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1. 1 Ave HOLIMS Ids NV 1 ISAS HOSNIS lt NOSN3S HOlVH3dO ONIOIAH3S 380438 LOANNOOSIG PR LolI EE gt aq w5 z SWITCH B P GY IGNITION MODULE TIMER PROVING C FAILURE CONTACTS IVENTERREL Y c VENTER OPTIONAL ITEMS 315 amp 360 ONLY BOX DEPICTS ce TR yl v y Q L TANK SENSOR 24VDC RELAY X LOUVER RELA 3S R NG 1 1 4 H TRANSFORMER SPILL 6 PUMP 1 CIRCULATION SWITCH L Y 3 O BK 1 J os rl R THERMOSTAT Eu MANUAL RESET HIGH LIMIT ARMING RELAY ARMING RELAY RED TAN WHITE TELLOW PK R T W Y 24VDC RELAY BK LOW AWER CUTOFF R L Y P VENT DAMPER ROLLOUT SWITCH CN1 1 OPERATOR CN1 2 J OFF RELAY GRAY ORANGE PINK PURPLE OPERATOR T L OFF RELAY GY OR PK PR BK BL 120 GROUND LINE IGNITION MODULE CUTOFF PR GY PR CN1 4 OPERATOR CN1 3 T 315 amp 360 ONLY 4 VENT DAMPE AUTO RESET HIGH LIMIT 5 WATER 1 BROWN GREEN BL BLACK BLUE CONTACTS ON ANY FAILURE BK BL BN G LBL2727 REV Installation amp Service Manual Copper Fin lagram s continued 10 p V 69107197 7 SWALI TWNOILdO S LOId3q ed 9 Un 315 000
2. CHIMMEY WALL OR PARAPET Figure 2 4_Vent Termination from Flat Roof 10 or Less from Parapet Wall 10 OR MORE HEIGHT ABOVE PARAPET REQUIRED WHEN DISTANCE FROM WALLS OR PARAPETS IS MORE THAN 10 CHIMNEY WALL OR PARAPET Figure 2 5 Vent Termination from Flat Hoof More Than 10 from Parapet Wall The vent can not terminate below grade bottom of the vent terminal shall be located at least 12 inches 30cm above grade To avoid a blocked vent condition keep the vent cap clear of snow ice leaves debris etc Flue gases will form a white plume in winter Plume could obstruct window view Flue gas condensate can freeze on exterior surfaces or on the vent cap Frozen condensate on the vent cap can result in a blocked vent condition Flue gas condensate can cause discoloration of exterior building surfaces Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate NOTICE Examine the venting system at least once a year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration Immediately correct any problems observed in the venting system 2 Ventin Q continued Masonry Chimney Installation A masonry chimney must be properly sized for the installation of a gas fired appliance Venting of an appliance into a cold or oversized masonry chimney can r
3. terat tao 45 Checking Gas Supply Pressure 22 7 DOMESTIC WATER HEATERS Combination Gas 23 Water Velocity Control 46 4 HYDRONIC PIPING Required Temperature Rise 46 Relief Valve 24 Water Chemistry 46 Water Flow Switch if equipped 24 Softened Water Systems 47 Low Water Cutoff if equipped 25 u LU wa u naa 47 Typical Heating Boiler Installations 25 26 Figure 7 1 Single Water Heater Piping w Single Tank 48 Piping of the Boiler System 26 Figure 7 2 Single Water Heater Piping w Multiple Tanks 49 Water Connections Heating Boilers Only 27 Figure 7 3 Multiple Water Heater Piping w Single Tank 50 Circulator Pump Requirements 27 Remote Sensor Installation 51 Circulator Pump Specifications 27 Heat Exchanger 51 Circulator Pump Operation Heating B
4. ETUR Oy hin T XS y t uh EAS tet w oe Y NN n ow ek gt P i i L Ld d p amp i Ey 5 L k N 7 V V Figure 2 3_Vent Termination from Peaked Roof More than 10 from Ridge The vent terminal should be vertical and exhaust outside the building at least 2 feet 0 61m above the highest point of the roof within a 10 foot 3 05m radius of the termination The vertical termination must be a minimum of 3 feet 0 91m above the point of exit A vertical terminal less than 10 feet 3 05m from a parapet wall must be a minimum of 2 feet 0 61m higher than the parapet wall The vent cap should have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment The venting system shall terminate at least 3 feet 0 9m above any forced air inlet within 10 feet 3 05m The venting system shall terminate at least 4 feet 1 2m below 4 feet 1 2m horizontally from or 1 foot 30cm above any door window or gravity air inlet into any building Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area 16 10 OR LESS H 10 OR LESS 4
5. 5 Pump is sized to heater input and water hardness Care should be taken to size the pump correctly See Water Chemistry this page The standard pump selection is based on the following pipe and fittings from the unit to the storage tank 2 ball valves 1 cold water tee 6 90 elbows 2 unions Plus the following length of straight pipe based on the heater Size 90 000 through 360 000 Btu hr Models Not more than 45 feet of straight pipe 399 999 through 500 000 Btu hr Models Not more than 25 feet of straight pipe For every elbow and tee in excess of those shown above DEDUCT 5 FEET from maximum allowable straight pipe in heater to tank circulating loop 47 Copper Fin Installation amp Service Manual 7 Domestic water heaters Figure 7 1 Single water heater single tank BALL VALVE BUILDING TYPICAL m COLD WATER FLOW CHECK 45 VALVE TYPICAL LP ON NS prod e MIXING VALVE K SUPPLY S EXPANSION TANK WATER SUPPLY UNION FLOW TYPICAL SWITCH TEMPERATURE amp PRESSURE RELIEF VALVE TYPICAL WATER HEATER WATER HEATER CIRCULATOR STORAGE Y STRAINER TANK DRAIN RECOMMENDED NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes Copper Fin Installation amp Service Manual f
6. Breathing Fresh air Exchanger Burner Access 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 8 2 e Disconnect gas valve wiring and remove gas manifold assembly 58 Copper Fin Installation amp Service Manual 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 8 2 page 59 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 j Remove the combustion chamber door Use caution to prevent damage to burners refractory pilot or wiring Inspection and Cleaning Procedure DANGER When cleaning burner DO NOT use a steel wire brush as it may spark and create a hazardous situation causing property damage serious injury or death Use a soft bristle brush when cleaning burner k 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 follow
7. A heat exchanger pressure drop chart Table 4C is provided to assist in proper pump selection Also provided is a System Temperature Rise Chart Table 4B This table provides GPM and boiler head loss at various temperature rises for each boiler based on Btu hr input Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing Example The boiler inlet temperature is 160 F and the boiler outlet temperature is 180 F this means that there is a 20 F temperature rise across the boiler The field installed boiler pump MUST NOT exceed 1 h p For continuous pump operation wire the system pump to the 120V supply The pump should be connected at the junction box as shown in FIG 4 3 Circulator Pump Specifications 1 Maximum operating pressure for the pump must exceed system operating pressure V TO 2 Maximum water temperature should not exceed CIRCULATION nameplate rating PUMP 3 Cast iron circulators may be used for closed loop Figure 4 3 Boiler Wiring Circulation Pump to Junction Box systems 4 A properly sized expansion tank must be installed near the boiler and located on the suction side of the pump 27 4 Hydronic piping PUMP INSTALLATION AND MAINTENANCE The boiler circulating pump must be purchased locally For installation and maintenance information on the circulator pump refer to the pump manufacturers instruction package included with the pump
8. Y STRAINER GAUGE RECOMMENDED EXPANSION TANK MAKE UP WATER BACK FLOW PREVENTER FLOW CHECK PRESSURE REDUCING VALVE TYPICAL VALVE BOILER CIRCULATOR BOILER UNION TYPICAL NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 31 Copper Fin Installation amp Service Manual 4 Hydronic piping Primary Secondary Piping Figure 4 8 Multiple Boilers Zoned with Circulators TEMPERATURE LOOP 3 TEMPERATURE LOO TEMPERATURE LOOP 1 AIR SEPARATOR RECOMMENDED SYSTEM SUPPLY TYPICAL l PRESSURE SENSOR SSURE WHEN USED FLOW CHECK VALVE MAKE UP WATER ALVE TYPICAL DRAIN POINT TYPICAL _ BACK FLOW PREVENTER lt 7 NOT EXC ED PRESSURE 12 APART REDUCING gt BOILER CIRCULATOR VALVE DRAIN TYPICAL MAY SUBSTITUTE LOW LOSS HEADER EXPANSION BOILER 2 TANK PRESSURE RELIEF TEMPERATURE VALVE PRESSURE GAUGE TYPICAL PRESSURE RELIEF FLOW CHECK VALVE INDIRECT DHW ALVE TYPICAL TANK ANTI SCALD MIXING VALVE BOILER 1 Our UNION TYPICAL DOMESTIC HOT WATER AN s CIRCULATOR COLD WATER IN NOTICE Please note that these illustrations are meant to show system piping concept only the Installer is responsible for all equipment and detailing required by local codes 32 5 Electrical connections This ap
9. 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 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 Associatio
10. 399 999 Btu hr Models MeVdS J1nGOlN Ave iagram D iring W M9 Un 999 Btu hr Models Diagram ic 399 B 24VDC RELAY 120 Bk GROUND LINE 000 Schemat 315 TRANSFORMER MOTI3A A ALIHM M NVL L 14544 1 CN1 2 Y 7112 J OPERATOR LOW WATER CUTOFF L CN1 1 Y BL 2 5 VENT DAMPER 13 R THERMOSTAT W BL Ld 24VAC RELAY MNid yd JONVHO HO ANVHO AO9 r WALSAS HOSN3S an weno MOC E eb HOSN3S 0 i L3 TINI T7 SPILL SWITCH P PR 4 R MANUAL RESET HIGH LIMIT C PR ROLLOUT SWITCH PR WATER CUTOFF 3 W ANY JYNLYYJdAN AL SJH9IH dO 38lM ASN ONIHIM 9NIOYIdIY N3HM N3dH9 9 9 79 MOV 18248 AlddflS H3MOd SS SS 19 3x Hf wo 330170 ON 9 1 1NIOd 3S ov iso O Mov18 2 L E J SNIOIA 3S 3HOd38 YAMOd LO3NNOOSIQ uosNas PR VENTER RELAY VENTER PROVING IGNITION 24V MODULE GND a E lt 315 amp 360 ONLY OPTIONAL ITEMS 77 7 BOX DEPICTS L 11 IGH FIR FAILURE CONTACTS OUVER RELAY pe Y AR
11. Appliances and Equipment or applicable provisions of the local building codes Adequate combustion and ventilation air must supplied to the room where the appliance is installed in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes 13 2 Venting The distance of the vent terminal from adjacent buildings windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment Vent connection is made directly to the top of the appliance This appliance is designed with a built in draft diverter No additional external draft hood 15 required The connection from the appliance vent to the common vent or chimney must be made as direct as possible A Conventional Draft Venting System Negative The negative draft in a conventional vent installation must be within the range of a negative 0 02 to 0 05 inches water column to ensure proper operation All draft readings are made while the appliance is in stable operation approximately 2 to 5 minutes Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance
12. Figure 5 1 Terminal Strip Connections TABLE 5A TERMINAL STRIP WIRING Wire Gauge Allowable Length Power Venter Connection to Terminal Strip A terminal connection strip is provided for ease of connection for Power Venting Systems see FIG 5 1 inset A A field supplied powered venter or powered louver damper may be connected to the boiler via a terminal strip located on the left side of the unit see FIG 5 1 inset B A 24 VAC relay can be powered from this location when a call for heat has been established A proving switch can be interlocked back to the appliance to ensure its operation before the appliance is allowed to fire Reference the wiring diagrams on pages 63 through 66 of this manual 33 Copper Fin Installation amp Service Manual 5 Electrical connections Pump Wiring for a Heating Boiler The heating boiler circulating pump must be purchased TEMPERATURE locally The maximum load for the pump switched by the ue internal pump relay must not exceed 1 HP The current draw for a field installed 120 VAC pump MUST be added to the boiler s current draw to determine the minimum wire size EE for 120 volt service TABLE 5B AMP DRAW DATA FOR STANDARD FIRING CODES Maximum Total AMPs 120VAC MANUAL RESET HIGH LIMIT IF EQUIPPED TRANSFORMER Figure 5 3 Intermittent Pilot System 500 000 Btu hr Control Panel Temperature Adjustment Operating Temperature Control The tempera
13. IV Heating Boilers The relief valve s is mounted directly into the heat exchanger inside the header see FIG s 4 1 and 4 2 To prevent water damage the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year A CAUTION Avoid contact with hot discharge water 24 Water Flow Switch if equipped FLOW SWITCH Figure 4 2 Water Flow Switch CBN315 500 A water flow switch is available as a factory supplied option on all heating boilers and water heaters see section 7 The flow switch should be wired between terminals X and B Remove the jumper between the X and B terminals on the terminal strip This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition A flow switch installed with the factory supplied minimum adjustment setting requires a specific minimum flow to make the switch and start burner operation The flow rate required is a function of the diameter of pipe and tee used for installation Ensure that the pump installed on the boiler will supply adequate flow to make the flow switch contacts and operate the appliance Copper Fin Installation amp Service Manual 4 Hydronic p
14. all strainers in the system and check for debris 8 Recheck all air vents as described in step 4 General Plumbing Rules 25 4 9 10 12 13 14 15 315 000 258 300 Hydronic piping Inspect the liquid level in the expansion tank The system must be full and under normal operating pressure to ensure proper water level in the expansion tank Ensure that diaphragm type expansion tanks are properly charged and not water logged Start the boiler according to the Section 6 Start Up Instructions in this manual Operate the system including the pump boiler and radiation units for one hour Recheck the water level in the expansion tank If it exceeds half the tank volume open the tank to reduce the water level Recheck pressure charge on diaphragm type tanks Shut down the entire system and vent all radiation units and high points in the system Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris Reopen the water makeup valve Verify system pressure with the boiler pressure gauge before beginning regular operation Within three days of start up recheck and bleed all air vents and the expansion tank using these instructions TABLE Copper Fin Installation amp Service Manual Piping of the Boiler System The drawings in this section see FIG s 4 4 through 4 6 show typical heating boiler piping installations Before beginning the in
15. and 5 3 on page 34 located on the front side of the control panel A label on the control panel indicates the exact location of the manual reset high water temperature limit control Blocked Vent and Flame Roll Out Flame Interlock Switch BLOCKED VENT SWITCH INVERTED TO SHOW RESET UNDERNEATH DRAFT HOOD Figure 5 8 Blocked Vent Switch Location UPPER FRONT JACKET PANEL DETAIL FLAME ROLL OUT SWITCH INTERLOCK SWITCH LOWER FRONT JACKET PANEL HEX FILLER BRACKET Figure 5 9 Flame Roll Out Flame Interlock Switch Location All units are equipped with manual reset blocked vent and flame roll out flame interlock switches These temperature switches are located in the controls compartment and in the relief opening of the boiler s built in draft hood Each switch has a red reset button In the event the system has actuated to shut off the main burner gas supply wait for the boiler to cool then press the red reset to return the boiler to operation Operation of a blocked vent and or flame roll out interlock switch usually indicates a problem with the venting system obstruction of the heat exchanger flue gas passageway and or a combustion air supply problem The cause for operation of the blocked vent and or flame roll out interlock switch must be determined and corrected If the boiler cannot be restored to normal operation contact a qualified service installer service agency or the gas supplier 39 6 Sta
16. draft hood see FIG 2 7 Do not alter the wire harness supplied with the vent damper Follow the instructions supplied with the vent damper An appliance which is shut down or will not operate may experience freezing due to convective air flow down the flue pipe connected to the unit Proper freeze protection must be provided see Freeze Protection in the Startup Section of this manual A WARNING A CAUTION 3 Gas connections Gas Supply Verify that the appliance is supplied with the type gas specified on the rating plate This appliance is orificed for operation up to 2000 feet altitude The appliance will be derated 496 per 1000 feet above 2000 feet elevation Consult the factory for installations above 2000 feet elevation Field conversions for operation at high altitude must be performed by certified personnel only The appliance will be marked to indicate suitability for high altitude operation GAS SUPPLY PRESSURE Measured at the inlet pressure tap located upstream of the combination gas valve s see FIG s 3 5 and 3 6 page 23 TABLE 3A GAS SUPPLY PRESSURE Natural Gas Min Inches Water Column a Min Inches Water Column Models 90 000 360 000 Btu hr Only Models 399 999 500 000 Btu hr Only Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment Max Inches Water Column MANIFOLD PRESSURE Measured at the pressure tap on
17. first year to determine Inspection interval Check all joints and pipe connections for tightness corrosion or deterioration Clean louvers and or screens in the combustion air intake system as required Have the entire system including the venting system periodically inspected by a qualified service agency Check water system Inspect appliance interior 1 Remove the outer access panels and inspect the interior of the appliance 2 Vacuum any sediment from inside the appliance and components Remove any obstructions Check all piping for leaks Listed below are items that must be checked to ensure safe reliable operation Verify proper operation after servicing A WARNING Eliminate all system or appliance leaks Continual fresh makeup water will reduce appliance life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 3 Gas Connections Verify all system components are correctly installed and operational Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 PSI Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Ex
18. gas supplier If the pilot will not stay lit after several tries turn the gas control to OFF and call your service technician or gas supplier Turn the gas control knob on the gas valve counterclockwise to the position Turn on all electric power to the appliance Re install the lower panel door Set the thermostat to the desired setting Re install the control panel door TO TURN OFF GAS TO APPLIANCE Set the thermostat to the OFF position Turn off all electric power to the appliance if service is to be performed Turn the gas control knob on the gas valve clockwise to the OFF position Do not force Should overheating occur or the gas fail to shut off turn off the external manual gas valve to the appliance Installation amp Service Manual Safety Shutoff Test For Standing Pilot Ignition System PILOT WITH THERMOCOUPLE PILOT WITH SPARK IGNITION Figure 6 4 Pilot with Thermocouple and Spark Ignition 1 With the main burners and firing unscrew the thermocouple connection from the gas valve FIG 6 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 c
19. hardness to 0 grains which may result in long term problems in the system Softened water will usually have a lower pH which can be aggressive and corrosive causing non warrantable damage to the heater pump and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions As water is heated it becomes less soluble The dissolved minerals and solids will precipitate and collect as scale if water velocity is not properly controlled Follow the temperature rise requirements for unsoftened water Consult the manufacturer when heating potable water with hardness or total dissolved solids exceeding these specifications Heating of high hardness and or high total dissolved solids water may require a larger circulating pump an optional cupro nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated Softened Water Systems Decreasing the flow rate will reduce the erosion process however the heat exchanger should be monitored to ensure the scale liming process is not made worse The unit should be placed on a comprehensive inspection schedule until optimum flow rates can be established Problematic water areas may require heat exchanger inspection every two weeks The total scale accumulation should never exceed the thickness of a piece of paper Should scale accumulation exc
20. piping concept only the installer is responsible NOTICE n U for all equipment and detailing required by local codes 50 7 Domestic water heaters Minimum Pump Performance Based on heating potable water with a hardness of 8 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm See Water Chemistry page 47 BTU hr INPUT GPM Et Hd 90 000 500 000 30 8 Remote Sensor Installation Water heaters are provided with an extra temperature sensor that MUST BE field installed The sensor is shipped loose in the I amp O packet This remote mounted sensor will be the primary temperature sensor which will inform the appliance s built in thermostat control For domestic water heating the sensor MUST BE installed into a bulbwell on the storage tank This is required to maintain the desired temperature in the tank and reduce cycling of the heater The sensor must also be connected to two blue wires provided in the upper left hand corner of the control panel It will be necessary to add additional wire to reach from the appliance to the remote water source Use twisted pair wire minimum 18 gauge or larger See Table 5A page 33 regarding distance versus wire gauge EXTERNAL SENSOR FOR TANK SYSTEM OR PUMP DELAY REMOTE SENSOR CONNECTOR IS 2 AND LOCATED ON SIDE OF UNIT WITH SENSOR PROVIDED CONNECTIONS ARE POLARITY INSENSITIVE SIDE PANEL Figure 7 4_External Sensor for Tank System or P
21. temperature on the initial boiler on cycles The exact temperature set point is based on your system s requirements Turn the control set point dial to the desired operating water temperature Observe the boiler discharge temperature after each set point adjustment to ensure proper operation Room Thermostat or Remote Thermostat Connection to Terminal Strip A room thermostat or remote temperature control may be connected to the boiler The room thermostat should be installed on an inside wall away from the influences of drafts hot or cold water pipes lighting fixtures televisions sun rays or fireplaces Follow the manufacturers instructions supplied with the thermostat for proper installation and adjustment The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection FIG 5 1 Copper Fin Installation amp Service Manual Remove the jumper between the R and W terminals on the terminal strip Refer to the chart in this section Table 5A to determine maximum allowable length and wire gauge recommended to connect the switching contacts of the room thermostat to the R and W terminals on the terminal strip Connection to the terminal strip will allow the room thermostat to make and break the 24 VAC boiler control circuit turning the boiler on and off based on the room ambient temperature requirements Set the boiler operating temperature control as described in this section
22. to gain access to the thermostat 3 Locate the sensor in the kit Determine the location of the remote sensor and measure the amount of wire needed to connect the sensor to the thermostat See Wiring of Remote Sensors on page 36 for guidelines 4 Use twisted pair wire minimum 18 gauge or larger See Table 5A page 33 regarding distance versus wire gauge Ensure all wire insulation is trimmed to reveal at least 3 8 of exposed wire 5 Connect the measured wire to the sensor wire using wire caps see FIG 5 5 Install 250 x 032 insulated female quick connect terminals to the end of the wires Feed the wires through the access hole located on the back of the unit and secure the connectors to the thermostat connections Sys Tank CN5 and CN6 located in the upper right hand of the thermostat 6 Turn on the electrical power and the main manual gas shutoff to the appliance 7 Replace the side access panel 8 Fire the appliance and resume operation Installation of a Tank Sensor Water Heater Application 1 Turn OFF the main electrical power and the main manual gas shutoff to the appliance 2 Remove the side access panel from the appliance to gain access to the wire harness 3 Locate the two blue wires with a tag notating the remote thermostat sensor Feed the blue wires through the access hole located on the back of the unit NOTE It will be necessary to add additional wire to reach from the appliance to the remote
23. 0 000 Btu hr Model 60 Copper Fin Installation amp Service Manual Review with owner 1 2 Review the User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the appliance or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season 9 Troubleshooting Troubleshooting Guide 315 000 500 000 Btu hr Models Boilers 90 000 500 000 Btu hr Water Heaters F9 M9 step I Is the spark par ignitor sparking Yes Is the pilot Step 2 staying on Step3 Is the gas valve getting 24 VAC to the MV terminal Check voltage to and from the transformer Check incoming 120 VAC Copper Fin Installation amp Service Manual Check continuity on the spark Check for an open cable Check for 24 VAC on sensor If no open the 24v terminal gray wire sensor make sure on the ignition module there s a call for heat If call for heat is present replace temperature control Check the pilot tube for gas Check draft Is there 24 VAC purple wire on the 4 pin connector plug on the temperature controller Is there 24 VAC tan wire on the 4 pin Replace the connector plug on ignition modul
24. CFA I S Rev B Copper Fin Installation amp Service Manual Models 90 000 500 000 Btu hr A WARNING This manual supplies information for the installation operation and servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation Perform CERTIFIED steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Save this manual for future reference High Efficiency Water Heaters Boilers and Pool Heaters Contents HAZARD DEFINITIONS 2 5 ELECTRICAL CONNECTIONS PLEASE READ BEFORE PROCEEDING 3 4 Boiler Operating Temperature Control 33 5 6 Room Thermostat or Remote Thermostat Connection 33 THE COPPER FIN HOW IT WORKS 7 9 Power Venter Connection to Terminal Strip 33 1 DETERMINE UNIT LOCATION Pump Wiring for a Heating Boiler 34 Location of Unit 10 Temperature Adjustment 34 Clearances from Combustible Construction 10 Temperature Control Settings 35 Combustion and
25. Cubic 1 700 1 540 1 400 1 500 Foot of Gas and 3 000 2 720 2 500 2 340 9 60 Specific Gravity 23 500 16 100 15 100 10 000 9 000 8 300 7 690 7 380 6 870 6 150 5 640 5 130 4 720 Gas Piping 2 GAS VALVE GAS SHUTOFF 3 r A DRIP LEG EE 5 Figure 3 1_Gas Line Connection All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and 4 natural gas All piping must comply with local codes Tubing installations must comply with approved standards and practices Reference FIG 3 1 for a typical installation 5 Install Piping to Control r 1 The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier 20 Use new properly threaded black iron pipe free from chips If tubing is used make sure the ends are cut squared deburred and clean All tubing bends must be smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide proper volume of gas Run pipe or tubing to the gas valve or manifold inlet If tubing is used obtain a tube to pipe coupling to connect the tubing to the gas valve or manifold inlet DO NOT OVER TIGHTEN Over tightening may result in damage to the gas valves Val
26. Domestic water heaters continued Figure 7 2 Single water heater multiple tank BUILDING RETURN FLOW CHECK COLD WATER VALVE TYPICAL SUPPLY MIXING VALVE THERMOMETER HOT WATER SUPPLY UNION TYPICAL RELIEF VALVE TYPICAL EXPANSION TEMPERATURE PRESSURE GAUGE FLOW SWITCH TEMPERATURE amp PRESSURE RELIEF VALVE WATER TYPICAL HEATER WATER HEATER CIRCULATOR BALL VALVE TYPICAL STORAGE TANK lt di Y STRAINER TYPICAL w DP RECOMMENDED TYPICAL NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes Copper Fin Installation amp Service Manual 7 Domestic water heaters Figure 7 3 Multiple water heater single tank BUILDING RETURN lt lt lt COLD WATER SUPPLY FLOW CHECK S VALVE TYPICAL NS Z lt NN 2 Vo MIXING VALVE THERMOMETER EXPANSION TANK WATER RESSURE UNION TEMPERATURE P TYPICAL TYPICAL PRESSURE RELIEF VALVE TYPICAL FLOW SWITCH TYPICAL TEMPERATURE amp PRESSURE RELIEF VALVE TYPICAL BALL VALVE TYPICAL WATER HEATER ee WATER HEATER TANK DRAIN CIRCULATOR TYPICAL Y STRAINER RECOMMENDED TYPICAL Please note that these illustrations are meant to show system
27. ER pg CN1 4 NO B O PR Row 7 1 M M BARS 2 411 ASNVS ANY 3381 VveidimWa L S3H9IH WNOA dO 3Sn ONIHIM N3HM gt ONM1d 1 H31VM 4136 ov 430 O HOLIMS InOTIOH O 14544 HOLIMS 1195 5 380438 H3MOd LO3NNOOSIQ L GAS VALVE INLET SENSOR TANK SENSOR 24VDC RELAY AUTO RESET HIGH LIMIT GY OPERATOR GRAY GY BLACK BLUE BK LBL2728 REV 5 gt NOI LV 1 1O234IOS BOX DEPICTS OPTIONAL ITEMS Llc TAN WHITE YELLOW T W Y ORANGE PK PINK PR PURPLE OR BROWN GREEN BL BN G Manual ICE ion amp Servi iagram F9 Un D Installat iring e 000 399 999 Btu hr Models Copper Fin W 315 F9 Uni 999 Btu hr Models iagram 399 iagrams Schematic D 000 315 10 p AH C 2C181 7 771 NOTI3A A N33H9 9 2 L SIN3 LI TVNOILdO JLIHM M YNid yd NMO3J8 N8 a 101 NVI L 39NV3O HO 3n1g 18 xis dev L J MOV 1828 LO 1ld XO8 NOILONNAL A lddfiS H3MOd A 1d ASAOLND MuHvds 3un1lv3 WS3lVvM NO L9VLINOO JINGONWN E 198550 1309135 19595011 SYIS HOIH ov 340 HOLIMS
28. Freeze Protection 1 For water heaters and boilers that utilize the pump delay option if either the inlet sensor or the optional multi purpose temperature sensor reads below 40 F the pump relay will turn ON When the temperature rises above 50 F the pump relay will turn OFF 2 Location Heating boilers and water heaters must be located in a room having a temperature safely above freezing 32 0 3 Caution room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing The cold outside air pulled down the flue may freeze a heat exchanger This condition must be corrected to provide adequate freeze protection 4 Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze Follow the manufacturers instructions DO NOT use undiluted or automotive type antifreeze 5 snow screen should be installed to prevent snow and accumulation around the appliance venting system in cold climates Copper Fin Installation amp Service Manual 6 Start u D continuea 6 Shut down and Draining If for any reason the appliance is to be shut off the following precautionary measures must be taken a Shut off gas supply b c d Drain the unit completely Remove one threaded Shut off water supply Shut off electrical supply pl
29. If you cannot reach your gas supplier call the fire department C Useonly 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 6 Start u D continuea Lighting Instructions 2 STOP Read the safety information page 40 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 valve clockwise to the OFF position Figure 6 1 Gas Valve 90 000 270 000 Btu hr Models F 1 GAS VALVE 90 000 270 000 BTU MODELS 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 on page 40 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 locat
30. MING RELAY P INLET SENSOR SYSTEM SENSOR X O R FLOW cl SWITCH 24VDC RELAY OR GY ARMING RELAY WHITE YELLOW GAS VALVE OR Y T 1 1 CN7 R RED T TAN 4 O GY j VENT DAMPER CN8 CN1 3 OFF RELAY OFF RELAY GRAY ORANGE PINK PURPLE OPERATOR 315 360 ONLY PK PR L 4 GY OR AUTO RESET HIGH LIMIT IGNITION 1 CN1 4 PR CONTACTS ON ANY FAILURE Copper Fin Installation amp Service Manual 0 Diagrams Schematic Diagram F9 M9 Unit Wiring Diagram F9 M9 Unit 500 000 Btu hr Models 500 000 Btu hr Models 120 STANDARD ON WATER HEATERS 120V GROUND LINE OPTIONAL ON BOILERS NEUTRAL CIRCULATION PUMP CN9 LBL2726 REV A 4 1 BOILERS ONLY SHUTOFF VALVE BOILER ONLY BK R VENT VALVE 2 OPTIONAL LOUVER CONTACTSIPROVING LOUVE CONTACTS D OPERATOR H LOUVER MOTOR A TRANSFORMER p 24V BL CN1 1 OPERATOR CN1 2 E uw T Low WATER 2 60Hz NEUTRAL FIELD PROVIDED T TIME DELAY MOUNTED ON OPERATOR OPTIONAL SYSTEM TANK BL Y E d 24VAC RELAY 5 VENT DAMPER 13 O THERMOSTAT w1 LUC JW E ee BOILERS PR NEN ONLY Ww gt lt OPTIONAL I O RESET BOARD BOILER
31. NT ROOM Outside Air from Outside Air from 2 Openings Directly from Input Outdoors Btu hr To Bottom Opening Opening in 90 000 2 4 100 100 i 148 cm 148 cm 194 cm 291 cm 291 cm 646 cm 646 cm 6 9 1 Opening Directly from Outdoors in T Opening in Inside Air from 2 Ducts Delivered from Interior Space Top Opening in Outside Air from 2 Ducts Delivered from Outdoors Bottom Opening in Bottom Opening in 2 4 4 180 180 80 000 291 cm 291 cm 388 cm 581 cm 581 cm 1 162 cm 1 162 cm 2 2 5 2 270 000 6 135 155 270 270 439 439 581 cm 871 cm 871 cm 1 742 cm 1 742 cm2 2 2 2 100 100 134 200 399 999 646 cm 646 cm 865 cm2 1 291 cm 500 000 125 125 167 250 250 500 500 d 807 cm 807 cm 1 078 cm 1 613 cm 1 613 cm2 3 226 cm 3 226 cm2 1122 J 2 2 J 315 000 7 105 158 158 315 315 510 cm 510 cm 678 cm 1 020 cm 1 020 cm2 2 033 cm 2 033 cm 90 120 180 180 360 360 360 000 581 cm 581 cm 775 cm 1 162 cm 1 162 cm 2 323 cm2 2 323 cm 2 2 2 2 P 1 5 45 2 34 8 68 135 135 3000 220 220 cm 291 cm 439 cm 439 cm 871 cm 871 cm 0 90 in 3 3 30 2 2 2 2 34 45 2 2 2 2 5 5 60 2 2 9 I 50 50 67 100 100 200 200 29 299 323 cm 323 cm 433 cm 646 cm olo em 1 291 cm 1 291 cm 7 57 75 113 113 225 225 2 000 568 cm 368 cm 484
32. ONLY SEE MANUAL 100000 CONTACT FIELD PROVIDED Low eer PR ROLLOUT MANUAL RESET SPILL CUTOFF SWITCH HIGH LIMIT SWITCH 3 O 7 L PE 5 PR cu L SE Jj t Q LOH v2 9 Ave a MANUAL RESET LOW MANUAL RESET HIGH GAS isng sw GAS PRESSURE SW eo 1405 RELAY 1 Ir RELAY T VENTER FR vent DAMPER TO PROVING BK Jo Ed L A AUTO RESET HIGH LIMIT GASVALVE 1 LOW FIRE BE prd GAS VALVE y L IGNITION MV MV IGNITION PV PV MODULE GND ee SPLICE CHASSIS GROUND G SENSOR 55 FIELD INSTALLED SENSORWIRING GREEN GY GRAY RED ROLL OUT SWITCH BURNER G HIGH FIRE GAS VALVE W WHITE BL BLUE BK BLACK Y YELLOW PR PURPLE BR BROWN O ORANGE R M L SPLICE OPTIONAL MANUAL HIGH LIMIT OPTIONAL ADJUSTABLE HIGH LIMIT PR RESET R W DISCONNECT POWER BEFORE SERVICING SPILL SWITC SPLICE H 2 6 CN2 2 INLET SENSOR i z _DJLp s CN3 p 1301146 aomas EM OPERATOR cna if BOILERS SPLICE SYSTEM PUMP STANDARD ON STANDARD ON WATER HEATERS PUMP DELAY RELAY SYSTEM TANK SENSOR H HH STANDARD L CNS ON WATER m J OPTIONAL ON BOILERS STANDARD ON WATER HEATERS B OPTIONAL 31415 ON BOILERS OPTIONAL POWER VENTER r OFF
33. Primary Secondary Boiler Piping Heating boilers with inputs of 315 000 500 000 Btu hr or larger installed on multiple zone systems are recommended to be installed with a primary secondary piping system as shown in FIG 4 4 A primary secondary piping system uses a dedicated pump to supply flow to the boiler only This pump is sized based on desired boiler flow rate heat exchanger head loss and head loss in the secondary system piping only The secondary pump installed in the boiler piping ensures a constant water flow rate to the boiler for proper operation Boiler installation with a primary secondary piping system can prevent noise problems caused by low system water flows A primary secondary piping system is recommended on any boiler where low water flow conditions may present an operational problem A primary secondary piping system is ideal for systems filled with a propylene glycol and water mixture A glycol and water mixture is more dense than water only and may result in a lower boiler flow rate A lower boiler flow may cause noise on operation or short cycling of the burners A larger secondary pump may be used on a primary secondary system to pro vide an increased boiler flow rate A glycol and water system may require from 10 to 20 more flow to compensate for the increased density of the glycol and its effect on the heat transfer process in the boiler The exact increase in flow that may be required is based on the type and per
34. RELAY ARMING RELAY 6 OFF RELAY FAILURE CONTACTS R OPTIONAL ARMING RELAY PROVING SWITCH JUMPER CONTACTS ON ANY FAILURE m SWITCHES REMOTE BK BLACK GY GRAY BL BLUE OR ORANGE T TAN BOX DEPICTS BN BROWN PK PINK W WHITE OPTIONAL ITEMS G GREEN PR PURPLE Y YELLOW Li tS HIGH LIMIT Avay OVAOZCL LN3A 2VAVZ TWN OILdO 6272181 OPTIONAL AUTO RESET HIGH LIMIT THERMOSTAT 66 Notes 67 Revision Notes Revision A ECO C06290 r initial release y High Efficiency Water Hone Boilers and Pool Heaters Revision B ECO C0969 1 reflects the update 300 Maddox Simpson Parkway of AHRI ASME logos on pages 5 and 6 Lebanon TN 37090 CFA I S Rev 1 12
35. This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage 56 Copper Fin Installation amp Service Manual Following installation the valve lever A WIRING must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the appliance until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing Copper Fin 8 Maintenance continued Check Wiring 1 Inspectall wiring making sure wires are in good condition and securely att
36. This water heater hot water supply boiler is normally supplied with a temperature and pressure relief valve sized in accordance with applicable codes Units may be supplied with an optional pressure only relief valve When a water heater hot water supply boiler equipped with this optional relief valve is piped to a separate storage vessel the storage vessel must have a properly installed temperature and pressure relief valve which complies with local codes Thermal Expansion A relief valve which discharges periodically may be due to thermal expansion in a closed system A hot water supply boiler installed in a closed system such as one with a backflow preventer or check valve installed in the cold water supply shall be provided with means to control expansion Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug or cap the relief valve discharge Cathodic Protection Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipe as the hot water begins to flow There should be
37. Ventilation Air 11 13 Maximum Set Point Determination 35 2 VENTING Outdoor Air Reset Option 36 A Conventional Negative Draft Venting System 14 15 Additional Temperature Controls 38 39 Vertical Vent Termination Clearances 16 Blocked Vent and Flame Roll Out Flame Interlock Switch 39 Masonry Chimney Installation 17 6 STARTUP Inspection of a Masonry Chimney 17 da Ee ire AD 0 RR L LLULLU sii 40 Automatic Vent Damper 18 Lighting Instructions for Standing Pilot Models F1 40 42 3 GAS CONNECTIONS Safety Shutoff Test for Standing Pilot Ignition System 42 Gas SUDINY AMM 19 Lighting Instructions for Spark Ignition Pilot Models F9 M9 43 44 Gas Pressure Test a SN FU ES 19 Safety Shutoff Test for Spark Ignition Pilot System 44 Gas Connection nn rU TU ER SU Aras 19 Intermittent Pilot Spark Ignition System F9 M9 44 45 Gas PIONO uu u Aries pde m aa PER POTES 20 Freeze Protection I I a aa 45 Gas Manifold Pressure Adjustment Procedure 21 Water Treatment
38. a a temperature sensor and will initiate a call for heat when the water temperature drops below the setpoint plus the differential on the thermostat Temperature gauge CW models only The temperature gauge monitors the inlet temperature of the water heater as well as the outlet temperature Transformer The transformer reduces 120 VAC supply voltage to 24 VAC for the control circuit 15 16 17 18 19 20 21 22 23 Installation amp Service Manual Water inlet The water inlet is a 2 pipe connection that receives water from the system and delivers it to the heat exchanger Water outlet The water outlet is a 2 pipe connection that supplies water to the system Burner not shown The burner is a cylindrical stainless steel tube used to regulate burner flame Pilot not shown F9 and M9 models only The pilot is a spark ignition device is used to light a pilot flame which in turn is used to light the main burners F1 models only The pilot uses a standing flame to light the main burner Sight Glass not shown The sight glass provides a view of the burner surface burner flame and the pilot flame Temperature and pressure gauge CB models only The temperature and pressure gauge monitors the outlet temperature of the boiler as well as the system water pressure Pump shipped with CW models only The pump ensures adequate flow to operate the unit Pump relay The pump relay energ
39. ached Check Control Settings 1 Adjust settings if necessary See Section 5 Electrical Connections for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform Start up and Checks 1 Start appliance and perform checks and tests specified Section 6 Start up 2 Verify cold fill pressure is correct and that operating pressure does not go too high Check Burner Flame Visually check main burner flames at each start up after long shutdown periods or at least every six months burner viewport is located on the burner mounting flange A WARNING The area around the burner and burner viewport is hot Direct contact could result in burns Figure 8 1 Flame Pattern lllustration NORMAL YELLOW TIP D YELLOW FLAME FLAME LIFT Normal Flame A normal flame is blue with slight yellow tips with a well defined inner cone and no flame lifting Yellow Tip Yellow tip can be caused by blockage or partial obstruction of air flow to the burner s Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner s or excessive gas input This condition MUST be corrected immediately Lifting Flames Lifting flames can be caused by over firing the burner s or excessive primary air If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air Installation
40. amp Service Manual Combustion Air Adjustment This appliance uses an atmospheric combustion process Combustion air is provided to the burners by the gas injection pressure into the venturi of the burners The burners do not have an adjustable air shutter Adequate combustion air must be supplied to the room where the appliance is installed to ensure proper burner operation Check frequently to be sure the flow of combustion and ventilation air to the unit is not obstructed When the main burners light observe the burner flame Flames should be light blue in color with slight yellow tips flames should be settled on burner head with no lifting when supplied with correct volume of combustion air Check Flue Gas Passageways Any sign of soot around the outer jacket at the burners or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted appliances seldom need flue cleaning NOTICE All gaskets on disassembled components must be replaced with new gaskets on reassembly Gasket kits are available from your distributor 57 8 Maintenance Inspect and Clean Burner ZNWARNINGI The combustion chamber insulation of D D D UD Heat this appliance contains ceramic fiber material The International Agency for Researcho
41. andard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting Figure 1 4 Combustion Air Through Ducts 2 If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the room where the appliance is installed each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu hr 11cm2 per kW see FIG 1 4 B Figure 1 3 Combustion Air Direct from Outside 1 If air is taken directly from outside the building with no duct provide two permanent openings see FIG 1 3 a Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW This opening must be located within 12 30 cm of the floor 3 Ifairistaken from another interior space that is adequately ventilated each of the two openings specified above should Figure 1 5 Combustion Air from Interior Space b Ventilation air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW This opening must be located within 12 30 cm of the ceiling have a net free area of one square inch for ea
42. ater for cleaning Rinse thoroughly and dry before re installing Use a vacuum to remove loose soot from surfaces and inner chamber r Remove the heat exchanger HEX filler bracket FIG 8 2 s 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 t Ensure that all burner ports are cleaned to remove any soot See Inspection and Cleaning Procedure page 58 u Carefully re install the heat exchanger V baffles jacket panels and wires v Reassemble all gas and water piping Test for gas leaks w Cycle the appliance and check for proper operation UPPER FRONT JACKET PANEL 2 DETAIL FLAME ROLL OUT SWITCH INTERLOCK SWITCH LOWER FRONT JACKET PANEL HEX FILLER BRACKET Figure 8 2 Outer Air Deflector and HEX Filler Bracket Water Circulating Pump Inspect pump every 6 months and oil if required Use SAE 30 non detergent oil or lubricant specified by pump manufacturer Copper Fin Installation amp Service Manual Clear Area 1 Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 Check frequently to be sure the flow of combustion and ventilation air to the boiler is not obstructed Inspection of Heat Exchanger Waterways Applia
43. ations of the fan manufacturer and provide proper clearances from any combustion or ventilation openings windows doors or other openings into the building All induced draft fan installations must comply with local code requirements Fan Assisted Venting A Power Venter kit is available on models 90 000 135 000 Btu hr water heaters only TABLE 2B VENT MATERIALS Input Btu hr KIT3104 90 000 Rated 135 000 CPVC Rated Minimum Vent Length 12 Equivalent Feet ALL UNITS Maximum Vent Length 25 Equivalent Feet ALL UNITS Equivalent Feet 90 Elbow 5 Feet 45 Elbow 3 Feet Figure 2 6 CW135 with Fan Assisted Venting 17 2 Venting Automatic Vent Damper This heating boiler is design certified for use with the automatic vent damper FIG 2 7 part number printed on the boiler s rating plate A vent damper is optional on heating boilers above 360 000 Btu hr Automatic vent dampers are not required or furnished on potable water heaters Water heaters with inputs of 360 000 Btu hr and less may be ordered with the vent damper as an option A vent damper is a useful tool for saving energy when installed inside the living space where air can circulate freely around the appliance The vent damper will not save as much if any energy if it is installed in locations such as Unheated garage Attic Crawlspace Mechanical room that is vented outdoors For installation and maintenance
44. ay also require a larger circulating pump to achieve the specified flow against the increased head loss of multiple unit common manifold piping If the temperature rise 15 too low the water velocity is too high Adjust as follows l Slowly throttle the valve on the outlet side of the water heater until the temperature rise is steady at the required temperature rise as noted in Table 7A Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchanger This is a non warrantable failure Temperature rise must be properly adjusted to achieve the specified flow rate Required Temperature Rise Temperature rise is based on the hardness of the potable water to be heated The temperature rise specified 1s for water with a hardness of 5 to 25 grains per gallon The total dissolved solids shall not exceed 350 ppm TABLE 7A REQUIRED TEMPERATURE RISE Btu hr Flow Rate INPUT G Temperature Rise F 90 000 135 000 180 000 1922229 225 000 270 000 315 000 360 000 299 999 500 000 30 Copper Fin Installation amp Service Manual 7 Domestic water heaters continued Water Chemistry The required temperature rise and the standard pump sizing are based on the heating of potable water with chemistry within the specified limits Caution should be used when heating water softened to less than 5 grains per gallon Many commercial water softeners reduce
45. by poor wiring practices Twist the wires between the unit and the remote sensor Turn wires at least three or four turns per linear foot of wiring This provides protection against some types of electrical interferences l Do not route temperature sensor wiring with building power wiring 2 Donotlocate temperature sensor wiring next to control contactors 3 Do not locate temperature sensor wiring near electric motors 4 Do not locate temperature sensor wiring near welding equipment 5 Make sure good mechanical connections are made to the sensor any interconnecting wiring and the controller 6 Do not mount sensor with leadwire end pointing up in an area where condensation can occur 7 Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists Shielded cable is recommended on all cable runs of more than 25 feet in length NOTICE Ground the cableshield atthe connection to the boiler temperature control only Do not ground the shielded cable at the sensor end To maintain temperature accuracy sensor wires should be 18 AWG two conductor 18 2 Use shielded wire if required Copper Fin Installation amp Service Manual 5 Electrical connections continued Installation of a Remote Sensor Boiler Application 1 Turn OFF the main electrical power and the main manual gas shutoff to the appliance 2 Remove the side access panel from the appliance
46. centage of glycol added to the boiler system Consult the manufacturer of the glycol for additional recommendations when using a glycol and water fill for your boiler system 28 Copper Fin Installation amp Service Manual The installer must ensure that the boiler has adequate flow without excessive temperature rise The temperature rise on a multiple zone system should be made when only the zone with the longest length and or highest head loss is open Low system flow can result in overheating of the boiler water which can cause short burner on cycles system noise and in extreme cases a knocking flash to steam System noise may also indicate an oversized boiler At no time should the system pressure be S CAUTION less than 12 PSIG NOTICE A boiler operated with an inlet BOE temperature of less than 140 F 60 C must have a low temperature bypass to prevent problems with condensation A VAL3048 1 1 2 LTV Valve Kit may be used Follow the piping diagram in FIG 4 5 to complete installation 4 Hydronic piping continued Low Temperature Bypass Requirements This piping is like a primary secondary boiler installation with a bypass in the secondary boiler piping Inlet water temperatures below 140 F 60 C can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue Condensation can cause operational problems bad combustion sooting flue gas spillage and reduced s
47. cessive pressure rise indicates expansion tank sizing or performance problem Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents 55 8 Maintenance Check Expansion Tank Expansion tanks provide space for water to move and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed diaphragm or bladder type See Section 4 Hydronic Piping tor suggested best location of expansion tanks and air eliminators Check Relief Valve l Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 4 Hydronic Piping before proceeding further Safety relief valves should be re inspected zen AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected
48. ch 1000 Btu hr 22cm2 per kW of input but not less than 100 square inches 645cm2 see FIG 1 5 11 1 Determine unit location Figure 1 6 Combustion Air from Outside Single Opening 4 Ifa single combustion air opening is provided to bring combustion air in directly from the outdoors the opening must be sized based on a minimum free area of one square inch per 3000 Btu hr 7 cm per kW This opening must be located within 12 30 cm of the top of the enclosure see FIG 1 6 Combustion air requirements are based on the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada refer to National Standard CAN B149 1 Check all local code requirements for combustion air All dimensions are based on net free area in square inches Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 2596 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the room where the appliance is installed Each opening must have a net free area as specified in Table 1B on page 13 Single openings shall be located within 12 30 cm of the ceiling 12 Copper Fin Installation amp Service Manual Under no circumstances should the room where the appliance is installed ever be under a negative pressure Particular care should be taken where exhau
49. cm 730 cm 730 cm 1 452 cm 1 452 cni 8 68 90 2 2 2 2 9 79 2 2 2 90 2 2 2 3 5 5 00 400 400 1 291 cm 2 581 cm 2 581 cm Outside air openings shall directly communicate with the outdoors When combustion air is drawn from the outside through a duct the net free area of each of the two openings must have twice 2 times the free area required for Outside Air 2 Openings The above requirements are for the boiler only additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances Combined interior space must 50 cubic feet 1 000 Btu hr input Buildings MUST NOT be of Tight Construction For buildings of Construction provide air openings into the building from outside combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1 000 Btu hr of all installed gas fired appliances Buildings MUST NOT be of Tight Construction Tight Construction is defined as a building with less than 0 40 ACH air changes per hour Vent installations for connection to gas vents or chimneys must bein accordance with Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI 27223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning
50. common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as 15 practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any other appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Copper Fin Installation amp Service Manual e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use g Any improper operation of the common venting system should be corrected so that the insta
51. e Check gas pressure and make sure gas valve knob 15 on the temperature controller Check 24 VAC at R and W on the terminal strip Check each of the Check each of the following for an open following for an open X and B on the terminal strip purple and gray wires on the vent damper plug the two gray wires on white and purple wire on the louver plug 315 the LWCO plug rollout switch and 360 models only V and P on the manual reset high limit terminal strip spill switch auto reset high limit If any of these devices are open press the reset button 61 Copper Fin Installation amp Service Manual 9 Troubleshooting Troubleshooting Guide 90 000 270 000 Btu hr Models Water Heaters F1 Step I Is the pilot lit Check gas pressure Check for an open Check the pilot assembly sensor If no open and thermocouple Clean sensor make sure the thermocouple and there s a call for Yes pilot or replace heat If call for heat is present replace temperature control Is the gas valve Step 2 p getting 24VAC to Is there 24 VAC purple wire on the 4 pin connector plug on the temperature controller the MV terminal Is there 24 VAC tan wire on the 4 pin connector plug on the temperature controller Step 3 Check gas pressure and make sure the gas valve knob 15 on Check each of the Check 24 VAC at R and W on following for an open the termi
52. e On two gas valve models remove the hex plug from the gas valve closest to the gas supply connection Range of scale should be 14 w c or greater to check inlet pressure See FIG s 3 3 and 3 4 for location Turn on gas supply at the manual valve turn on L P gas at tank if required Turn the power ON at the main disconnect switch gas knob to PILOT position on standing pilot models Follow the Lighting Turn valve control Instructions in Section 6 Startup for standing pilot models to light the pilot Turn gas valve control knob to the ON position when the pilot is established Turn gas valve control knob s to the ON position on spark ignition models 22 Copper Fin 10 iE 12 13 14 15 10 I 18 19 20 IMPORTANT Installation amp Service Manual Set the thermostat s to call for heat Observe the gas supply pressure with all burners firing Ensure Inlet pressure is within specified range Check gas supply pressure with all other gas fired appliances in operation to ensure proper gas volume during periods of peak gas usage If gas pressure is out of range contact gas utilty gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the appliance If the gas supply pressure is within the specified range proceed with the following steps to return the appliance to service Turn the power OFF a
53. ed on the right side of the burner approximately centered in the burner tray Copper Fin Installation amp Service Manual Figure 6 2_Pilot Location Pilot Location TOP OF FLAME SPREADER TO BE FLUSH WITH TOP OF BURNER 9 Turn the control knob on the gas valve counterclock wise to the PILOT position Figure 6 3_Lighting Wand USE AFIELD SUPPLIED LIGHTER OR THE FACTORY SUPPLIED LIGHTING WAND TO LIGHT THE STANDING PILOT The information package shipped with the appliance contains a wire lighting wand The loop end of the wand will hold a match The wand extends your reach to the pilot and makes lighting the pilot easier see FIG 6 3 41 Copper Fin 6 Start up 10 11 12 13 14 15 A WARNING 42 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 6 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 If the red button does not pop up when released stop and immediately call your
54. eed this thickness the flow rate will need to be increased The tubes should not have a bright shiny copper look This would indicate that the erosion process has begun and the flow rate will need to be decreased Once the proper flow rates have been established the inspection intervals can be increased to every 30 days once a quarter or to a bi annual inspection This procedure should ensure proper operation of the unit as long as the water quality stays consistent TABLE 7B COMMON WATER MANIFOLD SIZE FOR MULTIPLE HOT WATER SUPPLY BOILER INSTALLATIONS Pipe sizing chart provides minimum pipe size for common manifold piping and tank tappings to ensure adequate flow Number of Units Common Manifold Size Min Loa C oz La Pump Operation 1 Thewaterheater hot water supply boiler must be connected to a properly sized pump that circulates water between the heater and storage tank 2 A standard water heater is furnished with a 1 6 HP 120 VAC 3 6 AMP circulating pump to be mounted on the units inlet water connection This pump is sized based on installation of a single storage tank and heater in close proximity If the number of fittings and straight pipe exceeds the quantities shown in this section a larger pump will be required 3 The pump must run continuously when the burners are firing 4 Lubricate the pump to the manufacturers recommendations Pump damage due to inadequate lubrication is non warrantable
55. ervice life of the vent system and related components The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature above 140 F 60 C This should prevent the products of combustion from condensing in most installations The bypass should be fully sized with a balancing valve to allow for proper adjustment A valve must also be provided on the boiler discharge after the bypass Closing this discharge valve forces water through the bypass Start boiler adjustment with the bypass valve in the full open position and the boiler discharge valve half open A small amount of the higher temperature boiler discharge water is mixed with the system water to maintain the desired lower system temperature A remote low temperature range operator is recommended to control the boiler operation for temperatures lower than 100 F This remote operator should be wired across the R and W terminals see Room Thermostat Connection and Terminal Strip Instructions in Section 5 of this manual Three Way Valves The installation of a three way valve on this boiler is not generally recommended because most piping methods allow the three way valve to vary flow to the boiler This boiler is a low mass high efficiency unit which requires a constant water flow rate for proper operation Low flow rates can result in overheating of the boiler water which can cause short burner on cycles sy
56. esult in operational and safety problems Exterior masonry chimneys with one or more sides exposed to cold outdoor temperatures are more likely to have venting problems The temperature of the flue gases from an appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft This will result in condensing of flue gases damage the masonry flue tile insufficient draft and possible spillage of flue gases into an occupied living space Carefully inspect all chimney systems before installation If there is any doubt about the sizing or condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system Inspection of a Masonry Chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue gases A clay tile lined chimney must be structurally sound straight and free of misaligned tile gaps between liner sections missing sections of liner or any signs of condensate drainage at the breaching or clean out If there is any doubt about the condition of a masonry chimney it must be relined An unlined masonry chimney must not be used to vent flue gases from this appliance An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner systems Type B double wall or flexible or rigid metallic liners are recommended Consult with local code official
57. g shipment Check to ensure that gas connections have been made properly and the gas line is purged of air Check to ensure that water connections are tight and the appliance and piping system have been properly filled Ensure that discharge from the relief valve has been piped to a floor drain Verify that properly sized combustion and ventilation air openings are provided and not obstructed in any way 40 Copper Fim Installation amp Service Manual 7 Check carefully for gas leaks 8 Read the appliance s safety warnings lighting instructions and check out procedure carefully before firing the system Lighting Instructions for Standing Pilot Models F1 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 property damage personal injury or loss of life A This appliance has a pilot which must be ignited 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
58. hose 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 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 proper installation or service procedures Consult and follow all local Building and IMPORTANT Eire 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
59. iping continued A water flow switch meets most code requirements for Typical Heating Boiler Installations a low water cut off device on boilers requiring forced circulation for operation General Plumbing Rules Check all local codes Low Water Cutoff if equipped For serviceability of the boiler always install unions A hot water boiler installed above radiation level must be provided with a low water cutoff device either as part of the unit or installed at the time the boiler is installed An electronic low water cutoff is available as a kit on all units Low water cutoffs should be inspected every six months 5 Expansion tank must be installed near the boiler and on including flushing of float types the suction side of the pump Always pipe pressure relief valves to an open drain Locate system air vents at the highest point of the system 6 Support all water piping TABLE 4A i MINIMUM REQUIRED FLOW Placing the Boiler in Operation FOR HEATING BOILER Filling the System All air must be purged from the system for Input Btu hr GPM Flow proper operation An air scoop and air vent must be located 315 000 cose to the boiler outlet and there should be a minimum 360 000 distance between the cold water feed and the system purge valve 399 999 1 Close all drain cocks and air vents 22 2 Open the makeup water valve slowly fill the system Minimum flow is based on a 40 F 3 Ifa makeup water pump is employed adjust the pre
60. is to be adjusted follow the Gas Manifold Pressure Adjustment Procedure page 21 for proper adjustment Venting of Combination Gas Valves The combination gas valve regulator used on all models is equipped with an integral vent limiting orifice The vent limiter ensures that the volume of gas emitted from the valve does not exceed the maximum safe leakage rate allowed by agency requirements Combination gas valve regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors A dust cap is provided at the vent termination point on the valve to prevent blockage of the vent limiter by foreign material The combination gas valve regulator with an integral vent limiter complies with the safety code requirements of CSD 1 CF 190 a as shipped from the manufacturer without the installation of additional vent lines Two Stage Burner Control System The 315 000 through 399 999 Btu hr boiler models M9 will be equipped with a two stage gas valve to control high low burner operation The 500 000 Btu hr boiler model achieves two stage burner firing by staging the operation of the two combination gas valves 23 4 Hydronic piping Installation amp Service Manual Copper Fin Relief Valve RELIEF VALVE Figure 4 1_ Relief Valve CBN315 500 This appliance is supplied with a relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section
61. ive build up of minerals in the heat exchanger can cause a non warrantable failure 45 7 Domestic water heaters Domestic Water Heaters 90 000 500 000 Btu hr Models This section applies only to those units used to supply direct fired domestic hot water and installed with a storage tank s The use of a properly sized pump and the control of water velocity as explained in the Water Velocity Control section are important for correct operation of your hot water heater This section contains specific instructions for those units used to supply domestic hot water All warnings cautions notes and instructions in the general Installation and service sections apply to these instructions Water heaters are designed for installation with a storage tank The use ofa properly sized pump and the control of water velocity as explained below is important for correct operation of your water heater Water Velocity Control IMPORTANT To ensure proper velocity through the heat exchanger it is necessary to regulate the temperature rise across the heat exchanger from inlet to outlet This must be done on initial installation and periodically rechecked With the correct temperature rise across the heat exchanger you may be assured of the proper velocity in the tubes This will yield long life and economical operation from your water heater Excessive lime build up in the tube is a result of too little velocity in the tubes Excessive pitting or er
62. izes the pump on a call for heat Temperature sensor This sensor monitors inlet water temperature If selected as the controlling sensor the appliance will maintain the setpoint at this sensor Installation amp Service Manual Copper Fin The Copper fin How it works Model CWN399 Front View Models CWN270 Front View Model CWN399 inside unit Model CWN270 inside unit Copper Fime Installation amp Service Manual The Copper fin How it works continea Model CBN399 Front View Model CBN500 Front View Models CBN399 inside unit Model CBN500 inside unit 1 Determine unit location Location of unit 1 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components 2 The appliance must be installed indoors where it is protected from exposure to wind rain and weather 3 The appliance must be installed so that the ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement e 4 Appliances located in a residential garage and in ad
63. jacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18 46cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle 5 DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present 6 All units have been approved for alcove installation an ALCOVE is a closet enclosure without a front door 7 The appliance must not be installed on carpet 8 All units have been approved for use on combustible surfaces 9 Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the appliance NOTICE Clearances from combustible construction are noted on the appliance rating plate EN 10 Copper Fim Installation amp Service Manual _ H U 6 um Figure 1 1 Alcove installation 90 000 180 000 Btu hr Figure 1 2 Alcove Installation 225 000 500 000 Btu hr Copper Fin Installation amp Service Manual 1 Determine unit location Combustion and ventilation air requirements for conventionally vented appliances Provisions for combustion and ventilation air must be in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA St
64. llation conforms to the latest edition of the National Fuel Gas Code ANSI Z223 1 In Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 in the latest edition of the National Fuel Gas Code ANSI Z223 1 In Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment 15 2 Venting Vertical Vent Termination Clearances Copper Fin Installation amp Service Manual 10 OR LESS lt CHIMNEY 2 MIN gt x AN Ra re gt nay ey 255 416 K 721 E aY Ne tr TEC QA T Cn M VE er See pe EAD ED Veale Sar EERE t ae PARES Belge Sen pa ee A Le ra 22 oy L gt er eRe ORE panam n NER LL PM PM o mE D ees lt WEIT pos 7 i V 4 V Figure 2 2 Vent Termination from Peaked Roof 10 or Less from Ridge MORE THAN 10 m e CHIMNEY x 3 MIN Bie ite Nr S pe Mull ta Ua Quo Cu e qure M UIT ETE quy M ce dicia y 62 5
65. low the pipe to slide in the hanger resulting in noise transmitted into the system Padding is recommended CB500 on rigid hangers installed with a copper system The boiler 6 pressure relief valve must be piped to a suitable floor drain See the relief valve section on page 24 of this manual A CAUTION A leak in a boiler system will cause the system to intake fresh water constantly which will cause the tubes to accumulate a lime scale build up This will cause a 2 NON WARRANTABLE FAILURE CB 360 FT HD Water Connections Heating Boilers Only All water heaters and heating boilers with inputs of 315 000 500 000 Btu hr have 2 NPT Gallons per Minute A CAUTION Field installed reducing bushings may Circulator Pump Operation Heating Boilers Only decrease flow resulting in boiler noise or flashing to steam f f f f l l Boilers are equipped with a relay for controlling the circulation Circulator Pump Requirements pump for the hot water loop The relay turns ON and OFF in response to the W input from the wall thermostat or zone This is a low mass high efficiency hot water boiler which control must have adequate flow for quiet efficient operation The boiler circulating pump must be purchased locally The boiler circulator pump must operate continuously while the boiler is firing Pump selection is critical to achieve proper oper ation A pump should be selected to achieve proper system design water temperature rise
66. more information on wiring the sensor see Wiring of Remote Sensors this page Installation of Remote Sensors Make sure to insert the sensor all the way into the bulbwell leaving no air pocket between the front surface of the sensor and the back of the bulbwell Air pockets are thermally non conductive and will cause sensors to read inaccurately System Sensor The system sensor must be installed when piping the boiler in Primary Secondary fashion when using the Pump Delay option 36 Copper Fin Installation amp Service Manual Tank Sensor Water heaters are provided with an extra temperature sensor that MUST be field installed The sensor is shipped loose in the I amp O packet This remote mounted sensor will be the primary temperature sensor which will inform the appliance s built in thermostat control For domestic water heating the sensor MUST be installed into a bulbwell on the storage tank This is required to maintain the desired temperature in the tank and reduce cycling of the heater In both applications be sure to insert the sensor all the way into the bulbwell leaving no air pockets between the front surface of the sensor and the back of the bulbwell Air pockets are thermally non conductive and will cause sensors to read inaccurately Wiring of Remote Sensors To wire remote sensors follow the guidelines below Take care to correctly wire sensors to the unit Erratic temperature readings can be caused
67. must have draft within the proper range If the draft measured above the appliance s built in draft diverter exceeds the specified range in a dedicated chimney for a single appliance installation or in combined venting with other negative draft appliances a barometric damper must be installed to control draft 14 Copper Fin Installation amp Service Manual B 2 Figure 2 1 Conventional Negative Draft Vertical Venting TABLE 2A VENT PIPE SIZES 13500 Od x s On a conventionally vented negative draft appliance the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type B double wall or equivalent vent connectors and must be direct as possible with no reduction in diameter Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks The Type B vent and accessories such as firestop spacers thimbles caps etc MUST be installed in accordance with the manufacturer s listing The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes Any vent materials used must be listed by a nationally recognized test agency for use as vent material 2 Ven
68. n when local codes require 5 A trap drip leg MUST be provided by the installer in the inlet of the gas connection to the appliance see FIG 3 1 on page 20 6 The combination gas valve has an integral vent limiting device and does not require venting to atmosphere outside the building 7 Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes TABLE 3C FITTINGS TO EQUIVALENT STRAIGHT PIPE Diameter Pipe inches DIDI Equivalent Length of Straight Pipe feet GAS CONNECTIONS 19 Copper Fin Installation amp Service Manual Gas connections TABLE 3E MULTIPLE APPLIANCE INSTALLATIONS GAS PIPING SIZE CHART Nominal Iron Pipe Length of Pipe in Straight Feet Maximum Size Capacity of Pipe in Thousands of Btu hr per hour for gas pressures s s 256 20s ra Pas m us ee os Poe ops Taches Eee aren 0 5 PSIG or less 1400 974 789 677 ses sas sor 472 aar ato 333 sos 287 anda pressure drop of 0 5 Inch 112 1 500 1 210 1020 923 sso 76 707 eee 6 soa sis 472 Water Column Based on NAT 4 100 2 820 2 260 1 950 1 720 1 560 1 440 1 330 2102 6 460 4 460 3 610 3 100 2 720 2 460 2 310 2 100 3 11 200 7 900 6 400 5 400 4 870 4 410 4 000 wie Read GAS 1025 Bt hr per
69. n 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 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
70. n 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 21105 Installation amp Service Manual Copper Fim Installation amp Service Manual Ratings DOE ve d CERTIFIED Other Specifications AHRI Rating Net Model Number Input Gross Boiler MBH Output Ratings Water Note Change Note 4 MBH Water Content N to L for MBH Gallons L P J 05955 MIN MAX Note 1 Note 2 CBN315 158 315 258 224 CBN360 180 360 295 257 CBN399 200 399 328 285 CBN500 250 500 410 357 NOTICE Maximum allowed working pressure is located on the rating plate Notes 1 Theratingsare based on standard test procedures prescribed by the United States Department of Energy UNIT EQUIPPED FOR HIGH ALTITUDE UPTO 200 FT 2 Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 3 Copper fins require special gas venting Use only the vent materials and methods specified in the Installation and Service Manual 4 The Copper fin is orificed fo
71. nal strip X and B on the terminal strip purple and gray wires on the vent damper plug Check V and P on the voltage to terminal strip and from the auto reset high limit transformer Check each of the following for an open white and purple wire on the LWCO plug rollout switch manual reset high limit spill switch If any of these devices are open press the reset button Check incoming 120 VAC 62 Manual ICE Installation amp Serv Copper Fin 10 Diagrams F1 Un iagram D iring W 90 000 270 000 Btu hr Models F1 Un iagram ic D 270 Schemat 90 000 Btu hr Models 000 AAY LEZC181 MOTI3A A 31IHM M NVL L 559 SWALI TWNOILdO S19Id3G d 2 1454 4 1 TRANSFORMER W CIRCULATION PUMP TT THERMOSTAT W Y 12 24VDC RELAY I Pk CUTOFF R LOW AWER BK 10 L Y 2 ENT DAMPER L__ Ld CN1 1 OPERATOR 1 2 BL 120 BL GROUND LINE BK 9L sv MNid yd JONVHO HO AVHOZAO L J Bom MANUAL RESET HIGH LIMIT ROLLOUT SWITCH PR Low WATER W CUTOFF 3 4 L ool N33H9 9 NMOSZN8 an 1g 18 31OVv18 xg 5 198550 lt YOSNAS HOSN3S 131 NI 191 a L X __ 4 3 11 T CN1 VENT DAMPER OPERATOR 4 VENT
72. nces operated in hard water areas should have periodic inspections of the tubes to be sure that no sediment or scale accumulates on the heat transfer surfaces Inspection plugs are located at both ends of the heat exchanger Inspection plugs should be removed and tubes inspected at the end of the first 45 days of operation and again at the end of 90 days of operation If no scale accumulation is observed inspections can be made at the end of each six months of operation Pilot Flame Adjustment Procedure The pilot flame should envelop 3 8 to 1 2 10 to 13mm of the tip of the thermocouple see FIG 8 3 Figure 8 3 Pilot Flame on Thermocouple a Remove pilot adjustment cover screw on the gas valve See the Gas Valve illustrations in the Lighting Instructions section page 41 for the location of the cover screw b Turn the inner adjustment screw clockwise to decrease or counterclockwise to increase pilot flame c Replace the pilot adjustment cover screw on the valve Tighten firmly after adjustment to prevent gas leakage 59 8 Maintenance IMPORTANT Upon completion of any testing on the gas system leak test all gas connections with a soap solution while main burners are operating Immediately repair any leak found in the gas train or relat ed components Do Not operate an appliance with a leak in the gas train valves or related piping Gas Train and Controls i GAS FLOW Figure 8 5 Gas Train 50
73. ncrease regulator pressure beyond specified pressure setting 12 Turn gas valve control knob to PILOT position on standing pilot models Turn gas valve control knob to OFF position on spark ignition models 13 Remove fitting from the gas valve and replace the 1 8 hex plug that was previously removed and tighten 14 Repeat the adjustment procedure for the second gas valve on the 500 000 Btu hr model 15 Turn the gas valve control knob s to ON position 16 Turn the power ON at the main disconnect switch The appliance is now ready to operate If manifold pressure can not be properly adjusted use the procedure on page 22 to check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control 21 3 Gas connections Checking Gas Supply Pressure MANOMETER GAS SUPPLY PRESSURE GAS VALVE UNION Figure 3 4 Gas Supply Pressure Turn the power OFF at the main disconnect switch Turn gas valve control knob s to the OFF position The 500 000 Btu hr model will have two gas valves Turn the gas valve control knob on each valve to the OFF position Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P gas shut off gas supply at the tank Remove the 1 8 hex plug located on the inlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gaug
74. no smoking or open flames near the faucet at the time it is open Copper Fin Installation amp Service Manual 8 Maintenance and annual startup Table 8A Service and Maintenance Schedules Service technician see the following pages for instructions Owner maintenance see the User s Information Manual for instructions General Check appliance area Address reported problems Check pressure temperature gauge Inspect interior clean and vacuum If necessary Check for leaks water gas flue Check vent piping Monthly Examine venting system Check relief valve Check system water pressure system piping expansion tank Check control settings Test low water cutoff if used Periodically Check wiring and connections 9 Reset button low water cutoff Flame inspection stable uniform Check flue gas passageways Q p 6 s lt t Inspect and clean the burner Check appliance piping gas and water for leaks Every Perform start up check out and 6 months performance verification per Section Operate relief valve 6 Start up If combustion or performance indicate need 2 Shut appliance down unless of season boiler used for domestic hot e Clean heat exchanger months water e Remove and wash burner 54 Copper Fin Installation amp Service Manual 8 Maintenance continued A WARNING Follow the service and maintenance procedures given thr
75. of degrees below set point that the High Fire stage shuts down At that point the unit will continue to operate at the Low Fire stage until the set point is reached The High Fire Offset knob has settings between 0 F and 20 F If set at O F the High Fire Offset is disabled and the unit will operate the High Fire stage until the set point is reached and the temperature control shuts the unit off If the High Fire Offset knob 15 set to 0 or 1 the delay will be 10 seconds if set to 2 or above the delay will be 120 seconds Boiler Application Standard boiler units are equipped with one inlet water temperature sensor An optional sensor is also provided for use as a remote system sensor Boilers with the outdoor air reset option also have an outside air temperature sensor Water Heater Application Water heater units are shipped with an inlet water temperature sensor and a multi purpose temperature sensor to be used as a tank sensor The inlet water temperature sensor is factory installed on all water heaters 35 5 Electrical connections Temperature Control Sensors This is a two stage temperature control M9 F9 that controls the burner ignition and pump functions This temperature controller can measure up to three different sensor inputs depending upon how the unit is set up They are as follows 1 Inlet Water Temperature Sensor 2 Multi Purpose Temperature Sensor 3 Outside Air Temperature Sensor Inlet Water Tempera
76. oilers Only 27 Thermostat Settings 51 52 Primary Secondary Boiler Piping 28 Optional Relief Valve 53 Low Temperature Bypass Requirements 28 Thermal Expansion 53 Three Way Valves a a 29 Cathodic Protection 53 Boiler Flow 22 29 8 MAINTENANCE Figure 4 6 Prim Sec Piping of a Single Boiler 30 Maintenance and Annual 54 60 Figure 4 7 Prim Sec Piping w Low Temp Bypass 31 9 5 61 62 Figure 4 8 Multiple Boilers Zoned w Circulators 32 10 63 66 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 DANGER DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious Injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in dea
77. ompletion 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 6 Start u D continuea 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 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 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 unde
78. on the vent damper refer to the instructions supplied with the vent damper Larger input heating boilers and water heaters will have a jumper plug installed in the terminal block to allow operation without a damper Remove the jumper plug from the terminal block to connect an optional vent damper wire harness water heater shown in FIG 2 8 The jumper plug MUST be in place if an optional vent damper is not used on water heaters and larger input heating boilers A WARNING Do not install the vent damper within 6 152 mm of combustible materials Install the vent damper to service only the single appliance for which it is intended If improperly installed a hazardous condition such as an explosion or carbon monoxide poisoning could result A DANGER The damper position indicator must be in a visible location with access for service following installation The damper must be in an open position when appliance main burners are operating The part number for the automatic vent damper required on this heating boiler is printed on the rating plate Vent damper regulations are design certified per the latest edition of ANSI 721 66 18 Copper Fin Installation amp Service Manual Figure 2 7 CB with Vent Damper and Vent Damper Terminal Block VENT DAMPER TERMINAL BLOCK Figure 2 8 CW with Vent Damper VENT DAMPER The vent damper must be installed directly on the flue outlet located on the top of the
79. ontrol 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 Turn on all electric power to the appliance Set the thermostat to the desired setting Re install the control panel door If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier 43 6 Start up 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 1s to be performed 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 rotate 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 A WARNING to shut off turn off the external manual gas valve to the appliance Safety Shutoff Test for Spark Ignition Pilot System 1 Turn OFF gas supply to the appliance Turn thermostat to highest setting Turn electric power ON Pump relay pulls in to start pump The ignition will begin sparking at the pilot p NP uem e The ignition module will lock out after the 90 second trial for ignition period on the 90 000
80. osion in the tube is caused by too much velocity through the tubes Care should be taken to measure temperature rise and maintain a velocity as follows 1 The pump must run continuously when the burners are firing 2 With the pump running and the water heater off the inlet and outlet thermometers should read the same temperatures If they do not an adjustment must be made to your final calculation 3 Turn the water heater on and allow time for the temperature to stabilize Record the difference between the inlet and outlet temperatures This difference will be the temperature rise 4 Compare the temperature rise on the heater with the required temperature rise in Table 7A Should adjustment be needed proceed as follows If the temperature rise is too high the water velocity is too low Check the following 1 Check for restrictions in the outlet of the water heater 2 Besure all valves are open between the water heater and the tank 3 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 46 Copper Fin Installation amp Service Manual Be sure the circulation pipes between the water heater and storage tank are not less than 2 diameter for a single unit installation Common manifold piping for multiple unit installations will require larger minimum pipe sizes to tank tappings to ensure proper flow See Table 7B on page 47 Multiple unit installations m
81. ot models Ensure that the standing pilot remains on If the pilot goes out follow the Lighting Instructions in Section 6 Startup for standing pilot models to light the pilot Turn gas valve control knob to OFF position on spark ignition models 3 Remove the 1 8 hex plug located on the outlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge See FIG 3 3 Minimum range of scale should be up to 5 w c for Natural gas models and 10 w c for L P gas models 4 The 500 000 Btu hr model will have two gas valves with a pressure regulator on each valve Repeat the following adjustment procedure to set the manifold pressure on each gas valve 5 Remove the pressure regulator adjustment cap screw on the gas valve See FIG 3 3 for location Turn the power ON at the main disconnect switch Turn gas valve control knob to ON position Set the thermostat s to call for heat 2027 Observe gas regulator pressure when all burners firing See Table 3B Manifold Pressure page 19 for proper regulator pressure settings 10 If adjustment is necessary turn regulator adjustment screw clockwise to raise regulator gas pressure counterclockwise to lower gas pressure to proper setting NOTE Adjustment fitting is plastic and may require slightly greater turning force than a metal fitting 11 Turn the power OFF at the main disconnect switch NOTICE Do not i
82. oughout 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 A WARNING The appliance should be inspected annually only by a qualified service technician In addition the maintenance could result in equipment failure A WARNING and care of the appliance designated in Table 8A and explained on the following pages must be performed to assure maximum appliance efficiency and reliability Failure to service and maintain the appliance and system Electrical shock hazard Turn off power to the appliance before any service operation on the appliance except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Address reported problems Flue vent system 1 Inspect any problems reported by the owner and correct before proceeding Inspect appliance area 1 Verify that appliance area is free of any combustible materials gasoline and other flammable vapors and liquids 1 Examine the venting system at least once a year Check more often in the
83. ow burners to cool then cycle burners again to ensure proper ignition and flame characteristics Copper Fin Installation amp Service Manual 3 Gas connections continued Combination Gas Valves PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW OUTLET PRESSURE TAP INLET PRESSURE TAP e o uM PILOT OUTLET RED RESET BUTTON GAS CONTROL KNOB Figure 3 5_F1 Gas Valve standing pilot PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW WIRING TERMINALS SI BE OUTLET PRESSURE 3 1i Z E x Z s Z lt O O INLET PRESSURE Oj SSU o EN ss PILOT OUTLET 2 OFF GAS CONTROL KNOB Figure 3 6 F9 Gas Valve spark ignition Each unit has a combination gas valve s to control the gas supply to the burners The 500 000 Btu hr model has two combination gas valves to supply gas to the burners The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves The valve has a gas control knob that must remain in the open position at all times when the appliance is in service Each gas valve has pressure taps located on the inlet and outlet sides Manifold pressure is adjusted using the regulator located on the valve The manifold pressure is preset at the factory and adjustment is not usually required If the manifold pressure
84. partment 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 15 not covered under the manufacturer s warranty see Water Treatment and Water Chemistry 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 see Boiler Flow Rates and Temperature Rise for flow requirements 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 t
85. pliance is wired for 120 VAC service The appliance when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or In the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CSA C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes 1 appliance and field Installed devices shall be made with type T wire 63 F 35 C rise wiring between the 2 Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 The pump must run continuously when the appliance is being fired 4 To avoid serious damage DO NOT energize the appliance until the system is full of water Serious damage may result 5 Provide the unit with proper overload protection 6 Install a wall thermostat on the inside wall DO NOT install the thermostat in an area affected by drafts sunlight light fixtures hot or cold water pipes or near a fireplace See Terminal Strip Connection of a Room Thermostat this page for proper wiring connection Boiler Operating Temperature Control The operating temperature control is located in the control panel behind the control panel front access door The sensing element for the operator is placed in a bulbwell installed in the heat exchanger Carefully observe the inlet water
86. r operation up to 2000 Figure A High Altitude Label Location feet altitude The appliance will be derated 496 per 1000 feet above 2000 feet elevation Consult the factory for installations above 2000 feet elevation 5 Ratings have been confirmed by AHRI Copper Fin Installation amp Service Manual Ratings Model Number Water Water Connections Gas Connections Vent Size Content Gallons Note Change N to Note 1 L for L P gas models owo gt T _ Dow j omm w 2 ow ax own a we z ewm 2 rv v nim NOTICE Maximum allowed working pressure is located on the rating plate Notes 1 Copper fins require special gas venting Use only the vent materials and methods specified in the Installation and id T Service Manual Sie 2 The Copper fin is orificed for operation up to 2000 feet altitude The appliance will be derated 4 per 1000 mE feet above 2000 feet elevation Consult the factory for installations above 2000 feet elevation p D C Nd Figure B High Altitude Label Location Copper Fin The Copper fin How it works 1 10 11 12 13 14 Control panel cover The control panel cover provides access to the thermostat Ignition module and transformer Drain port not shown Location from
87. r 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 Installation amp Service Manual Operating Instructions 52 xm 6a 6b 8a 8b 10 11 12 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 This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand 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 180 000 360 000 Btu hr models rotate 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 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 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 180 000 360 000 Btu hr models rotate the gas c
88. re allows the unit to operate regardless of the outdoor air temperature This is needed for indirect domestic hot water systems for example Additional Temperature Controls High Water Temperature Limit Control The appliance is supplied with a fixed setting auto reset The setting of this control limits maximum discharge water temperature If water high water temperature limit control temperature exceeds the setting the limit will break the control circuit and shut down the appliance The limit control will only be reset after the water temperature has cooled well below the setting of the limit The auto reset high water temperature limit control is mounted in the outlet side of the front header Copper Fin Installation amp Service Manual 5 Electrical connections continued Manual Reset High Water Temperature Limit Control Standard Fixed Settings on Boilers and Water Heaters with Optional Adjustable Settings Water heaters are supplied with a fixed setting manual reset high water temperature limit control This manual reset temperature limit control has a fixed limit setting of 230 F 110 C If water temperature exceeds this setting the limit will break the control circuit and shut down the unit The limit control can only be reset after the water temperature has cooled well below the setting of the limit Reset of the limit control is accomplished by pushing the Red Reset Button Manual Reset High Limit see FIG s 5 2
89. rt up Initial Start up Follow the Lighting Instructions on the label applied to the appliance A On water heaters and boilers with the system pump delay option the operating temperature control will energize the pump relay which energizes the pump on a call for heat The operating temperature control will de energize the pump relay approximately 30 seconds after the call for heat ends If either the inlet sensor or the optional multi purpose temperature sensor reads below 40 F the pump relay will turn ON When the temperature rises above 50 F the pump relay will turn OFF On boilers the pump will operate whenever the W terminal is energized B Location The appliance should be located within a room having a temperature safely above freezing 32 0 Shutdown Draining If for reason the appliance is shut off the following precautionary measures must be taken Shut off gas supply Shut off water supply Shut off electrical supply om Drain the heat exchanger completely Remove one 3 8 NPT plug or bulbwell from the inlet side and one from the outlet side of the front header of the heat exchanger 5 Drain the pump Remove the 3 4 plug in the bypass loop Pre start Checklist 1 Inspect the burners to be sure they are properly aligned Inspect the pilot gas line thermocouple leads ignition leads and wire connections to the gas valve to be sure none were damaged durin
90. ry Some states may require a lower temperature setting Check with your gas supplier for local requirements governing the temperature setting Remem ber no water heating system will provide exact tem perature at all times Allow a few days of operation at this setting to determine the correct temperature setting consistent with your needs NOTICE 1 This water heater when set at the lower temperature setting is not capable of producing hot water of sufficient temperature for sanitizing purposes 2 Higher stored water temperature increases the ability of the water heater to supply desired quantities of hot water however remember Hotter water increases the risk of scald injury A CAUTION Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the heat exchanger and operational problems The cold water supply piping must be installed in the discharge piping from the heater to the storage tank This allows the cold water to be tempered in the storage tank before entering the heater See typical installation drawings provided in this manual Higher water temperatures reduce condensate formation 51 Copper Fin 7 Domestic water heaters CAUTION Setting the temperature selector to high er settings provides hotter water which Increases the risk of scald injury The manufacturer recommends the use of a properly sized thermostatic mi
91. s l 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 m Remove gas manifold as described in steps a through e in Heat Exchanger Burner Access n Loosen mounting screws and remove front control panel o 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 8 Maintenance continued p Check V baffles on top of the heat exchanger Remove and clean if necessary q 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 w
92. s to determine code requirements or the advisability of using or relining a masonry chimney Sidewall Venting This appliance is NOT approved for sidewall venting with the negative draft venting system as shipped from the factory An induced draft fan MUST be used if the installation requires that the flue gases be vented out a sidewall A properly sized and installed induced draft fan may also be used to vent the flue gases vertically if required by job site conditions The induced draft fan must be listed by a nationally recognized test agency be properly sized and installed per the recommendations of the induced draft fan manufacturer and meet local code requirements Use care to ensure that the mechanically supplied draft does not exceed the range of a negative 0 02 to 0 05 inches water column to ensure proper operation If draft exceeds the specified range the fan must be adjusted or the installation of a barometric damper in the flue may be required to properly control draft Copper Fin Installation amp Service Manual An induced draft fan MUST be interlocked into the appliance s control circuit to start when the appliance calls for heat The induced draft fan MUST also be equipped with a proving switch properly interlocked into the appliance s control circuit to prove fan operation before the main burners are allowed to fire A vertical or sidewall vent termination for an induced draft fan MUST be installed per the recommend
93. ssure temperature rise across the boiler to provide a minimum of 12 psi at the highest point in the Minimum flow may not prove a flow system If a pressure regulator is also installed in the line switch installed in the boiler piping it should be adjusted to the same pressure Use care when operating a boiler at or near the minimum recommended flow because conditions unique to the installation system pressure operation of multiple zone valves glycol variations in flow etc may result in overheating of the boiler water causing noise or nuisance operation of safety limit controls Typical heating boiler applications will operate with a 20 F to 5 Open all valves after all circuits have been purged Make 30 F temperature rise across the boiler sure there are no system leaks not use petroleum based stop eak products All system leaks must be repaired The constant addition of make up water can cause damage to the boiler heat exchanger due to scale accumulation Scale reduces flow and heat transfer causing overheating of the heat exchanger 4 Close all valves Purge one circuit at a time as follows A Open one circuit drain valve and let the water drain for at least five minutes Ensure that there are no air bubbles visible in the water stream before closing the drain valve B Repeat this procedure for each circuit 6 Run the system circulating pump for a minimum of 30 minutes with the boiler turned off 7 Open
94. st fans attic fans clothes dryers compressors air handling units etc may take away air from the appliance The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may becorrosiveto theappliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as freon tricholorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the heat exchanger finned tubes headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure The result is improper combustion and a non warrantable premature appliance failure EXHAUST FANS Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and or cause a downdraft in the venting system Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected If a fan is used to supply combustion air to the equipment room the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance Copper Fin Installation amp Service Manual 1 Determine unit location continued TABLE 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPME
95. stallation consult local codes for specific plumbing requirements The installation should provide unions and valves at the inlet and outlet of the boiler so it can be isolated for service The boiler circulating pump air separator expansion tank and other components required for proper installation must be purchased locally An air separation device must be supplied in the installation piping to eliminate trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type expansion tank is used The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation A CAUTION This boiler system should not be operated at less than 12 PSIG 4B SYSTEM TEMPERATURE RISE CHART Based on Boiler Output in Btu hr 20 F AT 360 000 410 000 500 000 26 360 000 5 omae zo wa 40 F AT 1 2 1 5 2 0 3 5 30 F AT GPM 13 0 14 9 16 5 20 7 35 s 27 35 Copper Fin Installation amp Service Manual 4 Hydronic piping continued Hot water piping must be supported by suitable hangers or TABLE 4C floor stands NOT by the boiler Copper pipe systems will be HEAT EXCHANGER PRESSURE DROP CHART subject to considerable expansion and contraction Rigid pipe hangers could al
96. stem noise and in extreme cases a knocking flash to steam These conditions can cause operational problems and non warrantable failures of the boiler If a three way valve must be installed please pipe in primary secondary system Based on boiler sizing and system flow requirements this piping may still result in boiler short cycling Copper Fin Installation amp Service Manual Boiler Flow Rates A CAUTION The maximum flow rate through the boil er with a copper heat exchanger must not exceed 30 GPM The heat exchanger is generally capable of operating within the flow rates of a residential heating system Should the flow rate exceed the maximum allowable flow rate through the boiler 30 GPM an external bypass must be installed The bypass should be fully sized with a balancing valve to allow for proper adjustment of flow Flow rate can be determined by measuring the temperature rise through the boiler The basic guide for minimum flow in this boiler is based on a 40 F temperature rise in most installations Lower flow and a higher temperature rise is acceptable if the boiler system is specifically designed for the characteristics of a higher tem perature rise A system not specifically designed for a higher temperature rise may experience overheating of the boiler water This can cause short burner on cycles system noise and in extreme cases a knocking flash to steam These condi tions can lead to operational problems and non
97. t the main disconnect switch Turn gas valve control knob to PILOT position on standing pilot models Turn gas valve control knob s to OFF position on spark ignition models Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P Gas shut off gas supply at the tank Remove the manometer and related fittings from the inlet side of the gas valve replace 1 8 hex plug in gas valve Turn on gas supply at the manual valve turn on L P Gas at tank if required Turn the power at the main disconnect switch Turn the gas valve control knob s to the ON position If the pilot is not burning follow the Lighting Instructions in Section 6 Startup for standing pilot models to light the pilot Spark ignition models will automatically light the pilot on a call for heat Set the thermostat to call for heat The appliance is now ready to operate Upon completion of any testing on the gas system leak test all gas connections with a soap solution while main burners are operating Immediately repair any leak found in the gas train or related components Do Not operate an appliance with a leak in the gas train valves or related piping Check burner performance by cycling the system while you observe burner response Burners should ignite promptly Flame pattern should be stable see the Maintenance Section Normal Flame Pattern Turn system off and all
98. th or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage CAUTION NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage NOTICE Copper Fin Installation amp Service Manual Please read before proceeding This is a gas appliance and should be installed NOTICE a licensed electrician and or certified gas supplier Service must be 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 e 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 de
99. that the set point knob will now indicate the minimum boiler temperature Target temperature is determined by the ratio and outdoor air temperature below the O A Max setting Ratio The Ratio knob allows control over the reset ratio to be used during Outdoor Air Reset The allowable ratios are as low as 0 5 1 or as high as 1 5 1 Selecting the 0 5 1 ratio will increase the set point 0 5 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature Selecting the 1 5 1 ratio will increase the set point 1 5 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature If the outdoor design and boiler design temperatures are known the Ratio setting can be calculated using the following formula Ratio boiler design temperature operator set point O A Max setting outdoor design temperature Note that the reset set point cannot exceed the maximum set point of the boiler thermostat These settings are illustrated graphically in FIG 5 7 38 Copper Fin Installation amp Service Manual RESET SET POINT lt 6 SET POINT RATIO 1 5 1 0 RATIO 0 5 OPERATOR SET POINT lt TEMP 0 A MAX Figure 5 7_Outdoor Air Control Example Chart Outdoor Air Shutdown Enable Disable Switch The Outdoor Air Shutdown Enable Disable switch turns the outdoor air shutdown feature On and Off Disabling the Outdoor Air Shutdown featu
100. the downstream side of the combination gas valve s see FIG s 3 5 and 3 6 page 23 The gas regulator settings for single stage and two stage operation are factory set to supply proper manifold pressure for normal operation To check manifold pressure see Manifold Adjustment Procedure Do not increase manifold pressure beyond specified pressure settings shown below in Table 3B TABLE 3B MANIFOLD PRESSURE Input Gas Btu hr Full or High Fire Settings Low Fire Settings 500 000 205 a two valves Copper Fin Installation amp Service Manual Gas Pressure Test 1 The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5kPa 2 The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5kPa 3 The appliance and its gas connection must be leak tested before placing it in operation Gas Connection 1 Safe operation of the appliance requires properly sized gas supply piping 2 Gas pipe size may be larger than appliance gas connection 3 Installation of a union is suggested for ease of service see FIG 3 1 on page 20 4 Install a manual main gas shutoff valve outside of the appliance gas connection and before the gas valve or manifold connectio
101. through 399 999 Btu hr models and after the 15 second trial for ignition period on the 500 000 Btu hr model 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 44 Copper Fin Installation amp Service Manual Intermittent Pilot Spark Ignition System F9 M9 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 and Control Timings F1 Standing Pilot Models thermocouple supervised Pilot Flame Failure Response Time 180 Seconds Maximum F9 Intermittent Spark Ignition Pilot Models Pilot Trial for Ignition Period 90 Seconds 90 000 through 399 999 Btu hr models Pilot Trial for Ignition Period 15 Seconds 500 000 Btu hr model Pilot Failure Response Time 0 8 Seconds at less than 1 0 uA flame current Pump Delay Timing Standard on Water Heaters and Optional on Boilers 30 Seconds after burner shutdown
102. tin Q continued Locate appliance as close as possible to a chimney or gas vent Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions Horizontal portions of the venting system shall be supported to prevent sagging Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm m from the appliance to the vent terminal Follow manufacturer s instructions Do not use an existing chimney as a raceway for a flue pipe if another appliance or fireplace is vented through the chimney The weight of the venting system must not rest on the appliance Adequate support of the venting system must be provided in compliance with local codes and other applicable codes All connections should be secured with rustproof sheet metal screws Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure Connection to a positive pressure chimney may cause flue products to be discharged into the living space causing serious health injury Common venting systems may be too large when an existing appliance is removed At the time of removal of an existing appliance the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while other appliances remaining connected to the common venting system are not in operation a Seal any unused opening in the
103. trol is factory set Boilers can De set to 240 F max water heaters are set to 190 F max and specialty state and local codes to 200 F These maximum set points are established by cutting the OJ1 and OJ2 jumpers located on the right side of the temperature controller The maximum set point is determined as shown below in Table 5C TABLE 5C MAXIMUM SET POINT DETERMINATION MAX Anytime that is the only jumper cut a a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 190 F Anytime the OJ2 jumper is cut with or without OJ1 a new overlay 15 required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 200 F Set Point The Set Point knob specifies the target inlet or system sensor if used water temperature in degrees Fahrenheit After the water temperature reaches the set point the temperature control shuts off the burners Differential The Differential specifies the number of degrees below the set point that the control will allow the water temperature to drop before it brings the unit back on again High Fire Offset The temperature control operates a two stage firing system The two stages are High Fire and Low Fire High Fire operates all burners at full rate while Low Fire operates the burners at approximately one half rate The High Fire Offset knob specifies the number
104. ture Sensor This sensor measures the inlet water temperature coming Into the unit The inlet water temperature sensor is placed into the inlet bulbwell on the boiler This sensor is installed by the factory Multi Purpose Temperature Sensor Depending upon how your unit is set up this sensor can be used as a system sensor in a boiler system or a tank sensor for water heater applications Connect this sensor to the two blue wires in the upper left hand corner of the control panel Outdoor Air Temperature Sensor The outside air temperature sensor will only be used for boiler systems The outside air sensor is optional This sensor allows you to tie boiler operation to the outdoor air temperature As outside temperatures drop the control will increase the temperature setting of the boiler As outdoor temperatures rise the control will decrease the temperature to the selected set point of the boiler You can set the control to shut the boiler off when a desired outdoor air temperature level is reached You must purchase the sensor from the appliance manufacturer The sensor comes with a housing that helps protect the sensor from the elements Mount the air sensor housing outdoors under the eve of the roof Make sure the housing is out of direct sunlight This will ensure that the sensor will accurately read the true outdoor temperature Connect the outdoor air temperature sensor to the terminal block on the outdoor air reset board For
105. ture controller is pre set at NOTICE dne ip the factory with test settings You may need to adjust the settings to meet your specific needs Return water temperatures must not be A WARNING A WARNING less than 140 F If lower return water temperatures are required follow the Instructions for Low Temperature Bypass Requirements or Three Way Valves see page 29 TEMPERATURE CONTROL PUMP RELAY MANUAL RESET HIGH LIMIT IF EQUIPPED TRANSFORMER INTERMITTENT PILOT SYSTEM M9 CONTROL PANEL Figure 5 2 Control Panel Assembly 90 135 000 BTU hr 34 Copper Fin Installation amp Service Manual 5 Electrical connections continued Locating Temperature Control Remove the control panel door on the front of the unit in order to locate and access the temperature control Temperature Control Settings Remove the control panel door on the front of the unit unless your unit is specified as a boiler only with an outdoor air reset option If your unit is a boiler only with an outdoor air reset option there are additional controls for this option They are explained under Outdoor Air Reset Option page 37 The three setting knobs on the temperature control are for Set point Differential and High Fire Offset see FIG 5 4 10 TN i 7 20 O OFF 240 DIFFERENTIAL HIGH FIRE O SETPOINT TST2314 OFFSET Figure 5 4 Temperature Control Maximum Set Point Determination The maximum set point for the con
106. ug or bulbwell from the inlet side of the front header and one from the outlet side of the front header on the heat exchanger Blow all water out of the heat exchanger e Drain pump and piping Freeze Protection for a Heating Boiler System if required l Use only properly diluted inhibited glycol antifreeze designed for hydronic systems Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible A CAUTION DO NOT use undiluted or automotive 2 type antifreeze A solution of 5096 propylene glycol will provide maximum protection of approximately 30 F Follow the instructions from the glycol antifreeze manufacturer The quantity of glycol antifreeze required is based on total system volume including expansion tank volume Glycol is more dense than water and changes the viscosity of the system The addition of glycol will decrease heat transfer and increase frictional loss in the heating boiler and related piping A larger pump with more capacity may be required to maintain desired flow rates in a glycol system Local codes may require a back flow preventer or actual disconnect from city water supply when glycol antifreeze is added to the system Water Treatment In hard water areas water treatment should be used to reduce the introduction of minerals to the system Minerals in the water can collect in the heat exchanger tubes and cause noise on operation Excess
107. ump Delay Copper Fin Installation amp Service Manual continued Heat Exchanger This is a highly sophisticated heat exchanger designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build up of impurities The straight line two pass design of the tubes sends water into the headers at a properly rated velocity The configuration of the headers in turn creates a high degree of turbulence which is sufficient to keep all contaminants in suspension This scouring action provides greater cost savings for owners Tubes are always able to transfer heat at peak efficiency Every surface within this water containing section is of a nonferrous material providing clear clean rust free hot water Straight copper tubes finned on the outside for maximum heat transfer glass lined cast iron one piece cored headers make up an entirely rustproof unit On all models header inspection plugs can be removed for field inspection and cleaning of copper tubes The entire heat exchanger may be easily removed from the unit Thermostat Settings 1 The thermostat is adjusted to a low test setting when shipped from the factory 2 Set the thermostat to a maximum water temperature of 125 F which will satisfy hot water demands and prevent risk of scald injury Households with small children or invalids require 120 F or lower temperature setting to reduce may risk of scald inju
108. ve distortion or malfunction may result if the pipe is inserted too deeply into the gas valve Apply a moderate amount of good quality pipe compound DO NOT use Teflon tape to pipe only leaving two end threads bare Remove seal over gas valve or manifold inlet Connect pipe to gas valve or manifold inlet Use wrench to square ends of the gas valve FIG 3 2 For L P gas consult your L P gas supplier for expert installation 3 Gas connections continued 1 WHEN FLANGE IS USED WHEN FLANGE APPLY WRENCH IS NOT USED TO FLANGE ONLY ZZ APPLY WRENCH FROM BOTTOM OF GAS CONTROL TO EITHER SHADED AREA Figure 3 2 Wrench Upon completion of any piping connections to the gas system leak test all gas connections with a soap solution while system is under pressure Immediately repair any leaks found in the gas train or related components Do Not operate an appliance with a leak in the gas train valves or related piping Gas Manifold Pressure Adjustment Procedure PRESSURE REGULATOR ADJUSTMENT INLET UNDER SCREW CAP PRESSURE TAP OUTLET A PRESSURE TAP ON Y FF PILOT PILOT OUTLET GAS CONTROL KNOB RED RESET BUTTON MANOMETER GAS VALVE Figure 3 3 Manifold Pressure Adjustment 1 Turn the power OFF at the main disconnect switch Copper Fin Installation amp Service Manual 2 Turn gas valve control knob to PILOT position on standing pil
109. ve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve is mounted directly into the heat exchanger inside the header see FIG s 7 6 and 7 7 To prevent water damage the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year CAUTION Avoid contact with hot discharge water Water Flow Switch if equipped A water flow switch is available as a factory supplied option on all water heaters The flow switch should be wired between terminals X and B Remove the jumper between the X and B terminals on the terminal strip This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition A flow switch installed with the factory supplied minimum adjustment setting requires a specific minimum flow to make the switch and start burner operation The flow rate required is a function of the diameter of pipe and tee used for installation Ensure that the pump installed water heater will supply adequate flow to make the flow switch contacts and operate the water heater FLOW men Figure 7 7 Water Flow Switch Water heater Pressure Only Relief Valve
110. warrantable failures of the boiler High temperature rise systems must be designed by a qualified engineer 29 Copper Fin Installation amp Service Manual 4 Hydronic piping Primary Secondary Piping Figure 4 4 Primary Secondary Piping of a Single Boiler MAY SUBSTITUTE LOW LOSS HEADER el O AIR SEPARATOR x 24 DRAIN POINT TYPICAL NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART SYSTEM SUPPLY SENSOR WHEN USED BALL VALVE TYPICAL SYSTEM CIRCULATOR PRESSURE GAUGE EXPANSION TANK ka Y STRAINER PRESSURE RELIEF VALVE TEMPERATURE PRESSURE GAUGE RECOMMENDED MAKE UP WATER BACK FLOW PREVENTER EON s VALVE TYPICAL PRESSURE REDUCING VALVE BOILER CIRCULATOR BOILER UNION TYPICAL NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 30 Copper Fin Installation amp Service Manual 4 Hydronic piping Primary Secondary Piping Figure 4 5 Single Boiler Primary Secondary with Low Temperature Bypass MAY SUBSTITUTE LOW LOSS HEADER SON eO AIR SEPARATOR bs DRAIN POINT y TYPICAL 2 EXCEED 4 PIPE DIA OR OF 12 APART SYSTEM SUPPLY SENSOR 4 BALL VALVE WHEN USED Re TYPICAL SYSTEM CIRCULATOR LOW TEMPERATURE BYPASS PRESSURE RELIEF VALVE TEMPERATURE PRESSURE
111. water source Use twisted pair wire minimum 18 gauge or larger See Table 5A page 33 regarding distance versus wire gauge Ensure all wire insulation is trimmed to reveal at least 3 8 of exposed wire 4 Connect the wires to the sensor wire using wire caps Turn on the electrical power and the main manual gas shutoff to the appliance 6 Replace the side access panel 7 Fire the appliance and resume operation ACCESS HOLE CONNECT THE MEASURED WIRE TO THE SENSOR WIRE Figure 5 5 Installation of Remote Sensors Outdoor Air Reset Option For boilers ordered with the Outdoor Air Reset option there 1s an additional control FIG 5 6 There are three setting knobs for Shutdown Outdoor Air Max and Ratio There is also a switch to turn the outdoor air shutdown feature On or Off An O A Sensor is also included 9 O A SENSOR ENABLE 40 70 DISABLE SHUTDOWN O A SHUTDOWN Figure 5 6 Optional Outdoor Air Reset Control 37 5 Electrical connections Shutdown The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the unit from operating Outdoor Air Max O A Max The O A Max knob allows a reset up to the maximum outdoor air temperature specified by this knob setting When the outdoor air temperature is above the specified setting the unit will not function in the O A Reset Mode but will continue to run at the selected set point temperature Note
112. which the heat exchanger can be drained Flue outlet The flue outlet allows the connection of the vent pipe to the unit Gas connection pipe The gas pipe connection on this appliance should be connected to the incoming gas supply for the purpose of delivering gas to the appliance Gas valve The gas valve allows the proper amount of gas to pass into the burner for combustion Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer The glass lined headers and copper finned tubing are encased in a jacket that contains the combustion process High limit sensor Device that monitors the outlet water temperature to ensure safe operation If the temperature exceeds its setting it will break the control circuit shutting the appliance down Ignition module F9 and M9 models only The ignition module responds to a call for heat signal to provide burner operation Junction box The junction box contains the connection points for the line voltage power and the pump Relief valve The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded Water heaters are supplied with a temperature and pressure relief valve Terminal strip The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection to contact points on the unit Thermostat The thermostat monitors the water temperature vi
113. xing valve to supply domestic hot water at temperatures less than 140 F Storing the water at a higher temperature and thermostatically mixing the water will increase the available quantity of mixed hot water greatly reduce the possibility of condensate formation on the heat exchanger and help prevent the growth of water born bacteria Adequate care MUST be taken to prevent potential scald injury when storing water at 140 F and hotter Water temperature over 125 52 can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at heating appliance Feel water before bathing or showering e If this appliance is used to produce water that could scald if too hot such as domestic hot water use adjust the outlet control limit or use temperature limiting valves to obtain a maximum water temperature of 125 F 52 Figure 7 5 Danger Warning A WARNING 52 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 Installation amp Service Manual Copper Fin Installation amp Service Manual 7 Domestic water heaters continued Relief Valve RELIEF VALVE Figure 7 6 Helief Valve Water heater This appliance is supplied with a relief val

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