9/16 wrench to remove all four 3/8-16 hex bolts (1 1/2 long) and washers that attach the exhaust manifold to the bottom flange of the heat exchanger. Do not remove the larger hex bolts that attach the heat exchangers to the base of the unit. Exhaust Manifold 3/8-16 Hex Bolts (4, 2 shown) Exhaust Vent (partial) Connection to Condensate Trap Figure 10. Exhaust Manifold Removal Partial Right Side View 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 8 of 12

9 6. Slide the exhaust manifold out from under the heat exchanger towards the rear of the unit. Check for any signs of deterioration or corrosion. 7. Remove the exhaust manifold seal and, if necessary, remove any remaining adhesive and debris from the exhaust manifold. 8. Peel the self-adhesive paper off the new exhaust manifold seal, included with the kit, and place it on the exhaust manifold with the holes aligned with the exhaust manifold s threaded holes. 9. Slide the exhaust manifold back under the heat exchanger to its original position. 10. Lift the exhaust manifold until it contacts the underside of the heat exchanger and hold it in place with two 3/8-16 hex bolts, adjusting the position of the exhaust manifold until the bolts aligns with the exhaust manifold s threaded hole. Partially tighten these bolts. 11. Reinstall and partially tighten the remaining 3/8-16 hex bolts. 12. Fully Tighten all four 3/8-16 hex bolts. 13. Reattach the exhaust vent to the exhaust manifold. The exhaust manifold is not yet reconnected to the condensate trap. You will complete that step at the end of section 4.6 or 4.7, below. 4.6 Replacing the Condensate Trap O-Ring New Style Trap There are two types of condensate traps in service, and older and a newer style. The instructions in this section apply ONLY to the NEWER style condensate trap. For the older-style trap, see section 4.7. These instructions replace the external 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 11. Condensate Trap Location 1. If you have not already done so, disconnect the external condensate trap from the exhaust manifold by loosening the thumb screw on the trap s inlet. 2. Disconnect the condensate trap outlet from the floor drain. 3. Remove the cover from the condensate trap, secured with four (4) thumbscrews, shown in Figure Replace the O-ring from under the cover 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 and then reinstall the float and float guide. If the trap cannot be thoroughly cleaned, replace the trap. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 9 of 12

10 7. Reassemble the float and float guide and then secure the cover with the four thumb screws. INLET OUTLET Figure 12. Newer-Style External Condensate Trap Cross-Section 8. Reconnect the condensate trap to the outlet piping and then reconnect it to the exhaust manifold drain by tightening the thumbscrew on the trap inlet. 4.7 Replacing the Condensate Trap O-Ring & Orifice Gasket Old Style Trap The instructions in this section apply ONLY to the OLDER style condensate trap. These instructions replace the external condensate trap O-ring (p/n 84017), located under the condensate trap s cover, and the condensate trap orifice gasket (p/n 81092). The condensate trap is attached to the exhaust manifold s condensate drain pipe (see Figure 11). 1. If you have not already done so, disconnect the condensate trap from the exhaust manifold. 2. Remove the connection on the outlet side of the condensate trap. 3. Remove the cover from the condensate trap, secured with four (4) thumbscrews. Cover Thumb Screws (4) Inlet Condensate Trap O-Ring Float Orifice Gasket Outlet Figure 13. Older-Style External Condensate Trap Cross-Section 4. Replace the O-ring from under the cover with the new condensate trap O-ring, included with the kit. 5. Remove the float and float guide from the condensate trap and then remove the orifice gasket. 6. Thoroughly clean the trap and float, and inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 10 of 12

11 7. Install the new orifice gasket, included with the kit, and then reinstall the float guide, float, cover and thumb screws. 8. Reconnect the condensate trap to the outlet piping and then reconnect it to the exhaust manifold drain. 4.8 Replacing the LWCO Capacitor The replacement LWCO probe sensor now comes with a capacitor assembly attached. This procedure replaces an old probe with the new LWCO capacitor assembly (p/n 69126). 1. From the end of the LWCO probe, unscrew the plastic acorn nut and first hex nut, then remove the wire lug. Figure 14. LWCO Capacitor Kit Hardware Callouts on Old Probe 2. Remove the LWCO probe from the recess by unscrewing the brass coupling to which it is attached. The probe should resemble the one in Figure 15. Figure 15. LWCO Capacitor 3. Sparingly apply an NSF approved pipe dope to the threads of the brass coupling to which the LWCO probe is attached (Do NOT use Teflon tape) and install into the recess hole vacated by the old probe. 06/06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 11 of 12

12 4. Next, cut old lug from wire (removed earlier from probe tip) and crimp onto the male crimp of capacitor assembly. If replacing a probe which already has the capacitor assembly attached, then there is already a male crimp instead of a lug and it may simply be inserted into the female crimp on the new probe/capacitor assembly. The finished capacitor assembly should resemble Figure 16. Figure 16. LWCO Capacitor Kit Connections 4.9 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. Open the gas supply valve to the unit. 4. Check that all connections are tight. 5. Replace all panels removed at the beginning of these instructions. Change Log Date Description Changed By 04/03/2014 Rev B: This kit now supports both BMK 2500 and BMK 3000 Chris Blair 06/06/2014 Rev C: Replaced fuel rod with per PIR Chris Blair AERCO International, Inc., /06/2014 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 12 of 12