Instruction Manual

Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
Page 96 of 192 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0082_0J
05/21/2014 Ph.: 800-526-0288 GF-130
Burner Assembly Inspection – Continued
NOTE
The burner assembly is heavy, weighing approximately 25 pounds.
16. Remove the burner assembly from burner flange by pulling straight up.
17. Remove and replace the burner gasket.
NOTE
During reassembly, apply a light coating of high-temperature, anti-
seize lubricant to the threads of the igniter-injector and grounding
screw. Also, ensure that the igniter-injector is properly positioned
as indicated in Figure 7-3. Torque the igniter-injector to 170 - 180
in-lbs.
18. Beginning with the burner assembly removed in step 16, reinstall all the components in
the reverse order that they were removed. When reinstalling the burner flange (removed
in step 15), tighten the 3/8-16 nuts using a typical torque pattern (for example, loosely
tighten one nut, then loosely tighten a second nut on the opposite side, a third at 90
degrees to the first two, and a fourth opposite the third, and then repeat this pattern with
the remaining four nuts. Repeat the entire pattern a second time to partially tighten all
eight nuts, and then repeat a third time until all eight nuts are fully torqued to 22 ft. lbs).
19. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly
aligned with the heat exchanger top flange.
7.8 CONDENSATE DRAIN TRAP MAINTENANCE
Benchmark boilers contain a condensate trap as shown in Chapter 2, Figure 2-6. The trap is
located external to the unit and attached to the drain pipe from the exhaust manifold. This trap
should be inspected and cleaned in accordance with the maintenance schedule shown in Table
7-1 to ensure proper operation. To inspect and clean the trap, proceed as follows:
Condensate Drain Trap Maintenance
1. Disconnect the external condensate trap by loosening the union pipe connection between
the trap and the exhaust manifold drain pipe.
2. Remove the connections on the inlet and outlet sides of the condensate trap shown in
Figure 7-6.
3. Loosen the four (4) thumbscrews securing the cover on the condensate trap. Remove the
cover.
4. Remove the float from the condensate trap.
5. Remove the O-ring and orifice gaskets from the trap. AERCO recommends that these
items 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.
7. After the above items have been inspected and thoroughly cleaned, replace the O-ring
(84017) and orifice gasket (P/N 81092, if using older trap) with new parts.
8. Reassemble all piping and hose connections to the condensate trap inlet and outlet.
Reconnect trap to exhaust manifold drain.