Lochinvar 500, 90 service manual Inspect and Clean Burner, Heat Exchanger / Burner Access

Page 58

Installation & Service Manual

8Maintenance

Inspect and Clean Burner

￿WARNING The combustion chamber insulation in this appliance contains ceramic fiber material. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline Silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this appliance are below the level to convert ceramic fibers to

cristobalite. Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite.

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines:

￿Avoid breathing dust and contact with skin and eyes.

•Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on

the jobsite conditions. Current NIOSH recommendations can be found on the NIOSH website at (http://www.cdc.gov/niosh/homepage.html). NIOSH approved respirators, manufacturers and phone numbers are also listed on this website.

•Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

￿Apply enough water to the combustion chamber lining to prevent airborne dust.

￿Remove combustion chamber lining from the appliance and place it in a plastic bag for disposal.

￿Wash potentially contaminated clothes separately from other clothing. Rinse clothes thoroughly.

￿NIOSH stated First Aid:

Eye: Irrigate immediately.

Breathing: Fresh air.

Heat Exchanger / Burner Access

a.Turn “OFF” main power to the appliance.

b.Turn “OFF” external manual gas shutoff valve to appliance.

c.Remove the control panel door.

d.Remove the outer air deflector (FIG. 8-2).

e.Disconnect gas valve wiring and remove gas manifold assembly.

f.Remove ignition wire leading to the pilot assembly from the ignition module.

g.Disconnect the wiring from the flame rollout/interlock switch, see FIG. 8-2, page 59.

h.Remove the lower front jacket panel.

i.Remove the control panel mounting screws. When removing the control panel, lay the control panel to the side with the wiring intact, being careful not to damage any of the wiring.

j.Remove the combustion chamber door. Use caution to prevent damage to burners, refractory, pilot or wiring.

Inspection and Cleaning Procedure

￿ DANGER

When cleaning burner, DO NOT use a

 

steel wire brush as it may spark and create

 

 

a hazardous situation causing property

 

damage, serious injury, or death. Use a

 

soft bristle brush when cleaning burner.

k.Check the heat exchanger surface for sooting. The external surfaces of the copper tubes should be free of any soot deposits. (A slight black smudge is normal with some types of gases.) If abnormal soot deposits are present, the heat exchanger must be cleaned and the cause of the soot problem corrected. Proceed as follows:

l.Remove soot from burners and bottom of the finned tubes with a stiff bristle brush. Dirt may also be removed from burner ports by rinsing the burner thoroughly with water. Drain and dry burners before re-installing. Damaged burners must be replaced.

An appliance installed in a dust or dirt contaminated atmosphere will require cleaning of the burners on a 3 to 6 month schedule or more often, based on severity of contamination. Contaminants can be drawn in with the combustion air. Non-combustible particulate matter such as dust, dirt, concrete dust or dry wall dust can block burner ports and cause non-warrantable failure. Use extreme care when operating an appliance for temporary heat during new construction. The burners will probably require a thorough cleaning before the appliance is placed in service.

m.Remove gas manifold as described in steps a. through e. in “Heat Exchanger/Burner Access.”

n.Loosen mounting screws and remove front control panel.

o.Loosen screws on the upper front jacket panel and remove toward front of the appliance. Use caution to prevent damage to refractory on the doors inner surface.

58

Page 57 Page 59
Image 58
Page 57 Page 59
Contents Models 90,000 500,000 Btu/hr Contents Please read before proceeding Checking equipmentCodes Ratings Copper-fin =B=R RatingCopper-fin Specifications Copper-fin How it works Gas connection pipeModels CWN270 Front View Model CWN399 Front View 422 Determine unit location Location of unitDetermine boiler location 3Combustion Air Direct from Outside6Combustion Air from Outside Single Opening Minimum Recommended Combustion AIR Supply to Equipment Room Conventional Negative Draft Venting System VentingVent Pipe Sizes Venting Vertical Vent Termination Clearances Less from Ridge From Parapet WallSidewall Venting Masonry Chimney InstallationVent Materials NumberAutomatic Vent Damper 7CB with Vent Damper and Vent Damper Terminal BlockGas Connection Gas connectionsGas Supply Gas Pressure Test Manifold PressureInstall Piping to Control Gas PipingGas Manifold Pressure Adjustment Procedure Clockwise to raise regulator gas pressure, counterclockwiseChecking Gas Supply Pressure 4Gas Supply PressureVenting of Combination Gas Valves Combination Gas ValvesTwo Stage Burner Control System Hydronic piping Water Flow Switch if equippedRelief Valve Minimum Required Flow For Heating Boiler Typical Heating Boiler InstallationsLow Water Cutoff if equipped General Plumbing RulesSystem Temperature Rise Chart Piping of the Boiler SystemWater Connections Heating Boilers Only Heat Exchanger Pressure Drop ChartCirculator Pump Specifications Circulator Pump RequirementsPrimary/Secondary Boiler Piping Three Way Valves Boiler Flow RatesPrimary / Secondary Piping 4Primary / Secondary Piping of a Single BoilerNot to Exceed 4 Pipe DIA or MAX. of 12 Apart 8Multiple Boilers Zoned with Circulators Power Venter Connection to Terminal Strip Terminal Strip WiringBoiler Operating Temperature Control Electrical connectionsPump Wiring for a Heating Boiler Temperature AdjustmentOperating Temperature Control Maximum SET Point Determination Locating Temperature ControlTemperature Control Settings Maximum Set Point DeterminationMulti-Purpose Temperature Sensor Temperature Control SensorsInlet Water Temperature Sensor Outdoor Air Temperature SensorInstallation of a Remote Sensor Boiler Application Outdoor Air Reset OptionInstallation of a Tank Sensor Water Heater Application Additional Temperature Controls Blocked Vent and Flame Roll-Out / Flame Interlock Switch Manual Reset High Water Temperature Limit ControlStart-up Pre-start ChecklistInitial Start-up Lighting Instructions 1Gas Valve 90,000 270,000 Btu/hr ModelsSafety Shutoff Test For Standing Pilot Ignition System To Turn OFF GAS to ApplianceOperating Instructions Freeze Protection Safety Shutoff Test for Spark Ignition Pilot SystemIntermittent Pilot Spark Ignition System F9/M9 To Turn Off Gas to ApplianceWater Treatment Freeze Protection for a Heating Boiler System if requiredDomestic water heaters Required Temperature RiseRequired Temperature Rise Domestic Water Heaters 90,000 500,000 Btu/hr ModelsSoftened Water Systems Water ChemistryPump Operation 1Single water heatersingle tank 2Single water heatermultiple tank 3Multiple water heatersingle tank Minimum Pump Performance Remote Sensor InstallationThermostat Settings Heat Exchanger5Danger Warning Thermal Expansion Water Flow Switch if equippedPressure Only Relief Valve Cathodic ProtectionOwner maintenance Maintenance and annual startupService technician See the User’s Information Manual for instructionsMaintenance Check Expansion Tank Check Relief ValveCombustion Air Adjustment Check All WiringCheck Control Settings Perform Start-up and ChecksHeat Exchanger / Burner Access Inspect and Clean BurnerInspection and Cleaning Procedure Inspection of Heat Exchanger Waterways Pilot Flame Adjustment ProcedureClear Area Water Circulating PumpReview with owner Gas Train and ControlsTroubleshooting Pilot or replace Wiring Diagram F1 Unit DiagramsSchematic Diagram F1 Unit 90,000 270,000 Btu/hr ModelsWiring Diagram F9 Unit Schematic Diagram F9 Unit315,000 399,999 Btu/hr Models Diagrams Diagrams Page Revision a ECO #C06290 initial release CFA-I-S Rev a 09/10
Top Page Image Contents