AERCO BMK 6000 - Manual (Page 106)

Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
Page 106 of 210 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D
03/20/14
Ph.: 800-526-0288
GF-133
7.8.2 Front Refractory Removal & Replacement
As previously mentioned in section 7.8, it is much easier to remove the rear refractory to inspect
the combustion chamber of the unit. However if the front refractory must be removed, it must be
replaced with a new refractory, part no. 83028.
Front refractory removal and replacement requires that the Burner, Blower and Air/Fuel Valve
assemblies be removed to access and remove the front refractory. This accomplished by
performing the following steps:
Front Refractory Replacement Procedure
1. T urn off gas and electrical power to the unit.
2. Follow the instructions in section 7.7 for blower and Burner assembly removal. The
instructions in section 7.7 include removal of the Main Flame Detector, Pilot Burner
assembly and two Pilot Flame Detectors.
3. Disconnect the wires from the thermal switch on the upper portion of the front (Burner)
plate.
4. Remove all bolts EXCEPT for the one at the top of the plate.
5. While supporting the plate, remove the remaining bolt and slide the plate outward. The
front refractory and Burner Shield should slide out of the combustion chamber with the
plate.
6. Spray the refractory with a water mist to reduce airborne dust.
7. Remove the three (3) 10-32 screws securing the Burner Shield to the Burner Plate (Figure
7-9).
8. Place the Burner Shield on a flat surface with the three tabs facing upward.
9. Straighten the 90º bend in each tab so they are even with the sides of the Burner Shield
(Figure 7-9).
10. Place the new refractory (part no. 83028) and shield, blanket-side down, onto the plate.
Align the holes for mounting.
11. Place 1” diameter wood or metal dowels into the 2 large holes on the front plate.
12. Slide the refractory, blanket-side up, over the shield. Align the 3 holes in the refractory with
the 3 tabs on the Burner Shield. Bend the tabs 90º and align them with the 3 tapped holes
in the front plate.
13. Using a magnetized Phillips screwdriver, secure the Burner Shield to the plate using the
10-32 screws removed in step 7.
14. Reinstall the plate, with the new refractory, onto the combustion chamber. Ensure it is
properly aligned to prevent damage to the fiber material.
15. Reassemble the items removed in section 7.7, steps 18 through 20.
I
MPORTANT
Following front refractory (P/N 83027) replacement, a two (2) hour burn-in
period at a 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.