Lochinvar 1, 000 Condensate Testing, Replenishing the Neutralizer, Condensate Trap Installation

Many codes will require the acidic condensate to be neutralized before it can be placed in a drain system. The optional condensate management system consists of a neutralizer kit to control the pH of the liquid discharged to a drain system. The neutralizer in the condensate management system consists of an industrial grade, non-corrosive plastic reservoir for collection of the condensate. The reservoir is charged with a reagent grade calcium carbonate. The initial calcium carbonate fill is shipped installed in the reservoir. The top to the reservoir is sealed and held in place with two straps. It is not necessary to open the reservoir before placing the neutralizer in service. The reagent grade calcium carbonate should fill approximately 3/4 of the reservoir in an even layer over the bottom. The condensate outlet from the appliance must be piped to the reservoir inlet. A barbed fitting is provided for connection to the appliance condensate drain hose (lower hose). The drain from the condensate drain tee in the venting system may also be routed to the reservoir inlet for disposal of any condensate formed in the flue. This would be accomplished by adding a field installed tee to the hose assembly. Ensure that a trap is provided in the drain line from the flue to prevent flue gases from escaping with the condensate. The condensate collects in the reservoir where it is in direct contact with the calcium carbonate. As the reservoir fills, it provides an extended residence time to neutralize the condensate. The neutralized condensate exits from the reservoir outlet to the condensate trap.

When the condensate level in the reservoir raises to the drain, the pH is controlled to a range of 6.5 to 7 before exiting the system. (A pH of 7 is neutral. As the pH number increases in numerical value, the relative acidity of the discharge decreases.) The neutralized condensate may then be discharged into a suitable drain system without fear of damage to the drain system. Ensure that the top remains on the reservoir keeping it sealed to prevent any contamination to the treatment process.

Condensate Testing

The initial fill of reagent grade calcium carbonate should sustain neutralization for 3 months of operation. An appliance operating at higher temperatures will produce condensate at lower levels allowing the calcium carbonate to remain effective as a neutralizer for a maximum of 6 months. The pH of the neutralized condensate discharged from the reservoir should be checked at 30 day intervals. A pH meter or indicating test strips may be used to monitor the relative acidity of the condensate. When the pH of the condensate discharged from the reservoir can not be maintained above a pH of 6.0, the calcium carbonate must be recharged. Recharge packages of reagent grade calcium carbonate are available from your distributor.

Replenishing the Neutralizer

All of the depleted calcium carbonate must be removed from the reservoir and properly disposed of. Rinse and clean the reservoir thoroughly before adding the new charge to the system. Ensure that the piping to and from the reservoir is clear with no obstructions. Add the new reagent grade calcium carbonate in an even layer over the bottom of the reservoir. Replace the top on the reservoir, replace the two straps to secure the top and return the appliance to service. Check the related piping for leaks on the initial firing after the system is recharged.

Condensate Trap Installation

1.Locate the condensate trap kit shipped loose with the appliance. The kit includes a sheet metal mounting base, two (2) nuts and the condensate trap.

2.Install the condensate trap mounting base on the rear of the appliance in the lower left-hand corner as depicted in Figure 73. Use the pre-drilled holes on the appliance to secure the mounting base to the appliance.

3.Secure the condensate trap to the base using the two (2) nuts supplied with the kit. The trap should be oriented so that the barb connections are pointing toward the appliance (Figure 73).

4.Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap.

5.Locate the two hoses exiting the back of the appliance. Attach the larger hose on the appliance to the lower barb connection on the condensate trap. Secure the hose to the barb with a field supplied hose clamp (Figure 73).

6.Attach the upper hose on the unit to the upper barb connection on the condensate trap. Secure the hose to the barb with a field supplied hose clamp (Figure 73).

7.Route the wire connector harness from the condensate trap to the matching connector on the lower back of the appliance as shown in Figure 73. This is the blocked drain safety switch. This switch will shut the appliance off if the condensate trap becomes too full of liquid.

8.Place the appliance in operation. While the appliance is firing, check the 1/2" connection on the condensate trap for flue gas spillage. If spillage is detected, check the routing of the hoses from the appliance to the condensate trap and verify that the trap is level.

9.If spillage is still occurring, shut the appliance off. Remove the four (4) screws securing the top cover to the condensate trap and remove the cover (Figure 73).

10.Locate the plastic ball inside the float tube. The ball prevents flue gas spillage from the condensate trap when there is not enough liquid in the trap to raise it and drain. Verify there is nothing under the ball causing it to not seat properly.

11.Replace the top cover on the condensate trap. Re-install the four (4) screws removed in Step 9 to secure the top cover.

12.A 1/2" pipe connection is supplied on the condensate trap. Connect a suitable pipe or tube to this connection (see Figure 73).