Lochinvar 3 Review with owner, Cleaning boiler heat exchanger, Handling ceramic fiber materials

Page 57

Installation & Operation Manual

11 Maintenance (continued)

Review with owner

1.Review the Crest User’s Information Manual with the owner.

2.Emphasize the need to perform the maintenance schedule specified in the Crest User’s Information Manual (and in this manual as well).

3.Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

4.Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

Cleaning boiler heat exchanger

1.Shut down boiler:

•Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 9 - Startup.

•Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2.Allow time for the boiler to cool to room temperature if it has been firing.

3.Remove the top access panel to remove the gas/air manifold assembly.

4.Remove the nuts securing the burner to the burner mounting plate. Remove the burner (FIG. 11-2).

5.Remove the nuts securing the burner mounting plate from the heat exchanger and set aside. Remove the entire burner mounting plate assembly.

￿WARNING The boiler contains ceramic fiber materials. Use care when handling these materials per

instructions on this page. Failure to comply could result in severe personal injury.

6.Use a vacuum cleaner to remove any accumulation on the tube sheet surfaces. Do not use any solvent.

7.Brush the heat exchanger (tube sheet, combustion chamber walls, and tube entry) while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum the heat exchanger.

8.Finish cleaning using a clean cloth dampened with warm water.

9.Temporarily remove the condensate drain line from the condensate trap and route directly to a drain.

10.Rinse out debris with a low pressure water supply. The water will drain through the condensate connection.

11.Allow the heat exchanger to thoroughly dry.

12.Reconnect the condensate drain line to the condensate trap.

13.Close isolation valves on piping to isolate boiler from system. Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the boiler.

14.When securing the burner, be sure to tighten the nuts, but DO NOT over-tighten. Tighten the nuts to a torque setting of no more than 6.2 ft.-lbs. When securing the burner mounting plate be sure to tighten the nuts, but DO NOT over-tighten. Tighten the nuts to a torque setting of no more than 15.5 ft.-lbs.

15.Replace the burner mounting plate assembly and gas/air manifold assembly. Ensure gaskets are in good condition and positioned properly. Restore boiler to operation.

16.Perform start-up and check-out procedures in the Check Flame and Combustion - Section 9 - Startup on pages 42 and 44 of this manual.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

￿WARNING The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. 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

job

site

conditions.

 

Current

NIOSH

recommendations

can

be found

on

the

NIOSH

website

at

http://

w w w . c d c . g o v / n i o s h / h o m e p a g e . 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 the combustion chamber lining from the boiler and place it in a plastic bag for disposal.

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

NIOSH stated First Aid.

Eye: Irrigate immediately.

Breathing: Fresh air.

 

57

 

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Contents Save this manual for future reference Contents Please read before proceeding When servicing boilerBlowers Crest How it worksCrest How it works Models 1.5 2.0 2.5 3.0 Crest Ahri Rating RatingsRecommended clearances for service access Installation must comply withDetermine boiler location Before locating the boiler, checkFlooring and foundation Provide air openings to roomVent and air piping Prevent combustion air contaminationWhen using an existing vent system to install a new boiler Products to avoidAreas likely to have contaminants When removing a boiler from existing common vent system Remove boiler from wood pallet 7Combustion Air from Outside Single Opening Minimum Recommended Combustion AIR Supply to Equipment Room General venting Direct ventingOptional room air Air inlet pipe materials Install vent and combustion air pipingAir intake/vent connections Approved Stainless Steel Vent Manufacturers Make ModelRemoving from existing vent Common venting Vent/air termination vertical Vertical direct ventingDetermine location Prepare roof penetrations4Alternate Vertical Terminations with Multiple Boilers Multiple vent/air terminationsVent/air termination sidewall Sidewall direct venting2Clearance to Doors and Windows Prepare wall penetrations4Multiple Vent Terminations must also comply with Figure Room airHydronic piping Circulator sizing Model20F 40F 60F Near boiler piping components Ball Valve Multiple Boilers Common Header Primary / Secondary Flow For all equipment and detailing required by local codes AIR Seperator Drain Port Typical System Supply Sensor Connecting gas supply piping Gas connectionsModel Gas Inlet Size Propane Gas Natural gasCheck inlet gas supply GAS Piping Size ChartGas Pressure Gas valve replacementField wiring Installation must comply withLine voltage connections Outdoor temperature sensor EnableLouver proving switch Low voltage connectionsAlarm contacts Auxiliary switch 1Wiring of the cascade System supply sensorField WiringCondensate drain Condensate disposalStart-up Freeze protection when usedCheck/control water chemistry Fill and test water systemCheck thermostat circuits Check for gas leaksInspect condensate system Inspect/check condensate lines and fittingsStart the boiler Final checks before starting the boilerIf boiler does not start correctly Check system and boilerFor Your Safety Read Before Operating Gas Natural Gas Propane Valve Set space heating operationVerify HWG circulator mode Set HWG target temperature Configuration of the cascadeSet clock General Operating informationProtection features Outdoor reset operation, if used Boiler temperature regulationCascade Sequence of operation Home Screen Crest control module2Main Menu Screen Service technician Maintenance Maintenance and annual startupOwner maintenance See the Crest User’s Information Manual for InstructionsMaintenance Check water system Flue vent system and air pipingCheck expansion tank Check boiler relief valveCheck all boiler wiring Check ignition ground wiringCheck control settings Check flame signalReview with owner Cleaning boiler heat exchangerHandling ceramic fiber materials Niosh stated First AidIntegrated Control Diagrams2Wiring Diagram
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3, 2, 3.5, 2.5 specifications

The Lochinvar 2, 3, 3.5, and 2.5 models are a standout lineup in the realm of commercial and residential water heating solutions. Known for their advanced technology and high efficiency, these units cater to a wide range of applications, ensuring optimal performance and reliability.

One of the key features of the Lochinvar models is their robust construction. Each unit is designed to withstand rigorous operational demands while providing excellent thermal efficiency. They are equipped with stainless steel heat exchangers, which offer superior resistance to corrosion and extend the lifespan of the equipment. This durability is essential for both commercial and residential settings where demand can vary significantly.

The Lochinvar 2, 3, 3.5, and 2.5 models utilize innovative control systems that enhance their operational efficiency and user convenience. The built-in Smart Control technology allows for easy monitoring and adjusting of system parameters, ensuring that users can maintain optimal performance with minimal effort. This feature is especially beneficial in commercial settings where large volumes of hot water are required, as it enables users to effectively manage their energy consumption.

Energy efficiency is another hallmark of the Lochinvar lineup. With high-efficiency ratings, these models help reduce energy costs significantly, making them an environmentally friendly option for heating water. The use of advanced combustion technology ensures that these units can deliver maximum heat output with minimal fuel consumption.

Additionally, the Lochinvar models are designed with safety and reliability in mind. They feature multiple safety controls and diagnostics that alert users to potential issues before they escalate, providing peace of mind. The integration of advanced venting options allows for flexible installation configurations, accommodating various building layouts and space requirements.

In summary, the Lochinvar 2, 3, 3.5, and 2.5 models define modern water heating technology with their combination of durability, efficiency, and advanced features. With their innovative design and user-friendly controls, they meet the demanding needs of both commercial and residential users, making them a top choice in the water heater market. Whether for new installations or replacements, these units deliver reliable performance and value.
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