Lochinvar Comprehensive Crest Service Manual for Efficient Boiler Maintenance

Service Manual

2 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 of the Crest Installation and Operation 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.

35