User Manual
Contents
1. PILOT WITH THERMOCOUPLE PILOT WITH SPARK IGNITION Figure 2 4_Pilot with Thermocouple and Spark Ignition 1 With the main burners on and firing unscrew the thermocouple connection from the gas valve FIG 2 4 and remove from the fitting The main gas valve should extinguish the burners immediately after removal of the thermocouple If burners do not extinguish immediately follow steps in To Turn Off Gas To Appliance Immediately call a qualified serviceman or installer to repair an ignition system that fails to operate properly and shut down the burners After successful completion of test turn the control knob on the gas valve clockwise to the OFF position Do not force Carefully reconnect the thermocouple to the gas valve Follow the Lighting Instructions to relight the pilot and establish normal operation 10 Copper Fin User s Information Manual Lighting Instructions for Spark Ignition Pilot Models F9 M9 Models 90 000 through 500 000 Btu hr Input FOR YOUR SAFETY READ BEFORE OPERATING A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor becaus2. not pop up when released stop and immediately call your gas supplier If the pilot will not stay lit after several tries turn the gas 9 Turn the control knob on the gas valve counterclockwise control to OFF and call your service technician or gas to the PILOT position supplier 11 Turn the gas control knob on the gas valve counterclockwise to the ON position Figure 2 3_Lighting Wand 12 Turn on all electric power to the appliance 13 Re install the lower panel door 14 Set the thermostat to the desired setting ise AEE D SUDSLIED LIGHTER OR TEE 15 Re install the control panel door FACTORY SUPPLIED LIGHTING WAND TO LIGHT THE STANDING PILOT TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to the OFF position NOTICE The information package shipped NOTICE with the appliance contains a wire 2 Turn off all electric power to the appliance if service is to lighting wand The loop end of the be performed wand will hold a match The wand extends your reach to the pilot and 3 Turn the gas control knob on the gas valve clockwise to makes lighting the pilot easier see the OFF position Do not force FIG 2 3 A WARNING Should overheating occur or the gas fail to shut off turn off the external manual gas valve to the appliance 2 Operating instructions Safety Shutoff Test For Standing Pilot Ignition System
3. performed by a qualified service installer service agency or the gas supplier A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors What to do if you smell gas Do not try to light any appliance Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Warranty Installation and service must be performed by a qualified service installer service agency or the gas supplier Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 Excessive water hardness causing a lime scale build up in the copper tube is not the fault of the equipment and is not covered under the manufacturer s warranty Refer to the Water Treatment an
4. the boiler pressure temperature gauge to make sure the system is pressurized Lift the relief valve top lever slightly allowing water to relieve through the valve and discharge piping If water flows freely release the lever and allow the valve to seat Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain Ifthe valve weeps lift the seat again to attempt to clean the valve seat If the valve continues to weep afterwards contact your qualified service technician to inspect the valve and system If water does not flow from the valve when you lift the lever completely the valve or discharge line may be blocked Immediately shut down the appliance Call your qualified service technician to inspect the appliance and system Shut appliance down unless boiler is used for Domestic Water 1 Follow To Turn Off Gas to Appliance on page 9 of this manual Do not drain the system unless exposure to freezing temperatures will occur Do not drain the system if it is filled with an antifreeze solution DO NOT shut down boilers used for domestic water heating they must operate year round 2 Operating instructions Lighting Instructions for Standing Pilot Models F1 Models 90 000 through 270 000 Btu hr Input FOR YOUR SAFETY READ BEFORE OPERATING A WARNING If you do not follow these instructions exactly a fire or explosion may result causing propert
5. Copper Fin User s Information Manual Models 90 000 500 000 Btu hr A WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Save this manual for future reference HAZARD DEFINITIONS cecceeceeeeeeeeeeteeeeeeeees 2 2 OPERATING INSTRUCTIONS eee 8 11 PLEASE READ BEFORE PROCEEDING 3 4 Revision NOTES sscssccacsscatsissesatigaceceieneesersesasviczcsae Back Cover 1 MAINTENANCE SCHEDULE 00 ceeeteees 5 Maintenance Procedures eeceeeeeeeeseeeeeeeneeeeeeneeereees 6 Appliance Must Be Serviced and Maintained 6 Check Appliance Area eeccetceeeeeeeneesereeeneeeeeeeeretaes 6 Check Pressure Temperature Gauge 6 Check Vent Piping ceccceseseeeeeeeteneeeeeeseaeetseeeeaeenaes 6 Check Air Piping
6. b on the gas valve clockwise to the line on the collar around the knob Depress the knob and continue rotation to the OFF position 7 Wait five 5 minutes to clear out any gas then smell for gas including near the floor If you smell gas STOP Follow the steps in the What To Do If You Smell Gas section in the safety information this page If you do not smell gas go on to the next step 8a 90 000 135 000 and 399 999 500 000 Btu hr models rotate the gas control knob on the gas valve counterclockwise to the ON position 8b 180 000 360 000 Btu hr models rotate the gas control knob on the gas valve counterclockwise to the line on the collar around the knob Allow the knob to pop up and continue rotation to the ON position 9 Turn on all electric power to the appliance 10 Set the thermostat to the desired setting 11 Re install the control panel door 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier To Turn Off Gas to Appliance 1 Set the thermostat to the OFF position 2 Turn off all electric power to the appliance if service is to be performed Copper Fin User s Information Manual 3a 90 000 135 000 and 399 999 500 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the OFF position Do not force 3b 180 000 360 000 Btu hr models rotat
7. d Water Chemistry section in the Copper Fin Installation and Service manual 2 Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer s warranty Refer to Boiler Flow Rates and Temperature Rise for flow requirements section in the Copper Fin Installation and Service manual A WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or additional information consult a qualified installer service agency or the gas supplier Checking equipment Upon receiving equipment check for signs of shipping damage Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on the packing slip with those actually received In case there is damage or a shortage immediately notify the carrier Do not use this appliance if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced A Owner warning NOTE Retain this manual for future reference The information contained in this manual is intended for use by qualified professional installers service technicians or gas suppliers Consult your local expert for p
8. e some gas is heavier than air and will settle to the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced 2 Operating instructions Operating Instructions 1 STOP Read the safety information first 2 Remove the control panel door 3 Set the thermostat to the lowest setting OFF 4 Turn off all electrical power to the appliance 5 This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand 6a 90 000 135 000 and 399 999 500 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the OFF position 6b 180 000 360 000 Btu hr models rotate the gas control kno
9. e the gas control knob on the gas valve clockwise to the line on the collar around the knob Depress the knob and continue rotation to the OFF position Do not force Should overheating occur or the gas fail to A WARNING shut off turn off the external manual gas valve to the appliance Safety Shutoff Test Ignition Pilot System for Spark 1 Turn OFF gas supply to the appliance 2 Turn thermostat to highest setting 3 Turn electric power ON 4 Pump relay pulls in to start pump 5 The ignition will begin sparking at the pilot 6 The ignition module will lock out after the trial for ignition period 7 Immediately call a qualified serviceman or installer to repair an ignition system that fails to lock out and properly shut down burner operation 8 After successful completion of the test readjust the thermostat to normal setting 9 Turn ON gas supply 10 Turn power OFF then ON to reset ignition module 11 If ignition system fails to operate properly repair work must be performed by a qualified serviceman or installer Intermittent Pilot Spark System The ignition module is not repairable Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty ignition module must be replaced with a new module Ignition 11 t Lo High Efficiency Wate
10. fumes could reach the appliance or vent air intake system Codes The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Where required by the authority having jurisdiction the installation must comply with the Canadian Association Code CAN CGA B149 1 and or local codes This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas fired appliances ANSI Z21 13 and ANSI Z21 10 3 User s Information Manual Copper Fin User s Information Manual 1 Maintenance schedule Service technician Refer to the Copper Fin Installation and maintenance Service manual General Check appliance area Check pressure temperature gauge Address reported problems Inspect i
11. it off Press the RESET button on the low water cutoff to turn the unit back on Copper Fin User s Information Manual 1 Maintenance schedule continued Check appliance piping gas and water i Access the appliance and perform a gas leak inspection per steps 1 through 7 of the Operating Instructions on page 8 If gas odor or leak is detected immediately shut down the boiler and call a qualified service technician Visually inspect for leaks around water piping Also inspect the circulators relief valve and fittings Immediately call a qualified service technician to repair any leaks A WARNING Have leaks fixed at once by a qualified service technician Failure to comply could result in severe personal injury death or substantial property damage Operate relief valve 1 Before proceeding verify that the relief valve outlet has been piped to a safe place of discharge avoiding any possibility of scalding from hot water A WARNING To avoid water damage or scalding due to valve operation a metal discharge line must be connected to the relief valve outlet and run to a safe place of disposal This discharge line must be installed by a qualified heating installer or service technician in accordance with the instructions in the Copper Fin Installation and Service Manual The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge Read
12. lammable materials Do not store combustible materials gasoline or any other flammable vapors or liquids near the appliance Remove immediately if found 2 Air contaminants Products containing chlorine or fluorine if allowed to contaminate the appliance intake air will cause acidic condensate in the boiler This will cause significant damage to the boiler if allowed to continue A WARNING Failure to inspect the vent system as noted above and have it repaired by a qualified service technician can result in vent system failure causing severe personal injury or death Check vent piping 1 Visually inspect the vent piping to be sure it is unobstructed Inspect the entire length of the vent piping to ensure piping is intact and all joints are properly sealed 2 Call your qualified service technician if you notice any problems Check relief valve 1 Inspect the appliance relief valve and the relief valve discharge pipe for signs of weeping or leakage 2 If the relief valve often weeps the expansion tank may not be working properly Immediately contact your qualified service technician to inspect the appliance and system Test low water cutoff if installed 1 Ifthe system is equipped with a low water cutoff test the low water cutoff periodically during the heating season following the low water cutoff manufacturer s instructions Reset button low water cutoff 1 Testing the low water cutoff shuts the un
13. lve clockwise to the OFF position Figure 2 1_Gas Valve 90 000 270 000 Btu hr Models F 1 GAS VALVE 90 000 270 000 BTU MODELS SIDE OUTLET Wait five 5 minutes to clear out any gas then smell for gas including near the floor If you smell gas STOP Follow the steps in the What To Do If You Smell Gas section in the safety information If you do not smell gas go on to the next step Remove the lower panel door to gain access to the pilot Find the pilot Follow the metal tube from the gas valve to the pilot The pilot is located on the right side of the burner approximately centered in the burner tray Copper Fin User s Information Manual 2 Operating instructions continued 10 Use the loop end of the wire lighting wand shipped with the instruction package to hold the match and reach the pilot An access slot is provided in the lower front jacket panel beside the burner to insert the lighting wand and match to the pilot Lift the pilot cover FIG 2 3 to access the pilot Push down and hold in the red button on the gas valve This should start gas flow to the pilot Continue to hold the red button in for about one 1 minute after the pilot is lit Release the button and it will pop back up The pilot should remain lit If the pilot goes out repeat steps 5 through 10 Figure 2 2_Pilot Location Pilot Location TOP OF FLAME SPREADER TO BE FLUSH WITH TOP OF BURNER O O If the red button does
14. nterior clean and vacuum if necessary Check for leaks water gas flue Examine venting system Check vent piping Monthly Check system water pressure Check relief valve system piping expansion tank Check control settings Check wiring connections Flame inspection stable uniform Test low water cutoff if used Periodically Check flue gas passageways Reset button low water cutoff Inspect and clean the burner Perform start up check out and performance verification Refer to the Startup section in the Copper Fin Installation and Service manual Q pes ao dp c lt Check appliance piping gas and water for leaks Every 6 months F rate relief valve If combustion or performance Operate indicate need e Clean heat exchanger Shut appliance down unless boiler used for domestic hot water e Remove and wash burner End of season months Copper Fin 1 Maintenance schedule Maintenance procedures Appliance must be serviced and maintained Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the appliance Failure to perform the service and maintenance could result in damage to the appliance or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage The appliance must be inspected and s
15. r Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com Revision Notes Revision A ECO C06290 initial release Revision B ECO C12077 reflects the update of ignition timing information on page 11 CFA USER Rev B 01 13
16. roper installation or service procedures Consult and follow all local Building and IMPORTANT fire Regulations and other Safety Codes that apply to this installation Consult your local gas utility company to authorize and inspect all gas and flue connections Your conventionally vented gas appliance must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance Copper Fin Please read before proceeding A WARNING To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules 1 Boilers and water heaters are heat producing appliances To avoid damage or injury do not store materials against the appliance or the vent air intake system Use proper care to avoid unnecessary contact especially children with the appliance and vent air intake components 2 Never cover your appliance lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to your appliance 3 UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance vent air intake system or any location from which
17. siiacndecianicis divans 6 Check Relief Valve ceeeesectesceeseeeeneeteeeseaeeeeeeeeaeenses 6 Test Low Water Cutoff if installed 00 0 eee 6 Reset Button low water cutoff 0 ee eeeeeeeereeeees 6 Check Appliance Piping gas and water ee 7 Operate Relief Valve oo ceceeeceeeeeeeseeeeeeeeneeeeeeeneeees 7 Shut Appliance DOWN missust airaa 7 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER aa indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION a indicates a potentially hazardous situation which if not avoided may result in minor or moderate CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not CAUTION avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Copper Fin User s Information Manual Please read before proceeding NOTICE This is a gas appliance and should be installed by a licensed electrician and or certified gas supplier Service must be
18. tarted annually at the beginning of the heating season by a qualified service technician In addition the maintenance and care of the appliance designated on page 5 of this manual and explained on pages 6 through 7 must be performed to assure maximum appliance efficiency and reliability Failure to service and maintain the appliance and system could result in equipment failure causing possible severe personal injury death or substantial property damage notice following information provides detailed instructions for completing the maintenance items listed in the maintenance schedule on page 5 In addition to this maintenance the appliance must be serviced and started up at the beginning of each heating season by a qualified service technician Check appliance area A WARNING To prevent potential of severe personal injury death or substantial property damage eliminate all materials discussed below from the appliance vicinity and the vicinity of the appliance combustion air inlet If contaminants are found Remove products immediately from the area If they have been there for an extended period call a qualified service technician to inspect the appliance for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to re pipe vent and air piping and locate vent termination air intake away from contaminated areas User s Information Manual 1 Combustible f
19. y damage personal injury or loss of life A This appliance has a pilot which must be ignit ed by hand When lighting the pilot follow these instructions exactly B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Copper Fin User s Information Manual Lighting Instructions 1 2 STOP Read the safety information first Remove the control panel door Set the thermostat to the lowest setting OFF Turn off all electrical power to the appliance Turn the gas control knob on the gas va
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