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Benchmark 2500DF-3000DF Installation, Operation & Maintenance Manual
7.6 BURNER ASSEMBLY INSPECTION
The burner assembly is located at the top of the unit's heat exchanger. The burner assembly may be hot.
Therefore, allow the unit to cool sufficiently before removing the burner assembly.
In order to do this procedure most efficiently with a minimum of steps, a
simple support rig has been designed to hold up the blower and Air/Fuel
Valve assembly while the blower plenum is removed to allow the burner
assembly to be removed for maintenance. Using this support will relieve
the blower's weight from bearing down upon the connection to the gas
train. This support rig prevents having to dismantle the entire blower and
A/V Valve assembly from the gas train. The support rig is available as an
after-market part.
The following parts will be required for reassembly after burner inspection:
Part No.
88173
81180
81185
81048
To inspect or replace the burner assembly, proceed as follows:
Burner Assembly Inspection and Maintenance Procedures
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit and turn off the gas supply.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up.
This will disengage the shroud from the four (4) pins in the side panels.
3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure
7-2.
4. Remove the two (2) screws securing the flame detector to the plate. The flame detector is
secured to the burner plate with one (1) #10-32 screw and one (1) #8-32 screw.
5. Remove the flame detector and gasket from the burner plate.
6. Disconnect the cable from the igniter-injector.
7. Using a 7/16" open-end wrench, disconnect the compression nut securing the gas injector
tube of the igniter-injector to the elbow of the staged ignition assembly (see Figure 7-2).
Disconnect the staged ignition assembly from the igniter-injector.
8. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end
wrench.
9. Retrieve the blower support rig and attach it to the blower and unit as described in the
instructions provided with the rig.
10. Loosen and remove the four 5/16x1-3/4" bolts, washers, and nuts from the burner plenum
where it is attached to the blower (see Figure 7-4a & 7-4b).
11. Remove the eight (8) 3/8-16 nuts, using a 9/16" (or 11/16") wrench, attaching the blower
plenum to the burner beneath (see Figure 7-4a and 7-4b).
Page 96 of 234
05/21/2014
CHAPTER 7 – MAINTENANCE
Description
Burner Upper Release Gasket
Burner Gasket (Middle)
Burner Lower Release Gasket
Flame Detector Gasket
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
NOTE
OMM-0099_0A
GF-145
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