Lochinvar 90 Clear Area, Inspection of Heat Exchanger Waterways, Pilot Flame Adjustment Procedure

Page 59

Installation & Service Manual

8 Maintenance (continued)

p.Check “V” baffles on top of the heat exchanger. Remove and clean if necessary.

q.Remove soot from the heat exchanger with a stiff bristle brush. Soot may also be removed from the heat exchanger by washing thoroughly with

detergent and water. Remove the heat exchanger before using water for cleaning. Rinse thoroughly

and dry before re-installing. Use a vacuum to remove loose soot from surfaces and inner chamber.

r.Remove the heat exchanger (HEX) filler bracket (FIG. 8-2).

s.The heat exchanger can be removed by sliding towards the front of the appliance. Once the heat exchanger is removed from the appliance, a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces.

t.Ensure that all burner ports are cleaned to remove any soot. See Inspection and Cleaning Procedure, page 58.

u.Carefully re-install the heat exchanger, “V” baffles, jacket panels, and wires.

v.Reassemble all gas and water piping. Test for gas leaks.

w.Cycle the appliance and check for proper operation.

Clear Area

1. Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

2.Check frequently to be sure the flow of combustion and ventilation air to the boiler is not obstructed.

Inspection of Heat Exchanger Waterways

Appliances operated in hard water areas should have periodic inspections of the tubes to be sure that no sediment or scale accumulates on the heat transfer surfaces. Inspection plugs are located at both ends of the heat exchanger. Inspection plugs should be removed and tubes inspected at the end of the first 45 days of operation and again at the end of 90 days of operation. If no scale accumulation is observed, inspections can be made at the end of each six months of operation.

Pilot Flame Adjustment Procedure

The pilot flame should envelop 3/8" to 1/2" (10 to 13mm) of the tip of the thermocouple (see FIG. 8-3).

1/2"

UPPER FRONT

JACKET PANEL

DETAIL

FLAME

ROLL-OUT SWITCH /

INTERLOCK SWITCH

LOWER FRONT

JACKET PANEL

HEX FILLER BRACKET

Figure 8-2_Outer Air Deflector and HEX Filler Bracket

Water Circulating Pump

Inspect pump every 6 months and oil if required. Use SAE 30 non-detergent oil or lubricant specified by pump manufacturer.

Figure 8-3_Pilot Flame on Thermocouple

a.Remove pilot adjustment cover screw on the gas valve. See the Gas Valve illustrations in the Lighting Instructions section (page 41) for the location of the cover screw.

b.Turn the inner adjustment screw clockwise to decrease or counterclockwise to increase pilot flame.

c.Replace the pilot adjustment cover screw on the valve. Tighten firmly after adjustment to prevent gas leakage.

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Contents Models 90,000 500,000 Btu/hr Contents Checking equipment Please read before proceedingCodes Copper-fin =B=R Rating RatingsCopper-fin Specifications Gas connection pipe Copper-fin How it worksModels CWN270 Front View Model CWN399 Front View 422 Location of unit Determine unit location3Combustion Air Direct from Outside Determine boiler location6Combustion Air from Outside Single Opening Minimum Recommended Combustion AIR Supply to Equipment Room Vent Pipe Sizes VentingConventional Negative Draft Venting System Venting Less from Ridge From Parapet Wall Vertical Vent Termination ClearancesNumber Masonry Chimney InstallationVent Materials Sidewall Venting7CB with Vent Damper and Vent Damper Terminal Block Automatic Vent DamperManifold Pressure Gas connectionsGas Supply Gas Pressure Test Gas ConnectionGas Piping Install Piping to ControlClockwise to raise regulator gas pressure, counterclockwise Gas Manifold Pressure Adjustment Procedure4Gas Supply Pressure Checking Gas Supply PressureTwo Stage Burner Control System Combination Gas ValvesVenting of Combination Gas Valves Relief Valve Water Flow Switch if equippedHydronic piping General Plumbing Rules Typical Heating Boiler InstallationsLow Water Cutoff if equipped Minimum Required Flow For Heating BoilerPiping of the Boiler System System Temperature Rise ChartCirculator Pump Requirements Heat Exchanger Pressure Drop ChartCirculator Pump Specifications Water Connections Heating Boilers OnlyPrimary/Secondary Boiler Piping Boiler Flow Rates Three Way Valves4Primary / Secondary Piping of a Single Boiler Primary / Secondary PipingNot to Exceed 4 Pipe DIA or MAX. of 12 Apart 8Multiple Boilers Zoned with Circulators Electrical connections Terminal Strip WiringBoiler Operating Temperature Control Power Venter Connection to Terminal StripOperating Temperature Control Temperature AdjustmentPump Wiring for a Heating Boiler Maximum Set Point Determination Locating Temperature ControlTemperature Control Settings Maximum SET Point DeterminationOutdoor Air Temperature Sensor Temperature Control SensorsInlet Water Temperature Sensor Multi-Purpose Temperature SensorInstallation of a Tank Sensor Water Heater Application Outdoor Air Reset OptionInstallation of a Remote Sensor Boiler Application Additional Temperature Controls Manual Reset High Water Temperature Limit Control Blocked Vent and Flame Roll-Out / Flame Interlock SwitchInitial Start-up Pre-start ChecklistStart-up 1Gas Valve 90,000 270,000 Btu/hr Models Lighting InstructionsTo Turn OFF GAS to Appliance Safety Shutoff Test For Standing Pilot Ignition SystemOperating Instructions To Turn Off Gas to Appliance Safety Shutoff Test for Spark Ignition Pilot SystemIntermittent Pilot Spark Ignition System F9/M9 Freeze ProtectionFreeze Protection for a Heating Boiler System if required Water TreatmentDomestic Water Heaters 90,000 500,000 Btu/hr Models Required Temperature RiseRequired Temperature Rise Domestic water heatersPump Operation Water ChemistrySoftened Water Systems 1Single water heatersingle tank 2Single water heatermultiple tank 3Multiple water heatersingle tank Heat Exchanger Remote Sensor InstallationThermostat Settings Minimum Pump Performance5Danger Warning Cathodic Protection Water Flow Switch if equippedPressure Only Relief Valve Thermal ExpansionSee the User’s Information Manual for instructions Maintenance and annual startupService technician Owner maintenanceMaintenance Check Relief Valve Check Expansion TankPerform Start-up and Checks Check All WiringCheck Control Settings Combustion Air AdjustmentInspection and Cleaning Procedure Inspect and Clean BurnerHeat Exchanger / Burner Access Water Circulating Pump Pilot Flame Adjustment ProcedureClear Area Inspection of Heat Exchanger WaterwaysGas Train and Controls Review with ownerTroubleshooting Pilot or replace 90,000 270,000 Btu/hr Models DiagramsSchematic Diagram F1 Unit Wiring Diagram F1 Unit315,000 399,999 Btu/hr Models Schematic Diagram F9 UnitWiring Diagram F9 Unit Diagrams Diagrams Page Revision a ECO #C06290 initial release CFA-I-S Rev a 09/10
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