Lochinvar 45,000 - 260,000 BTU/HR service manual Inspection and Cleaning, Breathing Fresh air

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Installation & Service Manual

7Maintenance (continued)

￿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.

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. 7-2)

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. 5-8, page 38.

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.

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

Inspection and Cleaning

j.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:

k.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.

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

m.Loosen mounting screws and remove front control panel.

n.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.

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

p.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.

q.Remove the heat exchanger (HEX) filler bracket (FIG. 7-2).

r.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.

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Contents Models 45,000 260,000 Btu/hr Contents Please read before proceeding WarrantyCodes Ratings Solution Boiler =B=R RatingTemperature and pressure gauge Solution How it worksSolution How it works Solution How it works Location of unit Determine boiler location3Combustion Air Direct from Outside 6Combustion 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 ClearancesFan Assisted Venting Masonry Chimney InstallationSidewall Venting Negative Draft Vent Materials7Vent Damper and Vent Damper Terminal Block Automatic Vent DamperGas Connection Gas connectionsGas Supply Gas Pressure Test Gas Piping Install Piping to Control2Wrench 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 equippedWater connections 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 ChartWater Connections Circulator Pump Operation Circulator Pump SpecificationsPrimary/Secondary Boiler Piping Boiler Flow Rates Low Temperature Bypass RequirementsFull Flow Application Make UP Water Primary / Secondary PipingMake UP Water 6Multiple Boilers Zoned with Circulators From System Full System Flow8Single Boiler Full System Flow with Low Temperature Bypass Auxiliary Device Connection to Terminal Strip Terminal Strip WiringBoiler Operating Temperature Control Electrical connectionsAMP Draw Data Temperature AdjustmentMaximum Set Point Determination Maximum SET Point DeterminationInstallation of Remote Sensors Outdoor Air Temperature SensorWiring of Remote Sensors Additional Temperature Controls Outdoor Air Reset Option7Blocked Vent Switch Location Blocked Vent and Flame Roll-Out / Flame Interlock SwitchLighting Instructions for Spark Ignition Pilot Models Pre-start ChecklistStart-up Initial Start-upTo Turn Off Gas to Appliance Safety Shutoff Test for Spark Ignition Pilot SystemOperating Instructions Ignition and Control Timings Intermittent Pilot Spark Ignition SystemFreeze Protection Water TreatmentSee the User’s Information Manual for instructions Maintenance Maintenance and annual startupService technician Owner maintenanceMaintenance Check Relief Valve Check Expansion TankPerform Start-up and Checks Check All WiringCheck Control Settings Heat Exchanger / Burner AccessBreathing Fresh air Inspection and CleaningWater Circulating Pump Review with ownerInspection of Heat Exchanger Waterways Gas Train and ControlsTroubleshooting Guide M9 Solution Boilers Troubleshooting45,000 260,000 Btu/hr Models DiagramsSchematic Diagram M9 Unit Wiring Diagram M9 Unit 45,000 260,000 Btu/hr ModelsPage Revision a ECO #C03746 initial release SBR-I-S Rev a

45,000 - 260,000 BTU/HR specifications

Lochinvar, a leader in high-efficiency heating solutions, presents the Lochinvar line of boilers, specifically the Lochinvar 45,000 - 260,000 BTU/HR models. These boilers are designed to meet a wide range of heating demands, making them ideal for residential and commercial applications alike.

One of the key features of the Lochinvar boilers is their impressive efficiency rating. Utilizing advanced condensing technology, these units can achieve efficiencies of up to 96% AFUE (Annual Fuel Utilization Efficiency). This high efficiency not only reduces fuel consumption but also lowers utility bills, making it a cost-effective solution for heating needs.

The Lochinvar boilers are equipped with a powerful heat exchanger constructed from durable stainless steel. This design not only maximizes heat transfer but also enhances the longevity of the unit. By preventing corrosion and minimizing maintenance requirements, the stainless steel heat exchanger ensures that the boiler operates at peak performance for years.

Another significant aspect of the Lochinvar boilers is their modulating burner system. This technology allows the boiler to adjust its output based on demand, ensuring that it only uses the energy necessary to maintain the desired temperature. This feature not only improves efficiency but also contributes to a more comfortable indoor environment by minimizing temperature fluctuations.

The Lochinvar series also showcases a user-friendly control interface. The advanced LCD display allows for easy monitoring and adjustment of system settings. Connectivity options are often included, providing the ability to integrate with modern building management systems for enhanced control and diagnostics.

Safety features abound in the Lochinvar models, which include built-in safeguards such as temperature and pressure relief valves, flame detection systems, and modulation cut-off to protect against overheating and other hazardous conditions.

Moreover, these boilers are designed for easy installation and maintenance. Compact dimensions and lightweight design facilitate straightforward setup, even in tight spaces. Additionally, users can take advantage of the unit’s self-diagnostic capabilities to simplify troubleshooting and reduce downtime.

In conclusion, the Lochinvar 45,000 - 260,000 BTU/HR boilers represent a pinnacle of innovation in heating technology. With high efficiency, advanced control systems, durable components, and safety features, they stand out as reliable and effective solutions for a variety of heating applications, ensuring comfort and efficiency in any environment.
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