Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
OMM-0086_0D
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, NY 10913
Page
103
of
210
GF-133
Ph.: 800-526-0288
03/20/14
Rear Refractory Replacement Procedure –
Continued
7. Remove all of the bolts from the rear plate, EXCEPT for the one at the top of the plate.
8. Loosen (but DO NOT remove) the top bolt and slide a thin metal object (such as a
hacksaw blade) between the rear plate and the fiber material of the rear refractory to
separate the material from the plate.
The rear plate weighs approximately 40 pounds. Therefore, it is
recommended that 2 people be used when removing the plate.
9. Remove the top bolt from the plate and remove it from the unit.
10. Refer to Figure 7-8 and note the position of the rear refractory. Prior to refractory removal,
mark as necessary using a permanent marker or tape.
11. Gently pull on the two opposing metal tabs located on the outer edge of the fiber blanket,
then alternately pull on the other two opposing tabs. Continue this process until the fiber
refractory package can be removed from the combustion chamber.
12. Place the fiber insulation package, metal face down, in a safe location to avoid damage.
13. The combustion chamber can now be viewed and inspected with a full view of the Burner
assembly and rear tubesheet.
14. Following inspection, reinstall the components in the reverse order that they were
removed.
IMPORTANT
If the rear refractory (P/N 83027) was damaged during removal, it
should be replaced with a new part. If rear refractory replacement
is required, a 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.
15. Tighten the bolts on the rear plate using an alternating pattern to ensure a uniform seal.
Torque bolts to approximately 20 ft-lbs.
16. To avoid exhaust leaks, ensure that a uniform seal is established when reconnecting the
flue system to the boiler.
CAUTION
