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Lochinvar COPPER-FIN II 402 - 2072 User's Manual

1. La COPPER FIN II Installation amp Operation Manual A high limit control is located on the inside of the left front panel as shown in FIG 8 6 The setting of this control knob limits maximum discharge water temperature The water heater temperature limit control is adjustable up to a maximum setting of 210 F 99 C This water heater also includes a fixed high water temperature limit control set to 200 93 3 C The RESET key on the display must be pushed whenever water temperature has exceeded the set point of the limit temperature of the water in the heat exchanger must drop a minimum of 15 F 8 3 C below the setting of the high limit control before the reset function can be activated A high limit message will be shown in the Operator Interface when water temperature exceeds the high water temperature limit control set point The high limit control will not reset until the NOTICE water temperature has dropped below the set point of the high limit Optional relief valve This water heater 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 is equipped with this optional relief valve and 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 e
2. 78 Installation amp Operation Manual COPPER FIN 21 30V443 1NI1I SNEAOMN NLH 3 Snadow C LNO C 9X C VX 0 8 4 V cals E LNO L 9X OL 8x gt lt lt L LNO 9 vX 8 9 191 davosvo 5 vS YOSNAS 9 9N9 21 8 L NOILOANNOO 91 8X S AN d33ds j WALSAS 9NO 9 8 Z LNO c NOILOANNOO 11 8 9 davosvo 6S HOSNHS 14110 ANZ END EN LS HOSN3S 1411 lt 1 8 1 9 gt lt 7 LAdLNO 1 28 HOSNIS LIINI 2 OL 9NO 31V4 LNO gt lt OL O 9 X 6 9 gt lt gt lt GL 8X 6 9 sna ZS HOSNZIS 9 LNO gt lt OL 0 NH L3 G 8X 9 SNIAOMd C o lOOd WALSAS VL 9X 2 6 S LNO 95 YOSNAS 100d WALSAS 1WLSL MNV L C o v 16 15 c ADVLS 1 15 LL 9X 21 4 100d SL 9X OL GNO 6L 8X 8S YOSNAS Alddfns lOOd 9 9X SNO VNO 11 3x L ELX SS HOSNIS 4371104 400d1NO0 C 9X 8 GNO c NOILOANNOO 9L 9X L GNO 1 9 L GNO
3. SLOVLNOO SWILNAY 9 VNO c x S VNO L EX L QUVOd NOILOANNOO HOLIMS 6548 4 SVO HOIH de 2 ANTH 11 4 EL 9X 9 GNO LBL20083 REV B 79 Ladder diagram continued 11 SSHHd SVO MOT L NOILOANNOO es gt 21 9 90174 6684 HIV H C m IV S d Wav ps agoud ddoino er 4391VvM MOTI SLOVLNOO 16 1 L RE 9X HOLIMS MOTI v er 9 L NOILOANNOO Lochinvar Revision Notes Revision ECO C08226 initial release High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 Rev 6 11 www Lochinvar com
4. 2903cm 3871 cm 5807 cm 5807 cm 11614 cm 11614 cm 518 518 690 1035 1035 2070 2070 3342cm 3342cm 4452 cm 6678 cm 6678 cm 13356 cm 13356 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 11 1 Determine unit location Exhaust fans Any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and or cause a down draft 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 boiler room the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the boiler Vertical DirectAire Horizontal DirectAire and Direct Vent venting systems have specific requirements for combustion air ducts from the outside which are directly connected to the unit See the requirements for combustion air duct in the venting section Use of filters having
5. n gt gt gt gt a SWITCH LOUVER RELAY COIL LOUVERS L NEU AQUASTAT CP TANK AQUASTAT AU TANK SENSOR 778 luNiTS I FROM 0 10 DC IN BMS J 1 common 67 0 10V DC OU BMS J COMMON moD 0 10 V RATE OUT SHIELD Bus A SHIELD POOL sc ie SAFETY sk SUPPLY 0909101 2 10K 20K VR fior 2 D POOL BOILER 10 FROM 1 OUTPUT A SAFETY 10K 20K O OUTLET lt lt p BL SENSOR Ww INLET _ 10K ien 24V COM MAIN POWER HARNESS Fly Sree 24V OPT ULON HARNESS GROUND Sogi CHASSIS ON OFF PUMP RELAY 120VAC COIL GROUND GROUND SWITCH MAIN UNIT 76 I Installation amp Operation Manual 10 Connection diagram continued Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubl
6. 3 Fill to correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure should be 12 PSI b Pressure will rise when boiler is turned on and system water temperature increases 4 At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further COPPER FIN Il Installation amp Operation Manual Continual A WARNING Eliminate all system leaks ntini fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water system Purge air from system a Connect a hose to the purge valve see purge drain valves in the piping diagrams on pages 39 42 Route the hose to an area where water can drain and be seen Close the boiler or system isolation valve between the purge valve and fill connection to the system Close zone isolation valves Open quick fill valve on cold water makeup line Open purge valve One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow 15 present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation val
7. A WARNING 1 2 10 11 Installation 8 Operation Manual To minimize the possibility of serious personal injury fire or damage to your unit never violate the following safety rules This unit is only for use with the type of gas indicated on the rating plate If you smell gas shut off gas supply do not try to light any appliance do not touch any electrical switch do not use any phone in your building immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions if you cannot reach your gas supplier call the fire department Boilers and water heaters are heat producing appliances To avoid damage or injury do not store materials against the appliance or the vent air intake system Use proper care to avoid unnecessary contact especially children with the appliance and vent air intake components Never cover your unit 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 unit 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 Appliance surfaces become hot during operation Be careful not to touch hot surfaces Keep all adults children and animals away from operation of the hot unit Severe burns can occur
8. 1 Disconnect the two external wires connected to the enable terminals on the connection board 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Allow the boiler to cycle Check vent and air piping Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Placing the boiler in operation Boiler operational checks 1 Turn the boiler main power switch to the ON position 2 Verify operation of the SMART SYSTEM control module and Operator Interface 3 Program the adjustable points from the Operator Interface 4 Push the reset for the low water cutoff if equipped 5 Ensure that maximum flow to the boiler does not exceed 55 GPM on Models 402 752 and 90 GPM on Models 992 2072 Verify by checking temperature rise while burner is firing at 10096 of rated input 6 Install a manometer on the gas supply
9. DHW Night Setback and Ramp Delay operation with cascade For indirect DHW operation any boiler s in the Cascade can be selected to provide heat for a DHW call Select a boiler to be designated as the DHW boiler Connect the tank thermostat or tank sensor to the corresponding terminals on the low voltage connection board When the boiler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it up to take its place The DHW boiler will adjust its set point to the programmed outlet set point and will adjust its firing rate to maintain this Once the DHW call has been satisfied the Leader control will place that boiler back into the Cascade sequence Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur The boiler will provide heat for the DHW demand until it is satisfied Night Setback operation of the boilers or water heaters within the Cascade is available Programming of the Space Heating SH Night Setback will be done through the Leader boiler Refer to the Copper fin II Service Manual for information regarding Night Setback Ramp Delay operation of the boilers as described in the Copper fin II Service Manual is available when the boilers are part of a Cascade system Installation amp Operation Manual 7 Operating information continued Sequence of operatio
10. Minimum Efficiency Reporting Value ratings higher than 4 is not recommended Higher efficiency low micron filters can limit combustion air leading to either nuisance problems or potential component damage if used over prolonged periods of time Filters having a MERV rating of 5 to 6 may be used on a limited basis during the construction phase of a project provided they are replaced once filter loading becomes apparent After the construction phase is completed it is recommended that the filter be changed to a 4 or lower MERV disposable type filter Figure 1 6 Metal Panel Covering Side Combustion Air Inlet CorPER FIN II Installation amp Operation Manual Combustion air filter This unit has a standard air filter located at the combustion air inlet This filter helps ensure clean air is used for the combustion process Check this filter every month and replace when it becomes dirty The filter size on Models 402 752 is 12 x 12 x 1 30 5cm x 30 5cm x 2 5cm and 16 x 16 x 1 40 6cm x 40 6cm x 2 5 cm on Models 992 2072 You can find these commercially available filters at any home center or HVAC supply store For convenience and flexibility you can direct the combustion air inlet from either the back or right side of the unit To arrange the combustion air inlet for side entry follow the steps below 1 Remove the metal panel from the unit s side wall see FIG 1 6 2 Remove screws from the air filter bracket
11. 120 VAC the temperature set point and other user adjustable points is made through the Operator Interface located on the front access door The outlet sensor is installed in the outlet side of the heat exchanger top header The inlet sensor is located on the inlet side of the heat exchanger top header 7752 752 operating sensor inlet outlet is selectable from the 17 9 screen in the Operator Interface 06 1262 179 exact temperature set point is based the system s 21 4 requirements Set the control set point s to the desired 21 4 operating water temperature 21 4 Standard Pump Supplied with Water Heaters Onl The maximum temperature set point that can be programmed into the control module from the Operator Interface on a heating boiler is 220 F 104 49 The manual reset high ELECTRICAL SHOCK HAZARD For your limit control for a heating boiler is adjustable up to a fixed safety turn off electrical power supply before maximum setting of 230 F 110 C making any electrical connections to avoid possible electric shock hazard Failure to do The maximum temperature set point for a water heater 1s so can cause severe personal injury or death 190 F 88 C The auto reset high limit is fixed at 200 F 93 and the adjustable manual reset high limit has a Notice Wiring must be N E C Class 1 maximum setting of 230 110 a T If original wiring as supplied with the boiler must be replace
12. The installed length of flue from the unit to the outside point of termination must not exceed 50 equivalent feet 15 2m Subtract 5 feet 1 5m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7m of equivalent length for each 45 elbow Sidewall vent termination clearances and location Follow all sidewall venting termination information for clearances and location under Sidewall Vent Termination Clearances and Location on page 22 TABLE 2C SIDEWALL VENT KITS KIT MAX VENT W POWER ASSY LENGTH MODELS 402 752 LENGTH These kits include a barometric damper 24 Coprer FIn Installation amp Operation Manual 2 Ventin Q continued Horizontal DirectAire venting Powered Venting see page 14 NOTICE Before installing a venting system follow all requirements found in the General Venting section The Horizontal DirectAire vent system is the same as the Sidewall Venting system except it pulls combustion air from the outdoors through a sidewall air inlet Follow all requirements in Sidewall Venting section on page 22 The Horizontal DirectAire vent system requires you to install two pipes directly to the unit one pipe for flue products and one for combustion air Install both pipes horizontally with a sidewall termination point For this F venting option you must purchase the DV box accessory from the appliance manufacturer The DV box att
13. AQUASTAT TO MONITORING DEVICE TO MONITORING DEVICE THREE WAY VALVE Oo A OO N 9 9 0 06 6 9 06 0 9 6 9 0 0 8 0 3 WAY VALVE EXTERNAL 92 7 STAGING SEQUENCER LOUVER PROVING 54 SWITCH 21 a O STAGING LINE TO LOUVER DHW TANK THERMOSTAT 2 10 SENSOR FROM 25 HEATER 26 TO NEXT HEATER 27 28 29 EXTERNAL 30 SEQUENCER BUILDING AUTOMATIC 32 CONTROL 33 34 35 22 TANK SENSOR SHIELD A B SHIELD 0 10V BMS IN 0 10V RATE OUT SHIELD A B SHIELD gt gt MODBUS 0 6 9 2 BOILER ONLY OUTDOOR SENSOR SYS SUPPLY SENSOR SYS RETURN SENSOR 0 10V SYS PUMP IN OUTDOOR AIR SENSOR SYSTEM SUPPLY SENSOR SYSTEM RETURN SENSOR PUMP SPEED INPUT GEEK C n 0 10VDC COMMON 6 Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Hardness less than 7 gra
14. Figure 3 1 Gas Line Connection NOTICE If an inline high gas pressure regulator is used it MUST BE of the lockup type and be located a minimum of 10 feet from the appliance Failure to do so may result in insufficient gas volume supplied to the appliance 31 3 Gas connections 2 Use new properly threaded black iron pipe free from chips If you use tubing make sure the ends are cut square deburred and clean Make all tubing bends smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide unit with proper volume of gas 3 Install a manual main gas shutoff valve at the unit s gas inlet outside of the unit 4 Run pipe or tubing to the unit s gas inlet If you use tubing obtain a tube to pipe coupling to connect the tubing to the unit s gas inlet 5 Install a sediment trap in the supply line to the unit s gas inlet see FIG 3 1 6 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 inlet to unit d Connect gas pipe to inlet of unit Use wrench to support gas manifold on the unit 9 For L P gas consult your L P gas supplier for expert installation 10 Ensure that all air is completely bled from the gas line before starting the ignition sequence Start up without properly bleeding air from the gas line may require multiple reset functions of the ignitio
15. It is strongly recommended that the system supply sensor be installed as well Connect these terminals to the system return sensor FIG 5 4 Boiler Management System BMS 1 external control may connected to control either the firing rate or the set point of the appliance boiler or water heater Connect the 0 10 VDC terminals to the 0 10 VDC output of the external control The SMART SYSTEM control can be programmed to use the enable output of the Boiler Management System or use the voltage signal to enable the heater Connect the Staging S1 or tank thermostat terminals to the enable output of the BMS when used Make sure the ground terminal is connected to the ground output terminal of the external control and the 0 10 V BMS IN terminal is connected to the 0 10 VDC terminal of the external control Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat 3 way valve out An electric 3 way mixing valve may be used when the return temperature to the heater is less than 140 F 60 Connect the Open output to the Open terminal on the 3 way valve Connect the Close output to the Close terminal on the valve and the COM output to the 24VAC terminal on the valve O 10V rate out A 0 10VDC signal is available to allow a Building Management S
16. This appliance uses a finned copper tube heat exchanger to maximize the heat transfer process The heat exchanger is mounted in the inner jacket of the appliance A series of V shaped baffles are installed between the individual tubes to control the movement of the flue products over the finned copper surface and increase heat transfer Water enters the heat exchanger and makes two passes over the area exposed to direct heat from the burner A circulating pump MUST be installed to ensure proper water flow over the heat transfer surfaces during burner operation Water temperatures in the heat exchanger are determined by water flow 34 COPPER FIN Il Installation amp Service Manual Initial set up of maximum water flow On initial start up of the Copper fin II the maximum water flow to the heat exchanger must be checked and manually limited with a valve or bypass before normal operation begins An appliance allowed to operate at return temperatures below the specified minimum setting may experience problems with the operating controls safety switches obstruction of the flue gas passages on the heat exchanger incomplete combustion and possible flue gas spillage Sustained operation at lower than specified water temperatures 140 F may cause hazardous conditions that may result in personal injury or non warrantable damage to the appliance Water flow switch A water flow switch is factory installed in the outlet on all he
17. guidelines Warranty Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 Excessive water hardness causing a lime scale build up in the copper tube is not the fault of the equipment and is not covered under the manufacturer s warranty 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 II Please read before proceeding Safety information Owner warning The information contained in this manual is intended for use by qualified professional installers service technicians or gas suppliers NOTICE Consult and follow all local Building and Fire Regulations and other Safety Codes that apply to this installation Consult local gas utility company to authorize and inspect all gas and flue connections A gas appliance that draws combustion air from the equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting A WARNING Should overheating occur or the gas supply fail to shut of
18. 0 H 2 ON SI O NPE H fe V TRTO H QJ 10 1 30 F AT 35 F AT 40 F AT 45 F AT 50 F AT c 2 55 F AT Ft hd 45 lt Ca 45 lt F SN TAR TH TH N TO TO D ON 8 Iw AMEN 1 2 _ _ 5 35 41513 54 58 46 NO gt w O IN N ND HM m N NO NX J T T 9 I BH Je 2 A 0 1 4 co amp O lt o win J OV gt amp FB 59 O ND WB bd Cupro Nickel Heat Exchanger Required at Flows Above 55 GPM on Models 402 752 and above 90 GPM on Models 992 2072 TABLE 4D BOILER TEMPERATURE RISE AT MAXIMUM FLOW Temperature Rise at Full Rate Fire 55 and 90 GPM Maximum Flow Model Temperature Rise F 12 55 GPM 15 55 Boiler bypass requirements The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded The bypass will help to ensure that the boiler can be supplied with adequate water flow Flow rates exceeding the maximum recommended flow will result in erosion of the boiler tubes A t
19. 16 This option uses a powered vent assembly to exhaust the flue products out a sidewall with air supplied by a pipe from the sidewall see page 25 HORIZONTAL DIRECTAIRE VENTING CONVENTIONAL NEGATIVE DRAFT VENTING NOTE CAT B VENT MATERIALS MAY BE USED WHEN THE POWERED VENT IS CONNECTED DIRECTLY TO THE OUTSIDE VENT IF THE POWERED VENT IS NOT CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP THEN CAT IV AL29 4C VENT MATERIALS MUST BE USED FROM THE POWERED VENT TO THE OUTSIDE VENT CAP This option uses a vertical conventional vent for This option uses a sealed AL29 4C flue and a flue products with air supplied by a pipe from the separate combustion air pipe to the outdoors sidewall or rooftop see page 19 This system terminates both the flue and combustion air inlet in the same pressure zone VERTICAL DIRECTAIRE VENTING DIRECT VENT See page 26 1 5 i MIN af 5 T BEES F 4 u This option uses powered vent assembly This option uses the installation of a special air to exhaust the flue products sidewall inlet vent cap on top of the unit see page 30 vent termination with air supplied from the equipment room see page 22 SIDEWALL VENTI
20. 6 _ 6 MIXING COLD VALVE WATER SUPPLY L S BUILDING HOT WATER SUPPLY RELIEF VALVE MIN 4 LOCK TEMP STORAGE SIZE TANK DRAIN BUILDING RETURN 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 67 8 Domestic water heaters TABLE 8C COMMON WATER MANIFOLD SIZE FOR MULTIPLE WATER HEATER INSTALLATIONS Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow Common Manifold Size Min Models Pump operation 1 The water heater must have a properly sized circulating pump This pump is sized to circulate water between the heater and the storage tank only 2 The pump is sized to the heater input and water chemistry specifications noted in the Water Chemistry section on page 63 3 The diameter and length of the piping installed between the storage tank s and water heater must be properly sized based on the capacity of the circulating pump 4 The pump must run continuously when the water heater is energized This is the standard operating system for a water heater A pump delay control function with an all bronze pump is installed as standard equipment on all water heater systems The pump will operate only while there is a Call for Heat and for a timed period after the water temperature set point is satisfied to r
21. B Vent Material CAT Venting Category Definitions Reference National Fuel Gas Code ANSI 7223 1 CAT 1 Negative pressure non condensing An appliance that operates with a non positive vent static pressure with a vent gas temperature that avoids excessive condensate production in the vent CAT IV Positive pressure condensing An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause excessive condensate production in the vent CAT IV Flue pipe materials The following manufacturers supply flue materials suitable for these models when installed as CAT IV All materials are made with AL29 4C stainless steel Heat Fab Inc Saf T CI Vent with AL29 4C stainless steel Protech Systems Inc Fas N Seal Vent with AL29 4C stainless steel Metal Fab Inc Corr Guard Vent with AL29 4C stainless steel Or other listed Category IV vent systems suitable for a condensing positive pressure gas fired appliance A Category IV flue MUST have all vent joints and seams sealed gastight and have provisions for a drain to properly collect and dispose of condensate that may occur in the venting system 13 COren FNI Installation amp Operation Manual 2 Venting Ve nt syste m opt IONS Note Installations shown below are representative actual installations may vary from those shown This option uses a vertical rooftop flue termination with air supplied from the equipment room see page
22. For venting flue products vertically to the outdoors follow all requirements in the installation instructions for conventional venting in this manual Follow all clearance requirements in Vertical Vent Termination Clearances and Location on page 17 A barometric damper is not required in the flue on Vertical DirectAire installations if the draft is within the negative 0 02 to 0 08 inches w c required for proper operation If the draft exceeds this range install a barometric damper TABLE 2B DIRECTAIRE KITS MODEL VERTICAL KIT 402 VDK3026 502 VDK3026 652 VDK3027 752 VDK3027 992 VDK3023 1262 VDK3024 1442 VDK3024 1802 VDK3024 2072 SVK3041 VDK3024 The SVK kits include a DV box adapter and sidewall air inlet cap The VDK kits include a DV box adapter and a rooftop air inlet cap 21 Coprer Fin IT Installation amp Operation Manual 2 Venting Sidewall venting see page 14 C 22 NOTICE Before installing a venting system follow all requirements found in the General Venting section This option uses a powered vent assembly which pulls the flue products out of the stack This fan generates a negative draft at the unit Combustion air is drawn from the equipment room see Combustion and Ventilation Air on 10 Sidewall with fan The sidewall fan can be mounted on the inside outside depending upon model with a sidewall vent hood installed on the exterior wall The sidewall fan an
23. If a space heating call for heat was on the boiler pump will turn Off a few seconds after the DHW pump turns on 51 7 Operating information Temperature control Firing rate Depending upon the model the Copper fin II is capable of staging its firing rate from a minimum of 25 to a maximum of 100 The firing rate is dictated by the call for heat i e space heating or domestic hot water the heating load ramp delay if enabled and various other temperature limitations Ramp delay boiler only For systems with lower flow the SMART SYSTEM can limit the firing rate when enabled when a space heating call for heat starts or when switching from a DHW call for heat to a space heating call for heat There are six 6 limits that can be programmed as well as six 6 time intervals corresponding to each limit The sixth limit will also limit the firing rate for the rest of the call for heat Gradient limiting If during operation of the heater the outlet water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Outdoor air reset boiler only With the outdoor air sensor connected the control module will calculate the set point based on the programmed reset curve The installer can change the slope of the reset curve by several adjustable parameters The user can limit the maximum set point for the system using the space heating set point Boost function boiler only If out
24. Screens By using the Previous Next 4 gt arrow keys on the SMART SYSTEM display panel you can navigate through the 11 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Display Shows The unit has been turned OFF by the Enter Reset button on the HTR OFF SMART SYSTEM display panel The unit has not received a call for heat from a remote thermostat nor BUS STANDE has it received a call for heat from a DHW thermostat The unit has met the water temperature set point but is still receiving HTR SETPOINT MET a call for heat from either a remote thermostat a DHW thermostat or a BMS HTR PRE PURGE The unit has initiated the 10 second air purge upon a call for heat Screen 1 The unit has begun the 30 second heatup time prior to the trial for Line 1 HTR IGNITER ON ignition Display will show IGNITER A or IGNITER B depending on which stage has priority j eer E RUN STG The unit has fired and is running at the displayed number of stages HTR DHW STG 1 2 3 4 TR The call for heat has been satisfied and the unit runs the fan for an HTR POST PURGE additional 10 seconds to clear the combustion chamber and vent system of residual flue products The unit has been placed in a temporary mode that will allow the unit to fire for the purpose of combustion analysis SERVICE MODE When the outlet sensor has b
25. THAN ONE DISCONNECT MAY BE emp LBL20082 REV A REQUIRED TO DEENERGZE THE EQUIPMENT FOR SERVICING 21 77 Installation amp Operation Manual COPPER FIN Ladder diagram 11 v clX SWITCH STATES MAY VARY FROM THOSE SHOWN ON DIAGRAMS DEPENDING UPON WHETHER UTILITIES ARE CONNECTED OR A FAULT CONDITION IS PRESENT SEE WIRING DIAGRAM FOR ADDITIONAL NOTES WHERE POSSIBLE SWITCHES ARE SHOWN WITHOUT UTILITIES GAS WATER OR ELECTRICITY CONNECTED TO THE UNIT AS SUCH ACTUAL gt lt G CIX dATVASV9E39VIS gt O 9 01 JAIWASVOZADVLS E 0IX QQ lt SOLX AAWASVD 16 201 L OLX QHVO8 Q3 VHOMH3 LNI L clX H3INHOJSNVH L H3INHOJSNVHL CCX 84 n 2 Ex Pd 1 4 o C BEFORE SERVICING AV 134 5 OT IH H3MO T8 MOI SLoldad Qqaads AV 13H LINN Qqaads H3MO 8 ISH 15 OL LX LX 431109 ISH 39VLS UM R iS IST diis AYA dINNd 941934 avNIWHSL 28099 LINN 061 14544 IVNNVW LINIYII VHOMH3 LNI AVT1T3Y OVIH HOLIMS 440 NO d AV T3 AV 134 99395 OYIH H3MO I8 41415
26. You must take adequate care to prevent scald injury when storing water at elevated temperatures for domestic use This unit must have an adequate supply of fresh air during operation for proper gas combustion and venting Make sure all exhaust venting is properly installed and maintained Improper venting of this unit could lead to increased levels of carbon monoxide Do not use this boiler if any part has been under water Immediately call a qualified service technician to replace the boiler The possible damage to a flooded boiler can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Do not alter this unit in any way Any change to this unit or its controls can be dangerous II Installation amp Operation Manual Copper fin How it works 1 10 11 12 13 14 Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer The glass lined headers and copper fined tubing are encased in a jacket that contains the combustion process Heat exchanger access cover The heat exchanger access cover is a galvanized steel door which allows access for service maintenance and removal of the heat exchanger from inside the combustion chamber Blower The blower pulls in and injects air into the individual burners along with gas from the gas manifold where the mix is bur
27. assembly 3 Move the filter bracket assembly from the rear of unit to the side opening see FIG 1 7 4 Attach filter bracket assembly to the unit s side using the pre drilled screw holes 5 Attach the metal panel to the rear combustion air opening to seal it off Figure 1 7 Moving Air Filter Bracket Assembly from Rear of Unit to Side During construction the air filter should be checked more frequently to ensure it does not become clogged with NOTICE combustion dirt debris Sustained operation of an appliance with a clogged filter may result in nuisance operational problems bad CAUTION combustion and non warrantable component failures 12 Coprer FIn II Installation amp Operation Manual 2 Venting BEFORE YOU BEGIN Identify your appliance s vent system This manual covers venting requirements for CAT I models and CAT IV vent materials Be sure to correctly identify the type of vent system your appliance requires before proceeding C F H N L 0402 C F H N L 0502 C F H 1 0652 C F H 1 0752 C F H N L 0992 C F H N L 1262 C F H N L 1442 C F H N L 1802 C F H N L 2072 Venting options Direct Vent Options CAT IV H Outdoor Vent Option allure to use correct venting materials result loss of trom flue gas spillage into working or livin A DANGER tail ing ial It in loss of life from flue gas spillage i king or living space
28. be sealed Select air inlet pipe material from the following specified materials PVC CPVC or ABS Dryer vent or sealed flexible duct not recommended for rooftop air inlet Galvanized steel vent pipe with joints and seams sealed as specified below Type B double wall vent with joints and seams sealed as specified below Plastic pipe may require an adapter not provided to transition between the air inlet connection on the unit and the plastic air inlet pipe Use only vent or air intake materials specified in this manual Follow vent pipe manufacturer s instructions A WARNING i 21 M Failure to do so can result in property damage personal injury or death Mixing of venting materials will void the warranty and certification of this unit Sealing Type B double wall vent pipe or galvanized vent pipe Follow the steps below to properly seal Type B double wall vent pipe or galvanized vent pipe 1 Sealall joints and seams of the air inlet pipe using either aluminum foil duct tape meeting UL Standard 723 or 181 A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric 2 On horizontal runs do not install vent pipe with seams pointing down Position vent pipe so that the seams are on the top side of the vent pipe 3 Secure all joints with a minimum of three sheet metal screws or pop rivets Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent p
29. burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next e f 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 to the floor because some gas is heavier knob will not turn by hand don t try to than air and will settle on the floor repair it call a qualified service tech nician Force or attempted repair may FOR YOUR SAFETY result in a fire or explosion WERE TO DOUE YOU SMERE GAS D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas con trol which has been under water Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information above on 5 Push in gas control knob slightly and this label turn clockwise to OFF 2 Turn off all electric power to the appliance NOTE On the 36C valve knob cannot be turned to OFF unless knob is pushed in slightly Do not force 3 Open control access panel 4 This appliance is equipped with an ignition device which automatically lights the burner Do no
30. change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point Cascade When multiple appliances are installed they can be wired together in a cascade sequence maximum of eight appliances can be controlled from a single control In this application one appliance would be designated as the Leader control and all others would be designated as Member controls The set point or firing rate can be controlled by the 0 10V input as well Once the Leader appliance receives a call for heat from a BMS tank sensor or external thermostat the control will determine what the set point will be A fixed temperature set point can be programmed into the control See Copper fin II Service Manual to program the set point On boilers if the water temperature at the system sensor is less than the set point the turn off offset the off on differential then the control will initiate a call for heat on the Cascade see the Copper fin II Service Manual for an explanation of the offset and differential The Leader will energize the lead appliance on the Cascade For a new startup this will be the Leader appliance On water heaters if the water temperature at the tank sensor 15 less than the tank set point the off differential then the control will initiate a call for heat on the Cascade 53 7 Operating information The appliance will fire at its ignition speed and will then stage its firing
31. for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations 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 e Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent airborne dust Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety
32. gas valves These units fire in multiple stages of burner input Each stage of burner operation has a combination gas valve s to cycle the gas supply on and off and regulate gas to the burners Each 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 unit is in service The gas control valve has pressure taps located on the inlet and discharge sides of the valve Manifold pressure is adjusted using the regulator located on the valve A manifold gas pressure tap for each burner stick is located on the discharge side of the valve The manifold pressure is preset at the factory and adjustment is not usually required If you must adjust regulator pressure follow the instructions Copper fin Service Manual Venting of combination gas valves The combination gas valve regulator used on all units is equipped with an integral vent limiting orifice per ANSI Z21 78 The vent limiter ensures that the volume of gas emitted from the valve in the event of a failed gas diaphragm does not exceed the maximum safe leakage rate allowed by agency requirements 3 Gas connections continued Combination gas valve regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors The termination of the vent limited opening on the combination gas
33. in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning You must locate the combustion air cap and the flue gas outlet on the same rooftop surface vertical direct vent system or sidewall surface horizontal direct vent system and in the same pressure zone as the vent termination Follow all clearance requirements listed on this page Purchase and assemble the combustion air inlet cap to protect the air inlet from wind and weather Alternatively assemble the combustion air inlet cap for vertical rooftop air inlet from items purchased locally The air inlet cap consists of two 90 elbows installed to the air inlet pipe see FIG 2 13 Install the first 90 elbow on the rooftop at the highest vertical point of the air inlet pipe Install the second 90 elbow on the horizontal outlet of the first elbow The outlet of the second 90 elbow will be pointing down You may use a 90 elbow and a 90 straight elbow to make this assembly If you use a straight piece of pipe between the two 90 elbows it should not exceed 6 51mm in length For horizontal direct vent termination of combustion air you must use the termination cap from the appliance manufacturer The sidewall air inlet cap 1s available as part of a direct vent kit See Table 2E page
34. page Flue 1 25 4 mm 2 Locate the appliance so that if water connections should leak water damage will not occur When such locations Hot Water Pipes 1 25 4 mm cannot be avoided it is recommended that a suitable An Alcove is a closet without a door Thirty six inches 36 drain pan adequately drained be installed under the unit to rear required for outdoor installation The pan must not restrict combustion airflow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this unit or any of its components Note No additional clearance is needed on the right side of the unit for the observation port An observation port 1s located on both the right and left side of the unit 3 The appliance must be installed so that the ignition system components are protected from water dripping Figure 1 1 Indoor clearances from combustible construction spraying rain etc during appliance operation and service gei 3 MIN MIN circulator replacement control replacement etc 4 Appliances located in residential garage and adjacent 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 46 cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving ve
35. ported stainless steel construction which uses a gas air mix to operate at a fixed input Banks of burners turn on or off to vary the firing rate Water outlet system supply The water outlet is a 2 or 2 1 2 depending on model pipe connection that supplies water to the system with connections for a flow switch see 426 a relief valve see 423 and a temperature and pressure gauge boilers only see 8 Water inlet system return The water inlet is a 2 or 2 1 2 depending on model pipe connection that receives water from the system and delivers it to the heat exchanger Gas supply pipe The gas supply pipe on this appliance is 1 1 4 or 2 depending on model diameter NPT Please reference the National Fuel Gas Code charts for connection details SMART SYSTEM Control Module The SMART System Control Module is the main control for the appliance This module contains the programming that operates the blower gas valve and pumps in addition to other programmable features 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Air intake Fresh air for combustion is drawn through a filter provided at the air intake located at either the rear or right side of the appliance Line voltage terminal strip The line voltage terminal strip provides a location to connect all of the line voltage 120 VAC contact points to the unit Low voltage connection board s The low voltage connection b
36. pump will cycle on at each call for heat before the burner fires The pump will continue to operate while the burner is firing The pump will run for a 30 second period after the temperature set point 15 satisfied This timing 15 selectable from the Operator Interface This timing will remove any of the residual heat from the combustion chamber before turning the pump off See the wiring diagram in Section 9 of this manual 35 4 Water connections Pump Maintenance Inspect the pump every six 6 months and oil as necessary Use SAE 30 non detergent oil or lubricant specified by the pump manufacturer The boiler is recommended for installation in a primary secondary piping system This type of system uses a separate boiler circulating pump to supply flow to and from the boiler only The secondary pump is sized based on the head loss of the boiler and related pipe and fittings in the secondary loop only A properly sized primary system pump provides adequate flow to carry the heated boiler water to radiation air over coils etc The fittings that connect the boiler to the primary system should be installed a maximum of 12 inches 0 30m or 4 pipe diameters apart to ensure connection at a point of zero pressure drop in the primary system There should be a minimum of 10 pipe diameters of straight pipe before and after the boiler secondary loop connections to prevent turbulent flow at the secondary loop connections The secondary loop pipi
37. see FIG 1 4 Each of the two openings must have a net free area of one square inch per 1000 Btu input 22cm per kW but not less than 100 square inches 645cm Figure 1 4 Combustion Air from Interior Space Coprer Fin Installation amp Operation Manual 1 Determine unit location continea All dimensions are based on net free area in square inches Metal louvers or screens reduce the free area of a combustion air en opening minimum of approximately 25 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 equipment room Each opening must have a minimum net free area as specified in TABLE page 11 Single openings shall be installed within 12 30 cm of the ceiling A CAUTION combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other Figure 1 5 Outside Combustion Air Through Ducts 4 Outside Combustion Air Using Direct Venting With this option you can connect combustion air vent pip
38. the display of the actual system return temperature and will also allow control of the system return temperature when the SMART SYSTEM control is programmed for inlet temperature control As always installation of the system supply sensor 15 strongly recommended as well This will reduce the potential for short cycling of the boiler and provide more responsive temperature regulation even when the SMART SYSTEM control is programmed for inlet temperature control A boiler allowed to operate at set point temperatures below the specified minimum settings may experience operational problems with the operating controls and safety switches obstruction of the flue gas passages on the heat exchanger incomplete combustion and possible flue gas spillage Operation at lower than specified water temperatures may cause hazardous conditions that result in non warrantable damage to the appliance Three way valves in system 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 appliance 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 cycles system noise relief valve discharge and in extreme cases a knocking flash to steam These conditions can cause operational problems and non warrantable fail
39. valve regulator complies with the safety code requirements of CSD 1 CF 190 a as shipped from the appliance manufacturer without the installation of additional vent lines Checking gas supply pressure Use the following procedure to check gas supply pressure 1 Turn the main power switch to the OFF position 2 Turn gas valve knobs to the OFF position 3 Shut off gas supply at the field installed manual gas cock in the gas piping to the unit If fuel supply is L P gas shut off gas supply at the tank 4 Remove the 1 8 hex plug located on the inlet side of the gas valve You may also use a tapping on the field installed main manual gas cock or gas piping Install a fitting in the inlet pressure tapping suitable to connect to a manometer or magnehelic gauge Range of scale should be 14 w c or greater to check inlet pressure 5 Turn on gas supply at the manual gas cock turn on L P gas at the tank if required Turn the power switch to the position Turn the gas valve knobs to the position Set the electronic temperature control or thermostat to call for heat 8 Observe the gas supply pressure as all burners are firing Ensure that inlet pressure is within the specified range See Connecting To Gas Supply page 31 for minimum and maximum gas supply pressures 9 If gas pressure is out of range contact gas utility gas supplier qualified installer or service agency to determine necessar
40. 1442 1802 amp 2072 Number of Units GPM Number of Units D pud 1 2 4 2 o 1 9 2107 MIXING BUILDING VALVE HOT WATER SUPPLY A COLD 22 WATER SUPPLY RELIEF VALVE LOCK TEMP STORAGE TANK DRAIN BUILDING RETURN 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 II Installation amp Operation Manual 8 Domestic water heaters Figure 8 3 Multiple Water Heater Piping with a Single Storage Tank COMMON MANIFOLD SIZE Min Models 402 502 652 22722 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units COLD WATER MIXING SUPPLY VALVE BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK TEMP ee STORAGE SONON TANK MANIFOLD SIZE DRAIN BUILDING RETURN 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 66 Installation amp Operation Manual 8 Domestic water heaters continued Figure 8 4 Multiple Water Heater Piping with Multiple Storage Tanks COMMON MANIFOLD SIZE Min Models 402 502 652 amp 752 3 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 amp 2072 Diameter Number of Units 2 3 5 7 _ 6 _
41. 2302 12 Minimum diameter for air inlet pipe Installer increase diameter pipe size for ease of installation if needed 62 S 8 ue 15 CoPPER FIN Installation amp Operation Manual 2 Venting 16 Conventional negative draft venting see page 14 NOTICE Before installing a venting system follow requirements found in the General Venting section This option uses Type B double wall flue outlet piping The blower brings in combustion air The buoyancy of the heated flue products cause them to rise up through the flue pipe The flue outlet terminates at the rooftop Negative draft The negative draft in a conventional vent installation must be within the range of 0 02 to 0 08 inches w c to ensure proper operation Make all draft readings while the unit is in stable operation approximately 2 to 5 minutes Connect the flue vent directly to the flue outlet opening on the top of the unit No additional draft diverter or barometric damper is needed on single unit installations with a dedicated stack and a negative draft within the specified range of 0 02 to 0 08 inches w c If the draft in a dedicated stack for a single unit installation exceeds the maximum specified draft you must install a barometric damper to control draft Multiple unit installations with combined venting or common venting with other Category I negative draft appliances requi
42. 27 for Horizontal Direct Vent Kits Vertical Combustion Air Inlet Clearances You must locate the air inlet termination elbow at least 12 30cm above the roof or above normal snow levels If the air inlet cap 1s within a 10 foot 3 05m radius of the flue outlet the point of termination for the combustion air inlet cap must be at least 3 feet 0 91m below the point of flue gas termination vent cap Do not install the combustion air inlet cap closer than 10 feet 3 05m from an inside corner of an L shaped structure Figure 2 13 Vertical Rooftop Air Inlet Horizontal combustion air inlet clearances You must locate the horizontal air inlet termination point at least 12 30cm above grade and above normal snow levels If the air inlet cap is within a 10 foot 3 05m radius of the flue outlet the point of termination for the combustion air inlet cap must be at least 3 feet 0 91m below the point of flue gas termination vent cap Do not install the horizontal combustion air inlet cap above the flue outlet Do not install the combustion air inlet cap closer than 10 feet 3 05m from an inside corner of an L shaped structure Multiple sidewall direct vent installations You must locate the horizontal air inlet termination points at least 12 30cm above grade and above normal snow levels The combustion air inlet caps for multiple appliance installations must maintain the same minimum clearance from the closest flue vent cap as specifi
43. 3 See Table 3A for maximum and minimum inlet pressures Do not exceed the maximum Minimum inlet pressure is for the purpose of input adjustment INLET GAS PRESSURE M Max W W C MODEL P SSES W C W C Manifold pressure gas regulator the unit s combination gas valve is adjustable to supply proper manifold pressure for normal operation See the Copper fin II Service Manual for net manifold pressure settings If you must adjust regulator pressure follow the instructions under Gas Manifold Pressure Adjustment Copper fin Service Manual Do not increase regulator pressure beyond specified pressure setting 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 5 kPa 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 5 kPa 3 The appliance and its gas connection must be leak tested before placing it in operation Gas piping To safely operate this unit you must properly size the gas supply piping See Tables 3B through 3D for piping and fitting requirements Gas pipe size may be larger than heater connection For ease of service install a union CoPPER FIN IT Installation amp Opera
44. 52 Right Side inside unit Models 402 752 Left Side inside unit 6 CorPEn FiN Installation amp Operation Manual Copper fin How it works continued T m 7 nib Models 992 2072 Front View Models 992 2072 Hear View Models 992 2072 Right Side inside unit Models 992 2072 Left Side inside unit EH 7 Installation amp Operation Manual COPPER FIN Il Ratings CERTIFIEDR Copper fin Il Other Specifications I B R Rating Net I B R Ratings Water MBH Gross Output MBH Model Number Appliance Water Content Gallons Air Vent Sizes Connections Connections Note Change to L for L P gas models Note 2 2 2 2 99 O 500 CFN0652 650 CFN0752 01 C1 Po 1 1 N 1 C1 C2 N 1 1 4 1442 2 1 2 2 1 2 2 2 1 2 2 12 14 2 1 2 2 12 14 2 1 1 4 2 1 1 4 2 1 1 4 N CHN0402 CHN0752 250 CHN0992 360 2 2 CHN2072 O1 1N lloll o 1 4 N 2 1 2 2 1 2 2 1 2 2 N N NOTICE Maximum allowed working pressure is
45. 95 26 Low Temperature Return Water Systems 36 Low Temperature Bypass Requirements 36 Three Way Valves 37 Radiant Floor and Snow Melt Heating Systems 37 Typical Heating Boiler Installations 38 Installation with a Chilled Water System 38 Primary Secondary Piping of a Single Boiler 39 Primary Secondary Piping of Multiple Boilers 40 Boiler w Low Temperature Bypass Piping 41 Primary Secondary Piping with Buffer Tank 42 5 ELECTRICAL CONNECTIONS Boiler Operating Control Module 43 Line Voltage Connections 44 Low Voltage Connections 44 Wiring of the 45 Low Voltage Field Wiring Connections 46 6 STARTUP Check Control Water 47 Freeze Protection when used 47 Fill and Test Water 47 Purge Air from Water System 47 Check for Gas 47 Check Thermostat 48 C
46. CFX CHX I O Rev COPPER FIN Il Installation amp Operation Manual Models 402 2072 WARNING Ifthe information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building mmediately call your gas supplier from a near by phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier CERTIFIED This manual supplies information for the installation operation and servicing of the appliance It is strongly recommended that this manual and the Copper fin II Service Manual be reviewed completely before proceeding with an installation Perform 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 HAZARD 5 2 PLEASE READ BEFORE 3 SAFETY 4 THE COPPER
47. FIN II HOW IT WORKS 5 7 RATINGS NERONE 8 1 DETERMINE UNIT LOCATION Location of TUNER E 9 Recommended Service Clearances 9 Non Combustible Combustible Flooring 10 Combustion Air Options 10 13 2 VENTING Belore 13 Vent System Options 14 General Venting Information 15 Conventional Negative Draft Venting 16 18 Vertical DirectAire 11222 19 21 Sidewall 22 24 Horizontal DirectAire 25 Direct 8 26 29 Outdoor Installation 30 3 GAS CONNECTIONS Connecting to Gas Supply 31 Gas Pressure 31 Checking Manifold Gas Pressure 31 Combination Gas 92 Checking Gas Supply Pressure 33 4 WATER CONNECTIONS Inlet amp Outlet Connections 34 Relief 35 Heating Boiler Installations
48. I Installation amp Operation Manual Electrical connections continued Louver relay When the heater is to control combustion air louvers a field provided 24VAC louver relay must be installed Connect the Louver Relay Coil terminals to the louver relay coil Louver proving switch The operation of a louver proving switch needs to be verified before the boiler fires Remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch FIG 5 4 System supply sensor recommended use l By installing the system supply sensor into the supply of the primary loop the temperature of the primary supply can be controlled The SMART SYSTEM control automatically detects the presence of this sensor and controls the boiler firing rate to maintain the system supply temperature to the set point if the outlet sensor control 15 currently selected Connect these terminals to the system supply sensor FIG 5 4 System return sensor optional use l By installing the system return sensor into the return of the primary loop the temperature of the primary return can be sensed when a 3 way valve or other device 15 installed ahead ofthe heater inlet TheSMART SYSTEM control automatically senses the presence of this sensor If the inlet sensor is selected as the controlling sensor the SMART SYSTEM control will adjust the firing rate to hold the system return temperature to the set point
49. NG OUTDOOR VENTING NOTE B VENT MATERIALS MAY USED WHEN THE POWERED VENT IS CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP IF THE POWERED VENT IS NOT CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP THEN CAT IV AL29 4C VENT MATERIALS MUST BE USED FROM THE POWERED VENT T TO THE OUTSIDE VENT CAP a o o oo 9 9 14 Correr Fin Il Installation amp Operation Manual 2 Ventin Q continued General information You must supply adequate combustion and ventilation air to this unit You must provide minimum clearances for the vent terminal from adjacent buildings windows that open and building openings Follow all requirements set forth in the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable local building codes Vent installations for connection to gas vents or chimneys must be in accordance with Venting of Equipment of the above mentioned standards NOTICE Examine the venting system at least once each year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration If you find any problems correct them at once Venting support Support horizontal portions of the venting system to prevent sagging Provide an upward slope of at least 1 4 inch per foot 21
50. Notes 00000111 Back Cover Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER 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 death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION NOTICE CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage II Installation amp Operation Manual Please read before proceeding Special instructions This is a gas appliance and should be installed NOTICE 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 15 not followed exactly fire explosion may result causing property damage personal injury o
51. T GAS OUTLET VALVE CONTROL KNOB MANOMETER Figure 3 3 Measuring Gas Supply Pressure at Combination Gas Valve TABLE 3D GAS PIPING SIZE CHART Nominal Iron Pipe Size Length of Pipe in Straight Feet es o 2 3 9 9 7 1 s 59 vs 200 e 256 s c ss Dos poc pis 106 os 9 z Maximum Capacity of Pipe in Thousands of Btu hr per hour for gas pressures of 14 Inches Water Column 11 2 0 5 PSIG or less and pressure Water Column Based on NAT GAS 1025 Btu hr 11 200 7 900 6 400 5 400 4 870 4 410 4 000 3 900 3 540 3 300 3 000 2 720 2 500 2 340 per Cubic Foot of Gas and 0 60 23 500 16 100 13 100 11 100 10 000 9 000 8 300 7 690 7 380 6 670 6 150 5 640 5 130 4 720 Specific Gravit 4 Water connections Inlet and outlet connections For ease of service install unions on the water inlet and water outlet of the unit The connection to the unit marked Inlet on the header should be used for return from the system The connection on the header marked Outlet is to be connected to the supply side of the system 2 NPT WATER INLET 2 NPT WATER OUTLET INSPECTION PLUGS Figure 4 1 Water Connections Models 402 752 2 1 2 NPT WATER INLET 2 1 2 NPT WATER OUTLET INSPECTION PLUGS Figure 4 2 Water Connections Models 992 2072 Heat exchanger
52. TABLE 8A MAXIMUM WATER FLOW CAUTION The maximum flow rate through a Copper fin II water heater with a copper heat exchanger must be set to provide and not exceed the following flow 402 502 652 and 752 55 GPM 992 1262 1442 1802 and 2072 90 GPM 62 COPPER FIN II Installation amp Operation Manual If higher flow rates are required through the water heater an optional Cupro Nickel heat exchanger is available Consult the factory for specific application requirements The heat exchanger is capable of operating within the design flow rates required for the water heater storage tank s and connecting piping Erosion of the finned copper tubes may occur if the flow rate exceeds the maximum allowable flow rate through the water heater The maximum flow rate through the water heater must be adjusted Maximum flow on Models 402 752 is 55 GPM and 90 GPM on Models 992 2072 Flow rate can be determined by measuring the temperature rise through the water heater when it is firing at full rate input TABLE 8B TEMPERATURE RISE AT FULL RATE FIRE 55 AND 90 GPM FLOW Temperature Rise F 1 The pump must run continuously when the burner is firing 2 With the pump running and the burner in the water heater in the off cycle the inlet water temperature and outlet water temperature readings on the Operator Interface should read approximately the same temperatures Water Temperature Rise on the Operator Interface s
53. Ventin Q continued Coprer Fin I Installation amp Operation Manual Only use a sidewall air inlet cap supplied by the appliance 2 WARNING manufacturer or a rooftop air inlet cap supplied by either the vent 1 L 12 MIN Figure 2 8 Vertical DirectAire Installation w Rooftop Combustion Air Inlet or appliance manufacturer Using any other air inlet cap for single unit installations or using a common air inlet cap for multiple units with insufficient free area and or protections from wind and weather may result in operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning For single unit installations with sidewall air inlet you must order the sidewall air inlet kit from the appliance manufacturer The part number for each SVK kit is listed by unit size in Table 2B For single unit installations with rooftop air inlet see FIG 2 8 you must order the rooftop air inlet kit from the appliance manufacturer The part number for each VDK kit 1s listed by unit size in Table 2B Purchase the flue pipe rooftop flue termination and air inlet pipe locally There is no vent kit for combined air supply systems for multiple units Make sure the air inlet cap is properly sized You must purchase this cap locally Venting of flue products
54. aches to the air inlet of the unit The pipe for combustion air attaches to the DV box see FIG 2 11 on page 28 Reference page 28 for a list of approved air intake materials Make vent connection directly to the top of the unit No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and a negative draft maintained between 0 04 to 0 08 inches w c The Horizontal DirectAire combustion air supply system has specific vent material and installation requirements The air inlet pipe connects directly to the boiler to supply combustion air The combustion air inlet pipe is a dedicated system with one air inlet pipe per boiler You must connect the air inlet pipe to a combustion air inlet cap as specified in this section Combustion air supplied from outdoors must be free of contaminants see the Combustion and Ventilation Air section on page 10 You must order the Horizontal DirectAire Vent Kit for sidewall installation from the appliance manufacturer See Table 2D for kit numbers Each kit includes a sidewall powered vent cap fan proving switch controls combustion air inlet cap to supply air to a single unit the transition adapter to attach the field supplied single wall air inlet pipe to the unit and installation instructions Purchase flue pipe and air inlet pipe locally The sidewall air inlet cap supplied in the Horizontal DirectAire Vent Kit is used t
55. and firing stages based upon the heat demand Gas valves regulate the amount of gas supplied for the firing stages which is then mixed with the combustion air supplied to the burner NOTICE If an inline high gas pressure regulator is used it MUST BE of the lockup type and be located a minimum of 10 feet from the appliance Failure to do so may result in insufficient gas volume supplied to the appliance If a pressure drop of more than 2 water column occurs between Standby static Mode and Operating dynamic Mode a gas volume problem exists Contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide the proper gas volume to the appliance NOTICE How the control module operates The SMART SYSTEM control module receives input from appliance sensors and external devices The control module activates and controls the blower and gas valves to regulate heat input and switches the boiler Domestic Hot Water DHW and system pumps on and off as needed The user programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and appliance operating modes Boiler operation can be based on boiler outlet water temperature boiler inlet water temperature system supply temperature or system return temperature depending on the parameter setting Water heater operation can be based on a tank sensor or a tank thermostat C
56. ardness of 5 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm See Water Chemistry section on page 63 When installing multiple water heaters and or multiple storage tanks the diameter of the inter connecting pipe and all fittings must be increased An increase in pipe diameter will decrease head loss in the system piping and ensure proper flow Proper pipe size between the heater and storage tank MUST be maintained to ensure that the standard pump supplied on the water heater will maintain desired flow When DHW Night Setback is enabled the system pump output can be used to control a building circulation pump The pump output will be on during the time Night Setback is not active and will be off when Night Setback is active A field installed contactor must be used when controlling a circulation pump larger than 1 6 HP 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 copper finned tubes send 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 wi
57. ate leaks water gas flue Examine venting system Check system water pressure system piping expansion tank Check control settings Check igniter Check wiring and connections Check flue gas passageways Flame inspection stable uniform inspect and clean the burner e Check manifold gas pressure e Perform start up checkout performance verification per Section 6 in the Copper fin Il Installation Operation Manual If combustion or indicate need performance Clean heat exchanger with a stiff bristle brush e Remove and clean burners using water Dry before re assembling Clean the blower wheel with a brush and vacuum Do not let dirt from cleaning get pulled into the blower CorPrn FiN II Installation amp Operation Manual Owner maintenance see the Copper fin User s Information Manual for instructions Check appliance area Check pressure temperature gauge Check vent piping Check air piping Monthly Check relief valve Replace combustion filter Note More frequent replacement may be necessary in dirty environments Test low water cutoff if used Periodically Reset button low water cutoff Check appliance piping gas and Every water for leaks 6 months Operate relief valve Shut appliance down unless boiler used for domestic hot water of season months 71 Maintenance Installa
58. ating boilers and water heaters The flow switch must prove water flow before a trial for ignition can begin The flow switch requires a minimum flow of 15 18 GPM on Models 402 752 and 26 GPM on Models 992 2072 to make the flow switch and start burner operation A water flow switch meets most code requirements for a low water cutoff device on boilers requiring forced circulation for operation A fault message Flow Sw LWCO will be indicated in the Operator Interface on a low water flow condition as sensed by the flow switch Low water cutoff it equipped If this boiler is installed above radiation level a low water cutoff device must be installed at the time of boiler installation An electronic low water cutoff is available as a factory supplied option on all models The low water cutoff should be inspected every 6 months fault message Flow Sw LWCO will be indicated in the Operator Interface on a low water condition as sensed by the low water cutoff 4 Water connections continea Relief valve This unit is supplied with a relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve s is installed in the vertical position and mounted in the hot water outlet No valve is to be placed between the relief valve and the unit To prevent water damage the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs No red
59. ble for all equipment and detailing required by local codes COPPER EIN II Installation amp Service Manual 4 Water connections Figure 4 4 Primary Secondary Piping of Multiple Boilers COMMON MANIFOLD SIZE Min Models 402 502 652 amp 752 Diameter COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 amp 2072 Number of Units in 4 PRESSURE EXPANSION RELIEF TANK VALVE LOW WATER CUT OFF MAKE UP OPTIONAL WATER TO SYSTEM AIR gt SEPARATOR D 12 OR 4X 22 SYSTEM PIPE DIAMETERS Ng PUMP FROM SYSTEM SECONDARY BOILER PUMP Please note that these illustrations are meant to show system piping concept only the installer is responsible for NOTICE M equipment detailing required by local codes 40 CorPrn FiN Installation amp Operation Manual 4 Water connections continea Figure 4 5 Boiler with Low Temperature Bypass Piping Using a Low Temperature Valve Hequired for Systems Operating at less than 140 F 60 Return Water Temperatures from the Heating Return Loop COMMON MANIFOLD SIZE Min Models 402 502 652 amp 752 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 amp 2072 Number of Units paa Number of Units D 1 2 1 2 o 1 J 9 212 TO EXPANSION TANK AND MAKEUP WATER SYSTEM MIXING VALVE HEATING RETURN LOOP HEATING SUPPLY LOOP NOTICE Please note that th
60. cal DirectAire vent system requires you to install two pipes directly to the unit one vertical pipe with rooftop termination for the flue products and one pipe for combustion air For this venting option you must purchase the DV box adapter from the appliance manufacturer The DV box attaches to the air inlet of the unit The pipe for combustion air attaches to the DV box see FIG 2 11 on page 28 Reference page 28 for a list of approved air intake materials Combustion air inlet piping Locate and install the combustion air inlet cap correctly Failure to do so can allow the discharge of flue products to be drawn into the combustion process This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning The sidewall or vertical rooftop DirectAire combustion air supply system has specific material and installation requirements The air inlet pipe connects directly to the unit to supply combustion air In most installations the combustion air inlet pipe will be a dedicated system with one air inlet pipe per unit You can combine multiple air inlets if the guidelines in Combined Air Inlet Points page 20 are followed The air inlet pipe will be connected to a combustion air inlet cap as specified
61. ch 90 elbow Subtract 2 5 feet 0 7m of equivalent length for each 45 elbow Do not exceed the limits for the combustion air inlet piping lengths Connecting the air inlet pipe to the unit Connect the air inlet piping directly to the unit by attaching it to the DV box adapter The DV box adapter is included in the direct vent kits The combustion air inlet area of the unit is located at the right rear corner of the unit This unit uses a simple air filter to ensure clean air is used for the combustion process Attach the DV box adapter over the air filter see FIG 2 11 Align screw holes on the DV box adapter with the screw holes surrounding the air filter hanger Insert sheet metal screws and tighten firmly For venting versatility you can move the air filter assembly and DV box adapter to the right side of the unit Remove the metal panel on the unit s right side see FIG 2 12 Remove the filter bracket assembly from the rear of the unit Attach the filter bracket assembly and DV box adapter to the right side opening using the pre drilled screw holes Make sure you attach the metal panel to the rear combustion air opening of the unit The DV box adapter has an air inlet pipe mounting ring Connect combustion air inlet piping to the direct vent box mounting ring Figure 2 11 Aitaching DV Box Adapter to Unit Figure 2 12 Moving Air Filter Assembly amp DV Box Adapter Air inlet piping materials The air inlet pipe s must
62. combustion air inlet in the same pressure zone The flue outlet and combustion air intake may terminate at either a sidewall or the rooftop use the optional Direct Vent system you must install specific vent kits venting materials following is a detailed explanation of Direct Vent installation requirements including the components used and vent kit part numbers reference Table 2E on page 27 for kit numbers Flue outlet piping Venting Guidelines If using this venting option a sealed AL29 4C venting system for flue products is required on all models of this appliance This venting system operates with a positive pressure in the vent The internal combustion air blower generates this positive pressure which operates the combustion process and also exhausts the flue products from the building This vent system has specific vent material and installation requirements Only use listed sealed AL29 4C vent system materials Follow all installation requirements See Table 2A page 15 for proper pipe size for your unit Seal all vent joints and seams gas tight Drain tee installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee must be installed as the first fitting after the horizontal ell on the top of the unit see FIG 2 9 on page 23 Plastic drain tubing sized per the vent manufact
63. condensation on the heat exchanger system temperature spikes and mechanical component failures To prevent short cycling of the boiler it is important to limit the boiler cycles to six or fewer per hour A buffer tank is an effective way to enhance a small system load and increase heating system efficiency see FIG 4 6 on page 42 of this manual Buffer tanks add water volume to the system and act as a flywheel to absorb the additional Btu s provided by the boiler when only a single zone of a large system 15 calling for heat To calculate the proper buffer tank size for a multiple zone system Run Cycle Output Minimum System Load Temp Rise 8 33 60 Min 2072 Min Load 100 000 Btu Hr Min Boiler Output 850 000 Btu Hr Cycle Time 10 Min Temp Rise 38 10 850 000 100 000 38 8 33 60 395 Gallons 37 4 Water connections COPPER FIN Il Installation amp Service Manual TABLE 4C SYSTEM TEMPERATURE RISE CHART Temperature Rise and Head Loss Based on Boiler Output in Btu hr Btu hr Output GPM 1 260 000 EN 1 440 000 70 5 1 800 000 1 530 000 102 11 8 87 2 070 000 1 759 500 100 GPM c m Input 399 999 500 000 650 000 750 000 990 000 Td T TIN TN TN TN 1 1 e 1 4 TO 1 ND db FJ 1 LO Pe
64. creen 2 RISE The difference between the inlet temperature and the outlet temperature Line 2 is displayed Press the Next gt arrow key the SMART SYSTEM display to access Screen 3 When the system supply sensor has been selected as the control sensor the control will display the system supply temperature as well as the set point in parenthesis SYSSUP F If the system supply sensor has not been selected as the control sensor SXSSUES TUE only the system supply temperature will be displayed Screen 73 Line 1 SYSSUP OPEN The control does not detect the system supply sensor SYSSUP SHORTED The system supply sensor wires or the sensor itself has become shorted When the system return sensor has been selected as the control sensor the control will display the system return temperature as well as the set point in parenthesis SYSRTN F If the system return sensor has not been selected as the control sensor only the system return temperature will be displayed Screen 3 Line 2 SYSRTN F SYSRTN OPEN The control does not detect the system return sensor The system return sensor wires or the sensor itself has become SYSRTN SHORTED shorted Screen 4 Line 1 Press the Next arrow key the SMART SYSTEM display to access Screen 4 The control will display the outdoor air temperature as sensed by the OUTDOOR F outdoor air sensor OUTDOOR OPEN The c
65. d use only type 105 C wire 120 VAC 15 Amp 1 ph 60 Hz circuit 15 required for or equivalent operation of the appliance controls 3 dd Boiler must be electrically grounded as The appliance when installed must be electrically grounded required by National Electrical Code ANSI in accordance with the requirements of the authority having NFPA 70 latest edition jurisdiction or in the absence of such requirements with Label all wires prior to disconnection when the latest edition of the National Electrical Code ANSI servicing controls Wiring errors can cause NFPA No 70 When the unit is installed in Canada it must improper and dangerous operation conform to the CAE C22 1 Canadian Electrical Code Part I and or local Electrical Codes Multiple units connected in a Cascade must be grounded to the same ground connection Installation must com ply with 1 All wiring between the appliance and field installed 1 National Electrical Code and any other national state devices shall be made with type T wire 63 F 35 provincial local codes or regulations rise 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 2 All line voltage wire exterior to the appliance must be and any local codes enclosed in approved conduit or approved metal clad cable 3 The circulating pump must run continuously when the appliance 15 being fired 4 To avoid serious damage DO NOT energize the appliance until the system 1s full of wat
66. d accessories are included in a venting kit provided by the appliance manufacturer See Table 2C on page 24 for kit numbers The venting kit includes the sidewall fan vent hood tapered vent adapter barometric damper 992 2072 Models proving switch and all necessary relays to interlock with the heaters control system The tapered vent adapter reduces the vent size at the inlet to the fan There should be no reduction in vent diameter from the unit s flue outlet to the sidewall fan The barometric damper must be installed on the flue and adjusted to supply a negative draft within the range of 0 04 to 0 08 inches w c while unit is operating Flue outlet piping With this venting option you must use Type B double wall or equivalent vent materials Vent materials must be listed by a nationally recognized test agency for use as vent materials Make the connections from the unit vent to the sidewall fan cap as 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 Follow the vent manufacturer s instructions when installing Type B vents and accessories such as firestop spacers vent connectors thimbles caps etc When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls The maximum installed length of sidewall vent pipe with an induced draft fan must not exceed 100 feet 30 5m Subtrac
67. door air reset is active and a space heating demand has been active continuously for a set period of time time adjustable by installer and there has been no DHW demands the control may be programmed to increase the set point by a fixed number of degrees adjustable by installer This process will repeat until the space heating demand ends the set point reaches the programmed set point or a maximum of 20 increases has occurred Once the system heat demand is satisfied the set point will revert to the value determined by the reset curve Night setback The controller may be programmed to reduce the space heating boilers and tank set points during a certain time each day A start and stop time can be programmed for each day of the week 52 COPPER FIN Il Installation amp Operation Manual Protection features Outlet temperature and temperature rise limiting The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 230 F 110 C boilers or 190 F 88 C water heaters the unit will reduce the firing rate If the outlet water temperature exceeds 235 F 113 C boilers or 200 93 C water heaters the control will shut the unit down until it cools off The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds the first limit the control will turn off stages If the temperature difference exceeds a second
68. e Section 1 of this manual Adjust settings if necessary See Section 1 of this manual for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary 73 0 Maintenance Perform start up and checks 1 Start appliance and perform checks and tests specified in Section 7 Start up of the Copper fin II Installation and Operation Manual 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 A burner viewport is located on the burner mounting flange A WARNING The area around the burner viewport is hot and direct contact could result in burns Figure 9 2 Flame Pattern Illustration NORMAL YELLOW TIP YELLOW FLAME FLAME LIFT Normal Flame normal flame at 10096 of burner input 15 blue with slight yellow tips a well defined flame and no flame lifting Yellow Tip Yellow tipping can be caused by blockage or partial obstruction of air flow to the burner Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner or excessive gas input This condition MUST be corrected immediately Lifting Flames Lifting flames can be caused by over firing the burner excessive primary air or high draft If improper flame i
69. e reminder The control can be programmed for service reminder notification This notification will become active when either a set time frame has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will alternate the standard text on the display screen with Service Due every 5 seconds The service reminder notification can be reset by the installer Error logging The control will hold in memory the last 10 error codes as well as the last 10 turn off functions The date and time of the occurrence will be recorded as well Only the 10 most current occurrences will be held in memory Boiler temperature regulation Operating temperature target The SMART SYSTEM control module senses water temperature and regulates appliance firing and firing rate to achieve a target temperature The target temperature be set between 70 21 and 220 F 104 C boilers or between 60 F 16 and 190 F 88 water heaters Target temperature is fixed when the outdoor sensor is not installed boilers Target temperature is calculated as described under Outdoor Air Reset Operation Boost Function when the outdoor sensor is connected boilers Outdoor reset operation if used boilers only Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See the Copper fin II Service Manual to
70. e shoot unit ALARM mHES T7 PR VOLTAGE HARNFSS ITAL HARNESS o 9 e e 5515 j M FLUE P 3 COMSWITCH NO AIR PROVE SWTICH SILENCING ALARM ALARM RELAY SWITCH BELL 120 COIL 7 r 555 GROUNDING DIGITAL e LT ma I G OPTION IDENTIFICATION PLUG HARNESS lt JUMPER MODEL SPECIFIC CONSULT T H FACTORY 3 1 1 i BL 2 SPD BLOWER RIG H Elo i E TO 1 3 BOARD oH xQ LOW GAS 2 SWITCH j STAGE 1 STAGE 1 STAGE 2 STAGE 3 STAGE 3 STAGE 4 TO 1 PWR 43 W 3 XFMR BURNER 1 BURNER 1 HSI GROUND i 2 HSI GROUND MODBUS ADAPTER HILO SPEED RELAY 120VAC COIL 1 FED CIRCUIT OPTIONS 1 OPTIONS J e W WHITE T TAN BK BLACK Y YELLOW PR PURPLE BR BROWN BL BLUE G GREEN P PINK GY GRAY R RED Y G YELLOW WITH GREEN STRIPE THIS HEATER MAY BE CONNECTED TO MORE THAN ONE BRANCH Mil CIRCUIT MORE
71. e vent cap See detailed instructions packed with the horizontal direct vent kit Horizontal Vent Termination Clearances and Location Follow all sidewall venting termination information for clearances and location under Sidewall Vent Termination Clearances and Location page 22 TABLE 2E DIRECT VENT KITS HORIZONTAL VERTICAL MODEL HORIZONTAL VERTICAL KIT KIT KIT KIT DVK3004 VDK3026 DVK3000 VDK3023 __ m 7 202 DVK3000 VDK3024 These kits include a DV box adapter air inlet cap and a sidewall vent termination The VDK kits include a DV box adapter and an air inlet cap Combustion air inlet piping The Direct Vent system requires the installation of a pipe to supply combustion air from the outdoors directly to the unit Make sure the combustion air inlet is in the same pressure zone as the vent terminal In cold climates use a Type B double wall vent pipe or an insulated single wall pipe for combustion air This will help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe A CAUTION Units that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe 27 COoPPER FIN Installation amp Operation Manual 2 Venting Length of air inlet pipe The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet 15 2m Subtract 5 feet 1 5m of equivalent length for ea
72. ectrical wiring inside walls ceilings and floors Locate the unit as close as possible to chimney or gas vent When a vent system 15 disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions The installed length of flue from the unit to the outside point of termination must not exceed 50 equivalent feet 15 2m Subtract 5 feet 1 5m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7m of equivalent length for each 45 elbow Vertical DV venting termination You must use the vent termination recommended by the vent manufacturer for vertical direct vent terminations Follow all vertical venting termination information for clearances and location under the Vertical Vent Termination Clearances and Location section on pages 17 18 26 CoPPER FIN Installation amp Operation Manual 2 Ventin Q continued Masonry chimney installation Do not use a standard masonry chimney to directly vent the combustion products from this unit To use a masonry chimney the chimney must use a sealed corrosion resistant liner system Sealed corrosion resistant liner systems single wall double wall flexible or rigid must be rated for use with a high efficiency positive pressure vent system Corrosion resistant chimney liner systems are typically made from a high grade stainless steel such as AL29 4C The liner must be properly sized and fully sealed throughout the entire len
73. ed in single appliance installations You may install multiple flue outlet caps side by side and multiple combustion air inlet caps side by side but the air inlet must always be at least 3 feet 0 91m horizontally and 3 feet 0 91m below the closest flue outlet Do not install combustion air inlet caps above the flue outlets Maintain all clearances and installation requirements for multiple appliance installations 29 Copper Fin I Installation amp Operation Manual 2 Venting Outdoor installation see page 14 Before installing a venting system follow all requirements found in the General Venting section Units are self venting and can be used outdoors when installed with the optional outdoor cap This cap mounts directly to the top of the unit and covers the flue outlet and combustion air inlet openings No additional vent piping is required Only install outdoor models outdoors and only use the vent cap supplied by the appliance manufacturer A WARNING 2 Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors Properly install all covers doors and jacket panels to ensure proper operation and prevent a hazardous condition Combustion air supply must be free of contaminants see Combustion and Ventilation Air page 10 To prevent recirculation of the flue products into the combustion air inlet follow all instructions in this section Outdoor vent air i
74. ee BOILER ONLY FIG 5 4 on page 46 UNIT UNIT PUMP SYSTEM DHW PUMP SUPPLY SUPPLY PUMP SUPPLY SUPPLY 00 Ensure that all wiring used to connect the switching contacts of the remote temperature controller to the connection board are a minimum of 18 gauge and have a maximum installed length of 300 feet 91 4m Set the SMART SYSTEM control to a set point temperature slightly higher than the setting of the remote temperature control This will ensure that the remote temperature controller functions as the operating control for the heater REMOTE ON OFF NO Ke o CONNECTION GROUND Figure 5 1_Line Voltage Field Wiring Connections Low voltage connections 1 Route all low voltage wires through the knockouts on the left side of the heater as shown in FIG 5 2 2 Connect low voltage wiring to the low voltage connection board as shown in FIG 5 4 on page 46 of this manual and the heater Figure 5 3 Hemote ON OFF Wire Connection wiring diagram DHW Domestic Hot Water thermostat LOW VOLTAGE KNOCKOUTS Connect the DHW tank thermostat FIG 5 4 to the tank thermostat terminals on the connection board DHW tank sensor If a tank sensor is used it must be connected to the tank J sensor terminals low voltage connection board p 4 correct Lochinvar sensor 15120015 MUST BE USED KNOCKOUTS Figure 5 2_Routing Field Wiring 44 5 COPPER FIN I
75. ee instruction manual before setting temperature at heating appliance Feel water before bathing or showering 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 8 C Figure 8 5 Danger Warning Location of Cold Water Supply Piping Connections Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the primary 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 for correct piping FIG s 8 1 thru 8 4 Higher water temperatures reduce the volume of condensate formed settings provides hotter water which increases the risk of scald injury 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 Optional adjustable auxiliary high water temperature limit control ADJUSTABLE AUXILIARY HIGH WATER TEMPERATURE LIMIT CONTROL OPTION Setting the temperature selector to higher
76. een selected as the control sensor Sa default the control will display the outlet temperature as well as the set point in parenthesis If the outlet sensor has not been selected as the control sensor or a system supply sensor is connected only the outlet temperature will be displayed OUT OPEN The control does not detect the outlet sensor OUT SHORTED The outlet sensor wires or the sensor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 2 Screen 1 OQUT Line 2 56 Coprer FIn II Installation amp Operation Manual 7 Operating information continued Status Display Screens By using the Previous Next 6 gt arrow keys the SMART SYSTEM display panel you can navigate through the 11 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Display shows When the inlet sensor has been selected as the control sensor the INLET F control will display the inlet temperature as well as the set point in parenthesis Screen 2 INLET If the inlet sensor has not been selected as the control sensor or a system Line 1 return sensor is connected only the inlet temperature will be displayed INLET OPEN The control does not detect the inlet sensor INLET SHORTED The inlet sensor wires or the sensor itself has become shorted S
77. emove any residual heat from the combustion chamber 5 Lubricate pump to manufacturer s recommendations Pump damage due to inadequate lubrication is non warrantable The tank sensor must be installed in the tapping provided in the lower 2596 of the storage tank to achieve proper operation As shipped from the factory the tank sensor is in the literature package shipped with the unit Placing the sensor in the tapping provided on the storage tank will improve temperature response and prevent short cycles of operation 68 CorPER FIN II Installation amp Operation Manual The standard circulating pump on this water heater 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 specified maximum equivalent number of straight feet for a specified diameter of pipe non warrantable operational problems may be experienced 402 752 Models 1 4 HP 120 VAC 5 8 Amps 992 2072 Models 1 2 HP 120 VAC 7 4 Amps The standard pump selection is based on the following pipe and fittings from the water heater to the storage tank 6 90 elbows 2 ball valves 2 unions 1 cold water tee Not more than 45 feet of straight pipe For every elbow and tee in excess of those shown above DEDUCT 6 5 FEET from the maximum allowable straight pipe in the heater to tank circulating loop TABLE D MINIMUM PUMP PERFORMANCE Based on heating potable water with a h
78. en it will switch back to the space heating demand The control will switch back and forth until one of the heat demands end Programmable controlling sensor boiler only The control module is programmed to use the outlet sensor as the control sensor by default If a system supply sensor is connected the control automatically uses it as the control sensor The control sensor can be changed by the installer to the inlet sensor In this case if a system return sensor is installed the control automatically uses it as the control sensor If the inlet sensor is chosen as the controlling sensor it is recommended that the system supply sensor be installed for the best system performance Anti cycling boiler only After the set point has been satisfied the control will delay the next burner cycle for a set time period time is adjustable by the installer The time delay will be bypassed if the system return temperature drops too far during the delay Boiler system and DHW pump control When a space heating call for heat starts and no DHW call is on the system and boiler pumps are turned on As long as the space heating call for heat is on the system pump will remain on If a DHW call for heat is on the boiler pump will wait to turn on until just before the DHW pump turns off After the space heating call for heat ends both pumps will run for an additional period of time When DHW call for heat starts the DHW pump is turned on
79. er Ensure that all air is removed from the heat exchanger and piping before beginning initial operation Serious damage may result if the appliance is operated without proper flow 5 Provide the appliance with proper overload protection 43 CorPEn FiN Installation amp Operation Manual 5 Electrical connections Line voltage connections EMS or remote thermostat connection 1 Connect 120 VAC power wiring to the line voltage terminal strip in the junction box as shown in FIG 5 1 An EMS remote thermostat or other remote temperature control may be connected to the boiler see FIG 5 3 Follow the manufacturer s instructions supplied with the remote temperature control for proper installation 2 Provide and install a fused disconnect or service switch 15 AMP recommended as required by the code see FIG 5 1 and adjustment Connection of a set of dry switching 3 To activate a system pump wire as shown in FIG 5 1 If contacts or a remote on off thermostat to the low voltage the motor is larger than 1 HP you must install a contactor connection board will allow the unit to be switched on and off by making or breaking a 24 VAC control circuit Remove the factory jumper between the Staging 51 terminals the low voltage connection board and 4 When connecting power to units which are to be cascaded each unit must be connected to the same ground connection e connect the remote temperature control in its place s
80. er water temperature above 200 F 93 3 C 3 Isthermostat set below room temperature 4 Is gas turned on at meter or boiler 5 Is incoming gas pressure less than 4 5 water column If none of the above corrects the problem refer to the Troubleshooting Section of the Copper fin II Service Manual A WARNING The venting system must be installed so that it will prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Set space heating operation boiler only Determine controlling sensor For space heating systems the temperature control can be based on one of four sensors the inlet outlet system supply sensor or system return sensor The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor The control will automatically switch to the system supply sensor once it is connected If it is desired to base the temperature control on the inlet sensor the appropriate parameter must be changed in the control See the Copper fin II Service Manual for a detailed explanation of this procedure The control will automatically switch to the system return sensor once it is connected It is recommended that a system supply sensor be installed even when using the inlet sensor as the controlling sensor Verify space heat circulator mode The Space Heating Mode controls both the system primary pump if connected and the boiler secondary pump W
81. erature and the tank target temperature if a tank sensor is used by using the UP and DOWN buttons FIG 7 1 at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date and night setback settings In User Mode the following parameters can be viewed but not changed Boiler outlet water target temperature in DHW Mode Appliance model number Software version Total operating hours Total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code see the Copper fin II Service Manual Saving parameters reference the Parameter Table in the Copper fin II Service Manual To save parameters and exit programming Press the ENTER RESET button then the MENU EXIT button 3 times To keep parameter settings only for a current operating cycle Press the MENU EXIT button 3 times after making all desired parameter changes To enter a parameter and continue programming Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings Remember to press the ENTER RESET button when finished programming in order to save the changes made See the Copper fin II Service Manual for a detailed description of parameters and access modes 57 COPPER FIN II Installation amp Operation Manual 7 Operating information Status display screens Status Display
82. ers on the Staging 51 terminals of all the Member heaters This will allow them to run independently should the Leader heater fail On water heaters connect the tank thermostat or BMS enable output to the low voltage connection board on the Leader heater at the terminals marked for the tank Aquastat If a tank sensor is used connect this sensor to the low voltage connection board on the Leader heater at the terminals marked for the tank sensor Communication between the Leader heater and the Member heaters is accomplished by using shielded 2 wire twisted pair communication cable Connect one of the twisted pair wires to terminal A on each of the low voltage connection boards and the other wire of the twisted pair to terminal B on each of the low voltage connection boards Connect the shield wire to the shield ground terminal on all of the heaters If more than two heaters are on the Cascade daisy chain the wiring from the Cascade terminals on the second heater to the Cascade terminals on the third heater then from the third to the forth and so on The connections can be made in any order regardless of the addresses of the heaters Try to keep each cable as short as possible 46 CorPER FIN Il Installation amp Operation Manual Figure 5 4 Low Voltage Field Wiring Connections ALARM CONTACTS RUN TIME CONTACTS OPEN CLOSE COM 51 51 52 52 53 53 54 54 LOUVER PROVING SW LOUVER RELAY COIL TANK
83. ese illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 41 Installation amp Operation Manual 4 Water connections Figure 4 6 Primary Secondary Piping with Buffer Tank COMMON MANIFOLD SIZE Min COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 amp 2072 in _ 6 _ 6 _ 6 1 TEMPERATURE PRESSURE GAUGE AUTOMATIC AIR ELIMINATOR VENT SYSTEM OUTLET COMMOM MANIFOLD SENSOR MUST BE SIZED TO LOCATION ACCOMODATE COMBINED FLOW RATE FOR ALL BOILERS SYSTEM INLET BUFFER DRAIN TANK NOTICE The Inlet Outlet System tappings are shown in the optional location on the side of the tank for pictorial purposes The standard location for the system tappings is 180 from the recirculation tappings Please note that these illustrations are meant to show system piping concept only the installer is responsible for NOTICE s all equipment and detailing required by local codes 42 CoPPER FIN Installation amp Operation Manual 5 Electrical connections Boiler operating control module TABLE 5A The operating control for the appliance is the SMART AMP DRAW DATA SYSTEM control module It is located on the inside of the Pump Approximate Total panel behind the ur 2 door Hind adjust Model Controls Blower FLA Amps
84. essure and are shipped standard as 150 PSI and 210 F 98 99 Power switch The power switch is used to engage and disengage power to the appliance on the 120 VAC circuit Air pressure switch The air pressure switch is a safety device which ensures proper blower operation The air pressure switch is wired in series with the low voltage control circuit in such a way that if the fan does not engage or shuts down prematurely the device will break the control circuit and the unit will shut down Flow switch The flow switch is a safety device that ensures flow through the heat exchanger during operation This appliance is low mass and should never be operated without flow The flow switch makes contact when flow is detected and allows the unit to operate If flow 15 discontinued during operation for any reason the flow switch will break the control circuit and the unit will shut down Drain port s The drain ports are located underneath the front header Manual shutoff valve not shown Manual valve used to isolate the unit from the gas supply CorPrn FiN II Installation amp Operation Manual The Copper fin How it works 23 26 Models 402 752 Front View Models 402 752 Hear View Models 402 7
85. exchanger If the flow rate is too low or the outlet temperature too high the control module modulates and shuts the appliance down This along with the flow switch ensures appliance shutdown in the event of low water or low flow conditions 2 Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff Consult local jurisdiction to determine Contact manufacturer for low water cutoff kit availability Monitor external limits Connections are provided on the connection board for external limits such as a louver proving switch The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The appliance provides dry contacts for indicating when the appliance is running and when it is unable to operate Run time and cycle counting The control uses two timers to monitor the total hours of burner operation One timer monitors the time the appliance is firing under 50 of rate The other timer monitors the time the appliance is firing over 50 rate The control uses four 4 ignition counters to monitor the amount of appliance cycles The first counter counts all ignitions of the control The second counter counts only ignition attempts that have failed The third and fourth counters are the same as the first and second respectively but can be reset by the installer Servic
86. f 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 Prevention of freezing Heat exchangers and headers damaged by freezing are not covered by warranty See Section 7 Operating Information Freeze Protection for more information 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 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 Gas Association Code CAN CGA B149 1 and or B149 2 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 hot water boilers ANSI Z21 13 and gas water heaters ANSI Z21 10 3
87. g of a high efficiency appliance into a cold or oversized masonry chimney can result 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 products from a high efficiency 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 products damage to the masonry flue tile insufficient draft and possible spillage of flue products into an occupied living space Carefully inspect all chimney systems before installation Do not vent this unit into a masonry chimney without a sealed stainless steel liner system Any breaks leaks or damage to the masonry flue tile will allow the flue products to leak from the chimney and into occupied living spaces This could cause serious injury or death due to carbon monoxide poisoning and other harmful flue products NOTICE Check with local code officials to determine code requirements or the advisability of using a masonry chimney with a sealed corrosion resistant liner system Inspection of a masonry chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products 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 draina
88. g runoff drains will spill onto the unit Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building or unit surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate The outdoor vent cap kit The optional outdoor vent cap kit is available from the appliance manufacturer The outdoor cap part numbers are listed by model number See Table 2F for kit numbers Install the outdoor vent cap on the rear of the unit Complete installation instructions are included with the outdoor vent cap kit Figure 2 14 Outdoor vent cap installed TABLE 2F OUTDOOR VENT CAP KITS p KIT WITHOUT KIT WITH MODEL KIT WITHOUT KIT WITH PUMP COVER PUMP COVER PUMP COVER PUMP COVER ODK3748 ODK3052 ODK3036 ODK3049 ODK3748 Lo 7 2072 02 _ ODK30001 These kits include an outdoor vent and gasket 3 Gas connections Connecting to gas supply Verify that the appliance is supplied with the type of gas specified on the rating plate This appliance is configured for operation up to 4 500 feet altitude Consult factory for installations above 4 500 feet elevation Inlet gas pressure Measured at the inlet pressure tap on the appliance gas manifold The pressure tap is located upstream of the combination gas valve s FIG 3 3 on page 3
89. ge Sustained operation at lower than specified water temperatures may cause hazardous conditions that may result in personal injury or non warrantable damage to the appliance The maximum temperature set point that can be programmed into the control module from the Operator Interface for water heater operation is 190 F 88 C The control is factory pre set at approximately 120 F 49 C Facilities with small children or invalids may require 120 F 49 C or a lower temperature setting to reduce risk of scald injury Some states may require a lower temperature setting Check with your gas supplier for local requirements governing the temperature setting Remember no water heating system will provide exact temperature 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 A CAUTION Hotter water increases the risk of scald injury 69 8 Domestic water heaters DA Water temperature over 125 F 52 8 C can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded S
90. ge at the breaching or clean out If there is any doubt about the condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system An unlined masonry chimney must not be used to vent flue products from this high efficiency unit 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 officials to determine code requirements or the advisability of using or relining a masonry chimney Vertical vent termination clearances and location 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 termination less than 10 feet 3 05m from a parapet wall must be a minimum of 2 feet 0 61m higher than the parapet wall Keep the vent cap clear of snow ice leaves and debris to avoid blocking the flue 17 Installation amp Operation Manual 2 Venting e 10 MCRE THAN 10 OR LESS 10 RIDGE Figure 2 2 Vent Termination from Peaked Roof 10 f
91. gth Both the top and bottom of the masonry chimney must be capped and sealed to provide a dead air space around the liner Do not vent this unit into a masonry chimney without a sealed stainless steel liner system Any breaks leaks A WARNING ae os damage to masonry flue tile will allow the positive pressure flue products to leak from the chimney and into occupied living spaces This could cause serious injury or death due to carbon monoxide poisoning and other harmful flue products NOTICE Check with local code officials to determine code requirements or the advisability of using a masonry chimney with a sealed corrosion resistant liner system Horizontal DV venting termination Horizontal venting uses the unit s internal combustion air blower to force the flue products out of the horizontally terminated flue You must purchase a horizontal direct vent kit from the appliance manufacturer to ensure proper operation When installing the vent cap the wall opening must provide an air space clearance of 2 inches 5 1cm around the flue pipe The diameter of the opening for installation of the sidewall cap will be 4 inches 10 2cm larger minimum than the nominal diameter of the installed vent pipe to the horizontal vent cap Install the horizontal vent cap from the outside Mount the vent cap to the wall using four screws or wall anchors Seal under the screw heads with caulking Install the Category IV vent pipe from the unit to th
92. he boiler For Example Night Setback of the system loop water temperature Night Shutdown and Weekend Shutdown of the entire boiler heating system and Indoor Outdoor Air Reset of the system loop water temperature If any of these control functions are being utilized some type of low return water protection MUST BE provided If the boiler heating system will be used on a Water Source Heat Pump System Radiant Floor Heating System Snow Melting Heating System etc some type of low return water protection must be provided Condensation can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the vent system and related components prevent system return water temperature below 140 F 60 from entering the boiler inlet an electrically actuated 3 way mixing valve is available consult manufacturer for kit availability see FIG 4 5 on page 41 By using this valve the SMART SYSTEM control will bypass outlet water back into the inlet of the boiler to maintain the inlet temperature above 140 F 60 fast acting self contained mixing valve set to 140 60 may also be used The installation of this valve must be done as shown in FIG 4 5 This arrangement will maintain the required flow through the boiler 4 Water connections continea When a mixing valve is used an optional system return sensor should be installed into the system return piping This will allow
93. heck Vent and Air Piping 48 Placing the Boiler in Operation 48 Start 48 If Boiler Does Not Start CorrectlYy 48 Set Space heating Operation boiler only 48 Operating Instructions 49 Set DHW Operation 50 7 OPERATING INFORMATION T elit 51 53 Cascade REPERI 53 54 Sequence of Operation 55 56 Copper fin Il Control 56 Access 57 Saving Parameters 57 Status Display 58 61 8 DOMESTIC WATER HEATERS Initial Setup of Maximum Water Flow 62 Water Chemistry esses 63 Typical Water Heater Piping w Storage Tank s 64 65 Multiple Water Heater Piping w Storage Tank s 66 67 Pump Operation 68 Minimum Water Temperatures domestic hot water 69 9 22 1 12108 6000000 0000104 71 75 10 CONNECTION DIAGRAM 76 77 11 LADDER 78 79 Revision
94. hen the SMART SYSTEM control receives a space heating call for heat it turns on the system pump If the boiler is not heating an indirect DHW Domestic Hot Water tank it also turns on the boiler pump After the space heating call for heat ends the system pump continues to run for a short period of time If the boiler pump was running it continues to run for a short period of time as well These pump delays are factory set to 30 seconds If different delays are desired the appropriate parameters in the control must be changed See the Copper fin II Service Manual for a detailed explanation of this procedure Set space heating set point temperature The UP and DOWN keys may be used during normal operation to adjust the space heating set point temperature see FIG 7 1 on page 56 of this manual Once the desired temperature is displayed press the ENTER RESET key to save the new setting If the ENTER RESET key 15 not pressed the new setting will be used for the current heating cycle only The old setting will become active after the current heating cycle ends COPPER EIN II Installation amp Operation Manual 6 Start u D continued Figure 6 1_Lighting Instructions FOR YOUR SAFETY READ BEFORE OPERATING 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
95. hicle 5 DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present 6 The appliance must be installed on a level floor 7 Combustible floor installation E MIN a Models 402 752 require an approved floor kit for lt p RIGHT SIDE installation combustible flooring reference Table SE 1 b Models 992 2072 approved for installation t on combustible flooring without a floor kit Note FRONT Concrete block over wood flooring is not considered Clearances from combustible construction non combustible NOTICE j are noted on the appliance rating plate 8 DO NOT install this appliance directly on carpeting or other combustible material TABLE 1A 9 Maintain required clearances from combustible surfaces COMBUSTIBLE FLOOR KITS reference the Indoor Clearances from Combustible Construction Section this page 4 CFK3301 5 CFK3302 6 10 For outdoor models you must install an optional vent cap Instructions for mounting the vent cap are included 02 02 52 the venting section of this manual not install 752 outdoor models directly the ground You must install the outdoor unit on a concrete brick block or other Freeze protection non combustible pad Outdoor models have additional special location and clearance requirements See Outdoor Installation Venting page 30 A wind proof cabinet protect
96. hould read near zero 3 Turn the water heater and allow time for the temperature to stabilize The Service Mode can be used to force the water heater to run at full fire See the Copper fin II Service Manual for a detailed explanation of the Service Mode Check the water temperature rise in the Operator Interface when the burner is firing at 10096 of rated input 4 Compare the water temperature rise in the Operator Interface with the required temperature rise Should adjustment be needed proceed as follows If the temperature rise is too high water velocity is too low adjust as follows 2 Check for restrictions the outlet of the water heater Be sure all valves are open between the water heater and the storage tank Ensure that all ball valves are fully ported Check the pump to be sure it is running properly and that the pump motor is running in the proper direction Check diameter and length of the piping between the storage tank and water heater against the head capacity of the circulating pump Be sure the pipes between the water heater and storage tank are notless than 2 or 2 1 2 inch 63 5mm diameter depending on model To increase flow and decrease temperature rise increase the piping to 3 inch 76 2mm diameter depending on model to decrease head loss in the piping to the storage tank Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tan
97. in this section For normal installations this system uses a single wall pipe to supply combustion air from outdoors directly to the unit In cold climates use a Type B double wall vent pipe or an insulated single wall pipe for combustion air This will help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe Length of air inlet pipe The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet 15 2m Subtract 5 feet 1 5m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7m of equivalent length for each 45 elbow Do not exceed the limits for the combustion air inlet piping lengths Sidewall air inlet The sidewall air inlet cap is supplied in the Sidewall Air Inlet Kit Order the kit from the appliance manufacturer This sidewall cap supplies combustion air for a single unit only See Table 2B page 21 for kit numbers Locate the unit as close as possible to the sidewall where you will install the combustion air supply system Figure 2 5 Sidewall Combustion Air Inlet Figure 2 6 Air Inlet Cap for Sidewall Termination 19 Coprer FIn II Installation amp Operation Manual 2 Venting To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet follow all applicable clearance requirements in the latest edition of the Nationa
98. ing halogenated compounds most commonly option 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 unit failure TABLE 1C MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Outside Air from Inside Air from Inside Air from Model 2 Openings Directly from Outside Air from 2 Ducts Delivered from 2 Ducts Delivered from Interior Outdoors 1 Opening Directly Outdoors Number Bottom from Outdoors in Bottom Bottom Opening in Opening in Opening Opening i Opening i Opening in 100 100 133 200 200 400 400 645 cm 645 cm 858 cm 1291 cm 1291 cm 2581 cm 2581 cm 125 125 167 250 250 500 500 806 cm 806 cm 1077 cm 1613 cm 1613 cm 3226 cm 3226 cm 163 163 217 325 325 650 650 1052 cm 1052 cm 1400 cm 2097 cm 2097 cm 4194 cm 4194 cm 188 188 250 2 5 375 750 750 1213 cm 1213 cmi 1613 cm 2420 2420 4839 4839 248 248 330 495 495 990 990 1600 cm 1600 cm 2129 cm 3194 cm 3194 cm 6388 cm 6388 cm 315 315 420 630 630 1260 1260 2032cm 2032cm 2710 cm 4065 cm 4065 cm 8130 cm 8130 cm 360 360 480 720 720 1440 1440 232 3c 2323cm 3097 cm 4646 cm 4646 cm 9291 cm 9291 cm 450 600 900 900 1800 1800 2903
99. ining heaters will be designated as Members See page 50 Configuration of the Cascade for a detailed explanation of this procedure On boilers connect the system supply sensor and outdoor air sensor if used to the Leader boiler The location of the system supply sensor should be downstream of the boiler connections in the main system loop FIG s 4 3 and 4 6 The system supply sensor should be wired to the low voltage connection board at the terminals marked for the system supply sensor see FIG 5 4 The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired to the low voltage connection board at the terminals marked for the outdoor air sensor FIG 5 4 If the outdoor air sensor is connected the Leader control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the space heating SH set point that is programmed into the control If a Thermostat Zone Control enable output or Building Management System enable output are available it should be wired to the low voltage connection board on the Leader boiler at the Staging 51 terminals If the boilers are to run continuously leave the jumper wire between these terminals This will initiate a call for heat on the Cascade Also leave the jump
100. ins 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower 3 Do not use the boiler to directly heat swimming pool spa water Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection when used 1 Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Appliance water content is listed on page 8 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level Fill and test water system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve
101. int and hot water from the boiler must enter the coil at this point Due to the fast heating capacity of the boiler it is not necessary to provide a ductstat to delay circulator operation Also omit thermostat flow checks as the boiler is cold when heating thermostat 15 satisfied This provides greater economy over maintaining standby heat DHW installation Boilers may be utilized with a Hot Water Generator tank for domestic hot water When used for DHW either a tank thermostat or sensor must be installed in a bulbwell within the tank and connected back to the unit in order for the controller to regulate water temperature and a pump for DHW Pumps used for DHW purposes should be sized to provide adequate flow to the boiler when in DHW Mode Reference FIG 4 3 shown with a Hot Water Generator for DHW on page 39 for a typical DHW piping scheme CoPPER FIN IT Installation amp Operation Manual 4 Water connections continued Figure 4 3 Primary Secondary Piping of a Single Boiler w DHW COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 amp 2072 COMMON MANIFOLD SIZE Min Models 402 502 652 amp 752 Number of Units c Number of Units D peu o 1 9 212 TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING RETURN LOOP 1 2 MAX HEATING HOT WATER SUPPLY GENERATOR LOOP NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsi
102. ion Hydronic systems anti freeze 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 appliance manufacturers instructions Do not use undiluted or automotive type antifreeze see page 47 Outdoor boiler installation Adequate hydronic system antifreeze must be used A snow screen should be installed to prevent snow and ice accumulation around the unit or its venting system Combustion and ventilation air Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Provide properly sized openings to the equipment room to assure adequate combustion air and proper ventilation when the unit is installed with conventional venting or sidewall venting Combustion air options A CAUTION Under no circumstances should the equipment room ever be under a negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the unit This unit has four combustion air options 1 Outside Combustion Air No Ducts You can direct outside combustion air to this unit using either o
103. ional Cupro Nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated Water with a hardness of less than 5 grains per gallon will usually have a 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 63 COPPER FIN II Installation amp Operation Manual 8 Domestic water heaters Figure 8 1_Typical Water Heater Piping with Storage Tank COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 amp 2072 COMMON MANIFOLD SIZE Min Models 402 502 652 amp 752 Number of Units o9 Number of Units GPM 74 2 COLD WATER SUPPLY BUILDING MIXING HOT WATER VALVE SUPPLY RELIEF VALVE RELIEF VALVE BUILDING RETURN LOCK TEMP STORAGE p TANK Please note that these illustrations meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes Coprer Fin Installation amp Operation Manual 8 Domestic water heaters continued Figure 8 2 Single Water Heater Piping with Two Storage Tanks COMMON MANIFOLD SIZE Min Models 402 502 652 amp 752 COMMON MANIFOLD SIZE Min Models 992 1262
104. ipe 4 Ensure that the air inlet pipes are properly supported Sealing PVC CPVC ABS dryer vent and flex duct vent pipe 1 Clean the PVC CPVC or ABS air inlet pipe using the pipe manufacturer s recommended solvents Seal the pipe joints using standard commercial pipe cement 28 Installation amp Operation Manual 2 Ventin continued 2 For PVC CPVC ABS dryer vent or flex duct air inlet piping use a silicone sealant to ensure a proper seal at the unit inlet and the air inlet cap 3 For Dryer vent or flex duct also use a screw type clamp to attach the inlet vent material to the unit inlet and the air inlet cap Properly sealing the air inlet pipe ensures that combustion air will be free of contaminates and supplied in proper volume 4 Ensure that the air inlet pipes are properly supported Properly seal all joints and seams in the inlet vent piping system Failure to do so may result in flue gas A WARNING 2 recirculation spillage of flue products and carbon monoxide emissions Carbon monoxide poisoning cause severe personal injury or death Vertical and sidewall combustion air inlet NOTICE To prevent recirculation of flue products into the combustion air inlet follow all instructions in this section Locate and install the combustion air inlet termination correctly Failure to do so can allow the discharge of flue products to be drawn into the combustion process This can result
105. k circulating tappings to ensure proper flow If the temperature rise is too low the water velocity is too high adjust as follows Temperature rise be increased by slowly closing field installed ball valve in the outlet piping from the water heater to the storage tank to achieve the proper temperature rise 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 Once temperature rise has been properly set return to normal operation Temperature rise cannot be adjusted A CAUTION when the burner is firing at less than 100 of rated input COPPER FIN Il Installation amp Operation Manual 8 Domestic water heaters continued Water chemistry Water temperature rise and maximum flow NOTICE data is based on heating potable water with a hardness of 5 to 25 grains per gallon and total dissolved solids not exceeding 350 The required temperature rise and the standard circulating pump are sized based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm Consult the manufacturer when heating potable water exceeding these specifications Heating of high hardness and or high total dissolved solids water may require a larger circulating pump an opt
106. l Fuel Gas Code and or CAN CGA B149 Installation Code and instructions in the Installation and Operation Manual Clearances You must install the combustion air inlet cap at least one foot 0 30m above ground level and above normal snow levels The point of termination for the combustion air inlet cap must be at least 3 feet 0 91m below the point of flue gas termination if it is located within 10 feet 3 05m of the flue outlet Make sure to properly install the air inlet cap assembly on the air inlet pipe Do not install the combustion air inlet cap closer than 10 feet 3 05m from an inside corner of an L shaped structure Vertical Rooftop Air Inlet Use the vertical air inlet terminations available from the appliance manufacturer recommended and or supplied by the vent manufacturer or use two 90 elbows as described on page 29 You must locate the air inlet termination elbow at least 12 30 above the roof above normal snow levels If the air inlet cap is within a 10 foot 3 05m radius of the flue outlet the point of termination for the combustion air inlet cap must be at least 3 feet 0 91m below the point of flue gas termination vent cap Do not install the combustion air inlet cap closer than 10 feet 3 05m from an inside corner of an L shaped structure Combined air inlet points The air inlet pipes from multiple boilers can be combined to a E sing
107. l stage as required to hold the actual temperature at the set point If the boiler lights due to a space heating call for heat and the ramp delay function is active default is disabled the staging will be held to a series of increasing limits after the burner has lit STG 1 8 129 8 If the space heating call for heat is active and a DHW call for heat becomes active the control will turn on the DHW pump wait 2 seconds and then turn off the boiler pump This will divert the hot water away from the heating zone s and send it to the DHW tank instead The control will then modulate to maintain the outlet temperature to the DHW boiler set point STG 123 8 180 9 If the DHW call for heat remains active for more than 30 minutes and the space heating call for heat is also on then the control will turn on the boiler pump turn off the DHW pump after 2 seconds and resume firing based on the space heating set point As long as both the space heating and DHW calls for heat remain active the control will switch back and forth between the two modes until one of them is satisfied STG 12 OF 129 10 Once both calls for heat are satisfied the control will turn off the burner The blower will remain on for the 30 second POSTPURGE postpurge cycle Any pumps that are running will continue to run 127 4F 129 for their respective pump delay times then turn off Standby 11 pump off system
108. lay is desired the appropriate parameter in the control must be changed See the Copper fin Service Manual for a detailed explanation of this procedure If there is an active space heating call for heat then the boiler pump will be turned on and the DHW pump will be turned off Set outlet target temperature boiler only When in the DHW Mode the control will modulate to maintain the outlet temperature to a set point This set point is set at the factory to 180 82 29 If a different set point is desired the appropriate parameter in the control must be changed See the Copper fin II Service Manual for a detailed explanation of this procedure Set tank target temperature If a tank sensor is used the tank set point can be adjusted by pressing either the UP or DOWN key menu will appear on the LCD display Press the DOWN key to select the tank set point and press ENTER Use the UP and DOWN keys to adjust the set point Press the ENTER key again to save the new set point and return to the normal display Set clock The SMART SYSTEM control has a built in clock that it uses for its night setback feature and for logging events This clock must be set when the appliance is installed and anytime the appliance has been powered off for more than one month Use the following procedure to set the clock 1 Press and hold the MENU key FIG 7 1 for at least 5 seconds 2 The display changes to ready ENTER MENU CODE with fo
109. le common connection if the common air inlet pipe has a cross sectional area equal to or larger than the total area of all air L inlet pipes connected to common air inlet pipe Example Two 10 air inlet pipes 78 5 in area each have a total Figure 2 7 Rooftop Combustion Air Inlet area of 157 in and will require a 15 176 7 in area common air inlet pipe The air inlet point for multiple boiler air inlets must be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet This exterior opening for combustion air must connect directly to the outdoors The total length of the combined air inlet pipe must not exceed a maximum of 50 15 2m equivalent feet Subtract 5 feet 1 5m for each 90 elbow in the air inlet pipe You must deduct the restriction in area provided by any screens grills or louvers installed in the common air inlet point These are common on the sidewall air inlet openings Screens grills or louvers installed in the common air inlet can reduce the free area of the opening from 2596 to 7596 based on the materials used You can terminate the combustion air pipe either horizontally with a sidewall air inlet or vertically with a rooftop air inlet The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet 15 2m 20 2
110. limit the control will shut the unit down The unit will restart automatically once the temperature difference has dropped 10 F 6 C and the minimum off time has expired Freeze protection DO NOT install the appliance in a room likely to freeze The following integral feature of the SMART SYSTEM control module provides some protection for the appliance only not for the system The SMART SYSTEM control module provides freeze up protection as follows when the appliance water temperature drops below 45 F 7 2 C Below 45 F 7 2 C the appliance and system pumps operate constantly Below 37 F 2 7 C the appliance turns on Appliance and pumps turn off if appliance water temperature rises above 45 F 7 2 C This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing The installer must still use recognized design installation and maintenance practice to prevent freeze potential for the appliance and system High limit operations When outlet temperature exceeds 240 F 116 C boilers or 210 F 99 C water heaters high limit action occurs The appliance shuts down until the outlet water cools down and the RESET button on the Operator Interface is pressed COPPER FIN Il Installation amp Operation Manual 7 Operating information continued Low water cutoff protection 1 The SMART SYSTEM control module uses temperature sensing of both inlet and outlet areas of the heat
111. located on the rating plate Notes Copper fin Is require special gas venting Use only the vent materials and methods specified in the Copper fin II Installation and Operation Manual m Theratings are based on standard test procedures prescribed 3 by the United States Department of Energy p Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building 4 The Copper fin II is orificed for operation up to 2000 and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 feet altitude and including up to 4 500 feet with no field adjustments The appliance will de rate by 496 for each 1000 feet above sea level up to 4 500 feet Consult the factory for installations above 4 500 feet elevation COoPPER FIN Installation amp Operation Manual 1 Determine unit location Location of unit Right Side 3 7 5 cm This unit meets the safe lighting performance criteria with the Rear 3 7 5 cm 3 min from any surface gas manifold and control assembly provided as specified in the ANSI standards for gas fired units ANSI Z21 13 CSA 4 9 cm 247 0 61 m suggested for and ANSI Z21 10 3 CSA 4 3 latest edition i 1 Maintain all clearances from combustible construction Front Alcove 30 0 76m suggested for service when locating appliance See Clearances from Combustible Top 3 7 5 cm Construction this
112. ments Flue outlet piping Venting Guidelines If using this venting option a sealed AL29 4C venting system for flue products is required on all models of this appliance This venting system operates with a positive pressure in the vent The internal combustion air blower generates this positive pressure which operates the combustion process and also exhausts the flue products from the building This vent system has specific vent material and installation requirements Only use listed sealed AL29 4C vent system materials Follow all installation requirements See Table 2A for proper pipe size for your unit A list of sealed AL29 4C flue pipe manufacturers is located on page 15 Seal all vent joints and seams gas tight Drain tee installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee must be installed as the first fitting after the horizontal ell on the top of the unit see FIG 2 9 Plastic drain tubing sized per the vent manufacturer s instructions shall be provided as a drain line from the tee The drain tubing must have a trap provided by a 3 7 6cm diameter circular trap loop in the drain tubing Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use caution not to collapse or restrict the condensate drain line with the nylon wire ties The co
113. mm m on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting installations Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney The weight of the venting system must not rest on the unit Provide adequate support of the venting system Follow all local and applicable codes Secure and seal all vent connections Follow the installation instructions from the vent material manufacturer Barometric damper location Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the unit s flue outlet The barometric damper MUST NOT be installed in a bull head tee installed on the unit s flue outlet The tee or collar containing the barometric damper should be approximately three feet vertically above the connection to the unit s flue outlet This location ensures that any positive velocity pressure from the unit s internal combustion fan is dissipated and the flue products are rising due to buoyancy generated from the temperature of the flue products Adjust the weights on the damper to ensure that draft is maintained within the specified range TABLE 2A FLUE AND AIR INLET PIPE SIZES MODEL FLUE SIZE AIR INLET SIZE MODEL FLUE SIZE AIR INLET SIZE 402 502 2 752
114. mponents Do not operate an appliance with a leak in the gas train valves or related piping 12 Reassemble outer jacket panels 13 Cycle unit and check for proper operation CorPER FIN Il Installation amp Operation Manual HEAT EXCHANGER Figure 9 3 Location of the Heat Exchanger Inside Jacket Review with owner l Review the Copper fin II User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Copper fin II 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 Oiled bearing circulators Inspect the pump every six 6 months and oil as necessary Use SAE 30 non detergent oil or lubricant specified by the pump manufacturer 120 SYSTEM PUMP RELAY 69 68 6 63 63 65 6388 Installation amp Operation Manual 10 Connection diagram BL 2 Y 79 D STAGE 185 oa 8 R imr R BK ALARM CONTACTS RUNTIME CONTACTS PR DIGITAL HARNESS STAGING a
115. n OPERATION DISPLAY 1 The manual reset high limit must be closed before any action will 14 21515 take place OUT 123 8F 129 2 Upon a call for heat the control turns on the appropriate pumps system and boiler pumps for space heating DHW pump for DHW call The flow switch and low water cutoff if equipped must close HTR Standby OUT 123 8F 129 3 f the unit is equipped with a proof of closure valve the proof of closure switch must be closed The proof of closure valve is then energized gas pressure switch es if equipped must close If the contact for the louvers is closed the louver proving and auto reset high limit water heater only inputs must close If the air pressure switch is open the prepurge cycle then begins by starting the combustion blower Once started the air pressure switch must close Standby 123 8 129 4 After the 15 second prepurge the blower slows down and the hot surface igniter HSI is energized HSI is heated for at least 20 seconds PREPURGE 123 9F 129 5 Once the HSI is hot the trial for ignition begins with the IGNITION opening of the gas valve 123 9F 129 POSTPURGE LOCKOUT 6 If the SMART SYSTEM control does not sense flame then it will 123 9F 129 lock out 7 Ifthe SMART SYSTEM control senses flame it will fire the burner to maintain the set point The firing rate wil
116. n control module to achieve proper ignition the gas line when bleeding air from the gas A WARNING line Gas may be present Gas train and controls NOTICE The gas train and controls assembly provided on this unit have been tested under the applicable American National Standard to meet minimum safety and performance criteria such as safe lighting combustion and safety shutdown operation Do not have any open flame in proximity to 402 MODEL COMBINATION VALVE COMBINATION VALVE 2072 MODEL DOWNSTREAM TEST VALVE TO BURNERS DOWNSTREAM TEST VALVE TO BURNERS Figure 3 2 Typical Boiler Gas Train Drawing 32 CorPER FIN II Installation amp Operation Manual TABLE 3B SUGGESTED GAS PIPE SIZE FOR SINGLE UNIT INSTALLATIONS 0 50 50 o2 iur gt gt 2127 75 112 2 2 212 95 7 gt 212 2177 Distance from Meter feet 51 100 100 101 200 201 300 301 500 N 2 172 2 L iur gt _ J z For each elbow or tee add equivalent straight pipe to total length from Table 3C TABLE 3C FITTINGS TO EQUIVALENT STRAIGHT PIPE Pipe 3 4 1 11 411 1 2 2 3 4 5 inches Equivalent lengthof gt 3 4 s 1011412 Straight Pipe feet Water heater models do not have downstream test valves but the rest of the gas train is represented by FIG 3 2 Diameter Combination
117. ndensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material Figure 2 9 Sidewall Vent Models 402 752 Only 23 CorPEn FiN Installation amp Operation Manual 2 Ventin g Do not combine the flue from this unit with the vent from any other appliance Do not combine flues from A WARNING multiple appliances into a common vent The flue from this unit must be a dedicated stack Connect the flue vent directly to the flue outlet opening on the top of the unit Make the connections from the unit vent to the outside stack as direct as possible with no reduction in diameter Provide adequate clearance to combustibles for the vent connector and firestop Follow the vent manufacturer s instructions when installing sealed AL29 4C vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls ceilings and floors Locate the unit as close as possible to chimney or gas vent When a vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions
118. ne or two permanent openings see FIG 1 2 One Opening The opening must have a minimum free area of one square inch per 3000 Btu input 7 cm per kW You must locate this opening within 12 30 cm of the top of the enclosure 10 CorPEn FiN Installation amp Operation Manual Figure 1 2 Outside Combustion Air Single Opening Two Openings The combustion air opening must have a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW You must locate this opening within 12 30 cm of the bottom of the enclosure see FIG 1 3 The ventilation air opening must have a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW You must locate this opening within 12 30 cm of the top of the enclosure 2 Leal 1 rm Figure 1 3 Outside Combustion Air Two Openings 2 Outside Combustion Air Using Ducts You can direct outside combustion air to this unit using two air ducts to deliver the air to the boiler room see FIG 1 5 Each of the two openings must have a minimum free area of one square inch 2000 Btu input 11cm per kW 3 Combustion Air from Interior Space You can direct combustion air to this unit using air from an adjoining interior space You must provide two openings from the boiler room to the adjoining room
119. ned inside the combustion chamber Gas valve The gas valves reference have a dual purpose changing the gas supply pressure to manifold pressure and the reference side of the gas valve is designed to allow chamber pressure to change the volume of gas through the valve and measured as net manifold pressure This is not a design to compensate for gas supply pressure issues System tank temperature sensor not shown When connected this sensor can be used as a system sensor or a tank sensor Outlet limit temperature sensor This sensor monitors the outlet water temperature If selected as the controlling sensor and a system supply sensor is not connected the appliance will maintain set point by adjusting the firing rate of the unit according to this sensor Inlet temperature sensor This sensor monitors inlet water temperature If selected as the controling sensor and a system return sensor is not connected the appliance will maintain set point by adjusting the firing rate of the unit according to this sensor Temperature and pressure gauge boilers only The temperature and pressure gauge monitors the outlet temperature of the appliance as well as the system water pressure Electronic display The electronic display consists of 6 buttons and a two line 16 character liquid crystal display used to monitor the operation of the heater as well as enter and view the programming of the main control board Burner The burner is a
120. ng to and from the boiler must have a fully ported ball valve installed in both the supply and return side piping The ball valves must be fully ported having the same inside diameter as the installed piping The ball valve in the piping supplying water to the boiler will only be used as a service valve The ball valve installed in the discharge from the boiler back to the primary system will be used to adjust boiler flow and temperature rise to ensure proper performance The boiler primary piping system must have a circulator installed in the main system loop to carry the heated boiler water to the point of use in the main system Multiple boilers may also be installed with a primary secondary manifold system Multiple boilers should be connected to the common manifold in reverse return to assist in balancing flow to multiple boilers The installer must ensure that the boiler has adequate flow without excessive temperature rise Low system flow can result in overheating of the boiler water which can cause short burner cycles system noise relief valve discharge and in extreme cases a knocking flash to steam These conditions indicate the need to increase boiler flow to and from the boiler This is generally accomplished by either increasing the size of the boiler pump or by increasing the diameter of the piping that connects the boiler to the primary system A larger diameter pipe reduces head loss and increases flow At no time should the
121. nlet location Keep venting areas free of obstructions Keep area clean and free of combustible and flammable materials Maintain a minimum clearance of 3 76mm to combustible surfaces and a minimum of 36 915mm clearance to the air inlet To avoid a blocked air inlet or blocked flue condition keep the outdoor cap air inlet flue outlet and drain slot clear of snow ice leaves debris etc Do not install outdoor models directly on the ground You must install the outdoor unit on a concrete brick block or other non combustible pad Do not locate unit so that high winds deflect off of adjacent walls buildings or shrubbery causing recirculation Recirculation of flue products may cause operational problems bad combustion or damage to controls Locate unit at least 3 feet 0 91m from any wall or vertical surface to prevent wind conditions from affecting performance Multiple unit outdoor installations require 48 1 22m clearance between each vent cap Locate outdoor cap at least 48 1 22m below and 48 1 22m horizontally from any window door walkway or gravity air intake Locate unit at least 10 feet 3 05m away from any forced air inlet Locate unit at least 3 feet 0 91m outside any overhang Clearances around outdoor installations can change with time Do not allow the growth of trees shrubs or other plants to obstruct the proper operation of the outdoor vent system Do not install in locations where rain from buildin
122. nspection 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 Following installation the valve lever 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 A WARNING 2 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 COoPPER FIN Installation amp Operation Manual Inspect replace hot surface igniter This unit uses a proven SMART SYSTEM control module and a hot surface igniter The SMART SYSTEM control m
123. o prevent damage to burners refractory hot surface igniter or wiring 7 Remove soot from burners with a stiff bristle brush Dirt may be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re installing Damaged burners must be replaced When installed in a dusty and dirty location the burners may require cleaning on a 3 to 6 month schedule or as needed 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 The standard inlet air filter will help eliminate dust and dirt from entering the unit Use extreme care when operating a unit for temporary heat during new construction The burners could require a thorough cleaning before the unit is placed in service 9 Maintenance continued Inspect and clean the heat exchanger 1 10 11 NOTICE While burners are removed check the heat exchanger surface for sooting If present heat exchanger must be cleaned and problem corrected Proceed as follows Remove gas manifold s orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning page 74 Disconnect wiring from the hot surface igniter and hose from the burner pressure tap Remove inner jacket panel mounting screws and slide door assembly out toward front of the unit Use cau
124. o supply combustion air to a single boiler Combustion air supply pipes from multiple units can not be combined into a single air inlet pipe and inlet point A WARNING Only use the sidewall air inlet cap recommended by the appliance manufacturer Using another sidewall air inlet cap may result in operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning Venting of flue products For venting flue products horizontally follow all requirements in the installation instructions for sidewall venting Termination point for the flue products must follow the clearance requirements in the Sidewall Venting Termination section on page 22 For proper operation a barometric damper is provided for Horizontal DirectAire installations The damper will help to ensure a draft between negative 0 04 to 0 08 inches w c TABLE 2D HORIZONTAL DIRECTAIRE KITS MODEL KIT HDK3031 O HDK3031 HDK3026 HDK3027 HDK3027 HDK3028 2072 HDK3028 These kits include a barometric damper 25 COPPER FIN IT Installation amp Operation Manual N Venting Direct venting see page 14 NOTICE Before installing a venting system follow all requirements found in the General Venting section This option uses sealed AL29 4C vent materials for the flue outlet piping and separate combustion air inlet piping 4 7 This system terminates both the flue and
125. oard provides a location to connect all of the low voltage devices to the appliance This is where most of the external safety controls are connected Front doors upper and lower The front doors provide access to the gas train as well as the blower burners and other key components for service and maintenance Hot surface igniter HSI The hot surface igniter is a device that is used to ignite the air gas mixture as well as monitor the performance of the flame during operation This device acts as a flame sense electrode Flame inspection window sight glass The flame inspection windows located on either side of the appliance allow for visual inspection of the burners and flame during operation Gas shut off valve downstream test cock boiler only The downstream test cock is provided in the gas train to ensure complete shut off of the gas to the burner in case of maintenance inspection or testing of the valve Manual reset high limit sensor This device monitors the outlet water temperature to ensure safe operation If the temperature exceeds its setting field adjustable it will break the control circuit shutting the appliance down Manual reset is performed through the display Relief valve The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded Boilers operate on pressure only and are shipped from the factory at a rating of 50 PSI Water heaters operate on temperature and pr
126. odule is not repairable Any modification or repairs will invalidate the warranty A WARNING Do not attempt to repair a faulty hot surface igniter or control module Any modification or repairs may create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty hot surface igniter or control module must be replaced with an identical part A specification igniter and control module for this specific unit is available from your local distributor Do not use general purpose field replacement control modules or igniters Ignition system checkout 1 Turn off gas supply to unit 2 Turn electric power on 3 Adjust the set point on the temperature control to a setting above water temperature or to the highest safe setting 4 The igniter will cycle on trial for ignition 5 control module will lock out and turn the alarm light on 6 Adjust the Set Point Differential and High Fire Offset to the desired settings 7 Turn on gas supply 8 Press the RESET button at the electronic display panel to reset the control module 9 If ignition system fails to operate properly repair work must be performed by a qualified service person or installer Check all wiring 1 Inspect all wiring making sure wires are in good condition and securely attached Check control settings 1 Set the SMART SYSTEM control module display to Parameter Mode and check all settings Se
127. ol Mode parameters Press the ENTER key to access these parameters Use the UP arrow key to access parameter H4 Cascade Press the ENTER key to access this parameter Use the DOWN arrow key to select Enable Press the ENTER key to program this into the control Press the EXIT key then press the DOWN key until I Cascade is selected Press the ENTER key to select the parameter I1 BLR Address Press the ENTER key to access this parameter Each unit in the Cascade system must be programmed with its own address The unit designated as the Leader will have an address of 0 The remaining units in the Cascade will be Members and have addresses from 1 7 Use the UP and DOWN arrow keys to select the appropriate address Press the ENTER key to program this into the control Press the MENU key twice to exit the control parameters Repeat this procedure for all appliances in the Cascade designating the Leader control and the Member controls CoPPER FIN II Installation amp Operation Manual 7 Operating information continued General How the appliance operates The Copper fin II uses a copper finned tube heat exchanger to transfer heat from the flue products to the water An electronic control module monitors various inputs to initiate a call for heat The blower provides both primary and secondary air to the burner and forces the flue products out of the combustion chamber and into the vent system The control module regulates the blower speed
128. ontrol does not detect the outdoor air sensor OUTDOOR SHORTED The outdoor air sensor wires or the sensor itself has become shorted The control will display the tank temperature as sensed by the tank sensor gt Z K 74 Line 2 The control does not detect the tank sensor TANK SHORTED The tank sensor wires or the sensor itself has become shorted gt 2 lt 59 COPPER FIN Installation amp Operation Manual 7 Operating information Status Display Screens cont d By using the Previous Next 4 gt arrow keys the SMART SYSTEM display panel you can navigate through the 11 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Screen Display shows Description Press the Next arrow key the SMART SYSTEM display to access Screen 5 Screen 5 Line 1 0 10V BMS V The control displays the BMS voltage input from 0 to 10 volts Ine Screen 5 Line 2 Press the Next arrow key the SMART SYSTEM display to access Screen 6 The control will display either OFF LOW or HIGH depending upon fan speed requirements of number of stages firing STG DEMAND The control displays the number of stages being called by the control Screen 6 FAN SPEED Line 1 Screen 6 0 10V RATE V The control will display O to 10
129. ontrol inputs and outputs Staging S1 S4 The S1 input tells the boiler to provide water for space heating The S2 S4 inputs are used when a sequencer controls the boiler Tank Aquastat This input tells the boiler to provide water for heating a domestic hot water tank 0 10V input set point or power The Copper fin can be controlled by a Building Management System BMS using 0 10 VDC signal The control can be configured by the installer to use this signal to either control set point or firing rate DHW priority boiler only The SMART SYSTEM control module allows connection of a DHW thermostat or tank sensor to the low voltage connection board When the DHW thermostat or tank sensor calls for heat the module activates the DHW pump shuts down the boiler pump and immediately sets the target outlet water temperature to 180 F 82 2 C This provides automatic priority heat allocation to the indirect water heater for maximum response and recovery The DHW pump continues for 30 seconds after the heating cycle to deliver the most possible heat DHW SH space heating cycling boiler only If an indirect DHW call for heat is received while a space heating call is in progress the control will start the DHW pump and shut the boiler pump off The system pump will remain on If the space heating call is still active while the DHW call is in operation the control will wait for 30 minutes time adjustable by installer th
130. oper system design water temperature rise Pipe diameter and length are critical to ensure proper flow through the boiler A System Temperature Rise Chart Table 4C on page 38 is provided to assist in proper pump selection This table provides GPM and boiler head loss at various temperature rises for each model based on Btu hr input Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing at full rate Example The boiler inlet temperature 1s 160 F 71 19 and the boiler outlet temperature is 180 F 82 2 C This means that there is a 20 F 11 1 C temperature rise across the boiler The boiler temperature rise is visible in the Operator Interface on the boiler s front control panel Circulator pump specifications 1 Maximum operating pressure for the pump must exceed system operating pressure 2 Maximum water temperature should not exceed the nameplate rating 3 Cast iron circulators may be used for closed loop systems 4 Aproperly sized expansion tank must be installed near the boiler and on the suction side of the pump Circulator pump operation heating boilers only The boiler pump must run when the boiler is firing Separate supply circuits can be provided or the two circuits pump and controls can be combined for connection to one circuit properly sized for both Pump delay operation A pump delay operation feature is provided The boiler s circulating
131. or in the attached venting system Use extreme caution when storing water at elevated temperatures A water temperature setting maintained above the dew point of the products of gas combustion should prevent condensate formation and ensure proper performance of the venting system manufacturer recommends the use of a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 140 F 609 Storing the water at a higher temperature and thermostatically mixing the water will increase the available quantity of mixed hot water greatly reducing the possibility of condensate formation on the heat exchanger or in the venting system and help prevent the growth of water borne bacteria NOTICE Adequate care MUST be taken to prevent a potential scald injury when storing water at elevated temperatures for domestic use Inlet water temperatures below the specified minimum recommendations can excessively cool the products of combustion resulting in condensation on the heat exchanger Condensation on the heat exchanger can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the related components An appliance allowed to operate at return temperatures below the specified minimum setting may experience problems with the operating controls safety switches obstruction of the flue gas passages on the heat exchanger incomplete combustion and possible flue gas spilla
132. pump continues its delay if longer OUT 124 7F 129 HTR Standby 12 System pump off OUT 122 9 129 55 CorPrn FiN II Installation amp Operation Manual 7 Operating information Copper fin Il control module Use the control panel FIG 7 1 to set temperatures operating conditions and monitor appliance operation Figure 7 1 Control Panel Operator Interface Hold 5 seconds to enter code Press to turn heater off or back on Input Mode Menu Mode Press to move up one level Press to select a menu item in Menu Mode or to exit Press after parameter programming Menu Mode to store parameter data Press to exit Service Mode MENU EXIT DISPLAY SCREEN ENTER RESET a e 12 DOWN PREVIOUS NEXT A Press to change boiler water temperature and or tank water temperature set point during normal operation Press to change displayed data values in Menu Mode Press to navigate through menu listing in Menu Mode 56 Press to toggle display during normal operation to show outlet and return temperatures fan speed flame signal etc Press to toggle between digits when entering access code or between hour minutes etc when entering date and time Press and hold both to enter Service Mode Coprer Fin IT Installation amp Operation Manual 7 Operating information continued Access modes User The user can adjust the space heating target temp
133. r 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 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 A WARNING 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 packing slip with those actually received In case there is damage or a shortage immediately notify the carrier Do not use this appliance if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced NOTICE 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 guides REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS H Avoid breathing dust and contact with skin and eyes e Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements
134. rate to maintain the set point If the first appliance reaches 100 of its firing rate the Leader will calculate at what point the second appliance could fire at its minimum firing rate At this point the Leader will fire the second appliance on the Cascade For a new startup this would be the first Member appliance The appliance will fire at its ignition speed and will then staging its firing rate to maintain the set point If the set point still cannot be met the Leader will continue firing more Members until either the heat demand is met or all appliances on the Cascade are firing As the heat demand decreases the last appliance on will stage down to its minimum firing rate Once the demand for that appliance is 096 it will shut down As the heat demand decreases further the second to last appliance will stage down and shut off This will continue until the demand is satisfied and all appliances are shut off Sequence of the cascade To equalize the run time of all appliances on the Cascade the firing sequence will automatically be changed at set intervals For the first 24 hours after initializing the Cascade the sequence will be changed every hour After that the sequence will be changed once every 24 hours The switching on off sequence will be as follows SWITCHING ON SEQUENCE 1 1 2 3 4 5 6 7 M1 M2 M3 M4 M5 M6 M7 L 2 3 4 5 6 7 1 1 54 COPPER FIN Il Installation amp Operation Manual
135. re each boiler to have a barometric damper installed to regulate draft within the proper range Do not connect vent connectors serving appliances vented by natural draft negative draft to any portion of a mechanical draft system operating under positive pressure Connecting to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury Flue outlet piping With this venting option you must use Type B double wall vent materials Vent materials must be listed by a nationally recognized test agency for use as vent materials Make the connections from the unit vent to the outside stack as 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 Follow the vent manufacturer s instructions when installing Type B vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls ceilings and floors Locate the unit as close as possible to a chimney or gas vent Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and a negative draft main
136. s Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank 1 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 Water Connections of the Copper fin II Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Maintenance continued Check relief valve 1 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 Water Connections of the Copper fin II Installation and Operation Manual before proceeding further A WARNING Safety relief valves should be re inspected 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 This i
137. s installed with a copper system boiler pressure relief valve must be piped to a suitable floor drain See the Relief Valve section on this page A CAUTION s leak 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 non warrantable failure Water connections heating boilers only Models 402 752 have 2 NPT inlet and outlet connections and Models 992 2072 have 2 1 2 NPT inlet and outlet connections A CAUTION Field installed reducing bushings must not be used COPPER FIN Il Installation amp Operation Manual Any reduction in pipe size may decrease flow resulting in high water temperatures boiler noise flashing to steam and non warrantable heat exchanger damage The boiler may be installed with a primary secondary piping system provided to the boiler It is important to guarantee that adequate flow is provided to properly dissipate heat from the boiler and also ensure that flow through the boiler does not exceed the maximum recommended flow rate of 55 GPM for Models 402 752 and 90 GPM for Models 992 2072 for a boiler equipped with a copper heat exchanger Boiler circulator requirements This is a low mass high efficiency hot water boiler which must have adequate flow for quiet efficient operation Pump selection is critical to achieve proper operation A pump should be selected to achieve pr
138. s observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 74 CorPER FIN Il Installation amp Operation Manual Check flue gas passageways Any sign of soot around the inner jacket outer jacket flue pipe connections burner 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 units seldom need flue cleaning NOTICE gaskets sealants on disassembled components or jacket panels must be replaced with new gaskets sealants on reassembly Gasket and sealant kits are available from your distributor When a Category IV vent system is A CAUTION did disconnected for reason the flue must be reassembled and resealed according to the vent manufacturer s instructions Inspect and clean burner Turn off main power to unit Turn off main manual gas shutoff to unit Remove the front outer jacket panels ae Disconnect manifold from gas train using union s just below each gas valve s 5 Remove mounting screws from manifold mounting brackets Pull the manifold orifice assembly away from burners Repeat for each manifold assembly 6 Remove two mounting screws from burner and slide burner out toward front of unit Use caution t
139. s the unit from weather Indoor clearances from combustible construction Maintain minimum specified clearances for adequate operation Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the unit See rating plate for specific service clearance requirements Although these units are CSA International design certified for outdoor installations such installations are not recommended in areas where the danger of freezing exists You must provide proper freeze protection for outdoor installations units installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower If freeze protection is not provided for the system a low ambient temperature alarm is recommended for the mechanical room Damage to the unit by freezing is non warrantable 9 1 Determine unit location Anytime the inlet temperature drops below 45 F the control turns on the pump contact If the inlet temperature is below 37 F and the unit is in the ON Mode the first stage will fire Location Locate indoor boilers and water heaters in a room having a tem perature safely above freezing 32 F 0 C A CAUTION A mechanical room operating under a negative draft pressure may experience a down draft in the flue of a boiler when it 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 protect
140. structions for those appliances used to supply domestic hot water All warnings cautions notes and instructions in the general installation and operation sections apply to these instructions Water heaters are designed for installation with a storage tank The operation of the circulating pump proper sizing of the piping between the tank and heater and the control of water velocity as explained in this section are important for correct operation of your water heater NOTICE 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 when the water heater is firing at 100 of rated input 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 scale build up in the heat exchanger tubes is a result of restricted flow and too little velocity in the tubes Excessive pitting or erosion in the tube is caused by high water flow and too much velocity through the tubes Care should be taken to measure temperature rise and maintain velocity as follows Initial set up of maximum water flow On initial start up of the Copper fin II the maximum water flow through the heat exchanger must be manually set before normal operation begins
141. system pressure be less ETSI than 12 PSIG Minimum boiler water temperatures Inlet water temperatures below the specified minimum of 140 F 60 C can excessively cool the products of combustion resulting in condensation on the heat exchanger Condensation on the heat exchanger can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the related components See the Low Temperature Bypass Requirements section for boiler system applications below the minimum specified temperature 36 COPPER FIN Il Installation amp Service Manual Low Temperature Return Water Systems Any non condensing boiler will develop operational problems when exposed to inlet water temperatures below 140 Lochinvar offers a low temperature protection valve LTV that 15 factory preset to maintain 140 F inlet water to the boiler regardless of the system return water temperature See Table 4A for available valve kits TABLE 4A LTV VALVE KITS MODEL LTV VALVE KIT 402 752 VAL3048 992 2072 VAL3047 Low temperature bypass requirements To prevent condensation problems a boiler MUST NOT be operated other than for brief periods during initial system startup with an inlet water temperature of less than 140 F 60 If normal system return temperatures are less than the required 140 F 60 C boiler inlet requirement a method of low return water temperature protection MUST BE provided to protect t
142. t or More From Ridge Figure 2 1 Vent Termination from Peaked Roof 10 ft or Less From Ridge NOTICE Vent terminations are not shown in FIG s 2 1 thru 2 4 Make sure all vertical vents are installed with vent terminations recommended by the vent manufacturer l k 10 ORLESS 10 ORLESS 10 OR MORE l l 1 1 1 2 MIN 2 MIN i L 3 MIN l l l l WALLOR NOTE NO HEIGHT PARAPET ABOVE PARAPET REQUIRED WHEN DISTANCE FOR WALLS OR PARAPETS 15 MORE THAN 10 CHIMNEY WALL OR CHIMNEY l PARAPET i CHIMNEY Figure 2 3_Vent Termination from Flat Roof 10 ft Figure 2 4_Vent Termination from Flat Roof 10 ft or or Less From Parapet Wall 1 More From Parapet Wall 18 CorPrn FiN II Installation amp Operation Manual 2 V en n g continued Vertical DirectAire venting see 14 NOTICE Before installing a venting system follow requirements found in the General Venting section The Vertical DirectAire vent system is the same as the Conventional Negative Draft vent system except it pulls combustion air from the outdoors through a separate air inlet pipe Follow all requirements in the Conventional gt gt Negative Draft Venting section on page 16 The Verti
143. t 5 feet 1 5m for each 90 elbow Subtract 2 5 feet 0 7m for each 45 elbow Sidewall venting termination The sidewall vent cap must be installed on an exterior sidewall The sidewall fan powered sidewall vent cap and accessories are included in a venting kit which is furnished by the appliance manufacturer in accordance with CSA International requirements This venting kit includes the powered sidewall fan cap proving switch and all necessary relays to interlock with the heaters control system The sidewall fan powered vent cap must be interlocked with the units control system to start the fan on a call for heat and prove fan operation before the boiler fires Plug in and terminal strip connections are provided on the unit for easy connection of the factory supplied vent kit and control package for the sidewall vent fan See the installation instructions provided with the vent kit Sidewall vent termination clearances and location Locate the bottom of the vent terminal at least 12 inches 30cm above grade and above normal snow levels Locate the bottom of the vent terminal at least 7 feet 2 13m above grade when located adjacent to public walkways Do not terminate directly above a public walkway Do not terminate the venting system in a window well stairwell alcove courtyard or other recessed area Do not terminate the venting system below grade Locate vent termination at least 3 feet 0 91m from an inside corner of an L shaped str
144. t try to light the burner by hand Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Turn gas control knob counterclockwise to ON ON Replace control access panel Turn on all electric power to the appliance If the appliance will not operate follow the instructions To Turn Off Gas To GAS CONTROL KNOB Appliance and call your service tech SHOWN IN THE ON POSITION nician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Turn off all electric power to the appliance 3 Push in gas control knob slightly and If service is to be performed turn clockwise to OFF Do not force ON 2 Open control access panel 4 Replace control access panel LBL2084 REV D 49 6 Start up Set DHW operation Verify DHW circulator mode boiler only The DHW Mode is programmed to heat an indirect domestic hot water tank When the tank thermostat or tank sensor calls for heat the SMART SYSTEM control will turn on the DHW pump and turn off the boiler pump if running If the system pump is running it will remain on When the DHW call for heat ends and there is no space heating call for heat the DHW pump will continue to run for a period of time This pump delay is set at the factory to 30 seconds If a shorter or longer de
145. tained between 0 02 to 0 08 inches w c Common Venting Systems You can combine the flue with the vent from any other negative draft Category I appliance Using common venting for multiple negative draft appliances requires you to install a barometric damper with each unit This will regulate draft within the proper range You must size the common vent and connectors from multiple units per the venting tables for Type B double wall vents in the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Common venting systems may be too large when an existing unit 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 1 Sealany unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch Make sure there is no blockage or restriction leakage corrosion and other unsafe conditions 3 If possible close all building doors and windows Close all doors between the space in which the appliances remaining connected to the common venting system are located and other building spaces CoprPER FiN II Installation amp Operation Manual 2 Ventin continued 4 Turn clothes dryers and any other appliances not connected
146. tallation amp Operation Manual 7 Operating information continued Status Display Screens cont d Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed These screens will provide information regarding the operation of the Cascade Each screen will contain two viewable items The following 18 a description of the individual items and what they can display Press the Next arrow key the SMART SYSTEM display to access Screen 10 Screen 710 Line 1 FLM SIG A pA The control displays the igniter flame signal of igniter A in microamps 710 Line 2 Press the Next gt arrow key the SMART SYSTEM display to access Screen 11 Screen 11 Line 1 FLM SIG B uA The control displays the igniter flame signal of igniter B in microamps IGN AMPS A The control displays the current of either igniter A or B Screen 11 Line2 MIX VAL POS 96 The control displays the mixing valve percentage open to the system me 61 8 Domestic water heaters This section applies only to those appliances used to supply domestic hot water installed with a storage tank s A circulating pump MUST be installed in the piping assembly to the storage tank and valves used to control water velocity through the appliance Proper water velocity is important for correct operation of your water heater This section contains specific in
147. the appliance 2 Vacuum any sediment from inside the appliance and components Remove any obstructions Check all piping for leaks Eliminate all system 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 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 of the Copper fin II Installation and Operation Manual Flue vent system and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping periodically inspected by a qualified service agency A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death 72 Check water system 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 PSI 3 Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem 4 Inspect automatic air vents and air separator
148. thin this water containing section is of a non ferrous material providing clear clean rust free hot water Straight copper tubes finned on the outside for maximum heat transfer and glass lined cast iron one piece cored headers make up an entirely rust proof unit On all models header inspection plugs in the heat exchanger can be removed for field inspection and cleaning of copper tubes The heat exchanger may be removed from the unit COPPER FIN Il Installation amp Operation Manual 8 Domestic water heaters continued Thermostat adjustment procedure 1 Press the UP or DOWN key to view the set point setting 2 Press either the UP or DOWN key to increase or decrease the displayed set point value 3 Press the ENTER key to permanently store the new set point into the control module s memory Failure to press the ENTER key after changing the display value will result in the set point reverting back to its previous value after the current heat demand ends The control may be adjusted any time regardless of call for heat status When pressing the UP or DOWN key to enter any new set points the control module will immediately begin controlling based on the new set point Minimum water temperatures domestic hot water use Domestic water temperatures This high efficiency water heater should be operated at a temperature setting high enough to prevent condensing of the products of combustion on the unit s heat exchanger
149. tion amp Operation Manual Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING shipped with the Failure to perform the service and maintenance could result 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 and care of the appliance designated in Table 9A 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 could result in equipment failure Electrical shock hazard Turn off power to the appliance before any service operation on the appliance except as A WARNING on es noted otherwise in this instruction manual Failure to turn off electrical power could result electrical shock causing severe personal injury or death Address reported problems 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 Inspect appliance interior 1 Remove the outer access panels and inspect the interior of
150. tion Manual Install a manual main gas shutoff valve outside of the unit gas connection within six feet of the unit in accordance with the requirements of the National Fuel Gas Code ANSI Z223 1 You must provide a sediment trap drip leg in the inlet of the gas connection to the unit NOTICE CAUTION It is the installer s responsibility to supply the sediment trap drip leg Do not block access to the electrical cover plate when installing the sediment trap The sediment trap must be a minimum of 12 inches from the appliance combination gas valves have an integral vent limiting device and do not require venting to atmosphere outside the building The unit will not operate properly if the reference hose is removed or a vent to atmosphere is installed Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes Gas connection All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum L P and natural gases All piping must comply with local codes and ordinances Piping installations must comply with approved standards and practices 1 Make sure gas line is a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier USE WRENCH TO HOLD SUPPLY PIPE COUPLING UNION MANUAL MAIN SHUT OFF VALVE dr NIPPLE CAP
151. tion to prevent damage to the refractory and hot surface igniter Check V baffles and frame runners along front and back edges of heat exchanger Remove and clean if necessary Remove soot from heat exchanger with a stiff bristle brush Use a vacuum to remove loose soot from surfaces and inner chamber The heat exchanger can be removed by sliding towards the front of the unit Once the heat exchanger is removed from the unit a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces Note Do not wet the unit s refractory Ensure that all burner ports are cleaned to remove any soot See Burner Removal and Cleaning page 74 Carefully reinstall the heat exchanger V baffles and frame runners if removed from the unit Note Make sure frame runners seal securely where they contact the front and rear compartment refractory Carefully reinstall inner jacket panels burners manifolds wires and hoses Use new gasket material to ensure a proper air seal Reassemble all gas and water piping Test for gas leaks Upon completion of any testing on the gas system leak test all gas connections with a soap and water solution while main burners are operating Do not spray soap and water solution on the SMART SYSTEM control module housing The use of an excessive amount of soap and water solution can damage the control Immediately repair any leak found in the gas train or related co
152. to the boiler and verify minimum gas supply pressure as the burner fires at 10096 of rated input 7 Verify operation of safeties as necessary low water cutoff high limit gas pressure etc 8 Verify that all adjustable points in the Operator Interface are set as required 9 Once the boiler analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down and registers an alarm Open the manual shutoff valve and reset the control 10 Place the boiler back into normal operation Boiler operation 11 Boiler should begin the start up process for the sequence of operation 12 The boiler will ignite at the proper ignition speed and will stage to meet the system demand 13 Ensure that inlet water temperature does not fall below the specified minimum for the boiler 14 Based on system demand boilers may run for an extended period of time at a reduced rate of input to maximize efficiency 48 CorPER FiIN Il Installation amp Operation Manual 15 As system demand is satisfied the burner will cycle off and the combustion air blower will run for a post purge operation before the boiler shuts down Start the boiler Read and follow the Lighting Instructions in FIG 6 1 on page 49 If boiler does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Is external limit control if used open Is boil
153. 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 5 Close fireplace dampers Place in operation the unit being inspected Follow the lighting instructions Adjust thermostat so unit will operate continuously 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 8 After making sure that each appliance remaining connected to the common venting system properly vents when tested as above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use 9 Correct any improper operation of the common venting system so that the installation conforms to the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment When resizing any portion of the common venting system resize to approach the minimum size as determined using the appropriate tables of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment Masonry chimney installations A masonry chimney must be properly sized for the installation of a high efficiency gas fired appliance Ventin
154. ucing 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 Heating boiler installations Piping of the boiler system The drawings in this section show typical boiler piping installations see FIG s 4 3 through 4 6 Before beginning the installation 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 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 The boiler system should not be operated at less than 12 PSIG Hot water piping must be supported by suitable hangers or floor stands NOT by the boiler Copper pipe systems will be subject to considerable expansion and contraction Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system Padding is recommended on rigid hanger
155. ucture Provide a minimum clearance of 4 feet 1 2m horizontally from electric meters gas meters regulators and relief equipment Never locate vent cap above or below electric meters gas meters regulators and relief equipment unless a 4 foot 1 2m horizontal clearance is maintained I Installation amp Operation Manual 2 Ventin Q continued Terminate the venting system at least 3 feet 0 9m above any forced air inlet within 10 feet 3 05m Terminate the venting system at least 4 feet 1 2m below 4 feet 1 2m beside or 1 foot 30cm above any door window or gravity air inlet into any building Locate vent termination at least 8 feet 2 4m horizontally from any combustion air intake located above the sidewall termination cap Units which are shut down or will not operate may experience freezing due to convective air flow in the flue pipe through the air inlet or from negative pressure in the equipment room In cold climates operate the pump continuously to help prevent freezing of boiler water Provide proper freeze protection See Freeze Protection page 47 Sidewall venting without fan For Models 402 752 which are approved for sidewall venting without an external power vent fan you must install specific vent kits and venting materials reference Table 2C on page 24 for kit numbers The following is a detailed explanation of Sidewall Venting Without an External Power Vent Fan installation require
156. ur 4 zeros below it 3 Change the zeros to match the user code factory set at 0704 Use the UP and DOWN keys to increment or decrement the flashing digit and the NEXT and PREVIOUS keys to select which digit flashes Press the ENTER key 5 display changes to read USER CODE for few seconds then displays a menu Press the ENTER key 7 Press the UP key twice to display A3 DATE AND TIME 8 Press the ENTER key once 50 CorPER FIN Il Installation amp Operation Manual 9 The date and time are displayed as YY MM DD W hh mm where minutes hh hour 24 hour time e g 2 00 PM 14 00 W day of the week 1 Sunday 2 Monday 3 Tuesday etc YY year MM month DD date The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Use the UP and DOWN keys to increment or decrement the flashing number and the NEXT and PREVIOUS keys to select which number flashes 10 Press the ENTER key to save the setting 11 Press the MENU key twice to exit the Programming Mode Configuration of the cascade When installed in a Cascade system the individual controls must be programmed for cascade operation This is accomplished by accessing the control parameters Input the Installer code as described in the Copper fin II Service Manual Once the control parameters have been accessed use the DOWN arrow key to select the H Contr
157. urer s instructions shall be provided as a drain line from the tee The drain tubing must have a trap provided by a 3 7 6cm diameter circular trap loop in the drain tubing Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use caution not to collapse or restrict the condensate drain line with the nylon wire ties The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material Do not combine the flue from this unit with the vent from any other appliance Do not combine flues from A WARNING i multiple appliances into a common vent The flue from this unit must be a dedicated stack Connect the flue vent directly to the flue outlet opening on the top of the unit Make the connections from the unit vent to the outside stack as direct as possible with no reduction in diameter Provide adequate clearance to combustibles for the vent connector firestop Follow the vent manufacturer s instructions when installing sealed AL29 4C vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or el
158. ures of the boiler Radiant floor and snow melt heating systems This type of heating boiler application operates in a low temperature range which requires a boiler bypass as described under the Low Temperature Bypass Requirements section non metallic rubber or plastic tubing installed in a radiant in floor system must have an oxygen barrier to prevent oxygen from entering the system through the walls of the installed tubing Excessive oxygen absorption into the system will result in an accelerated rate of corrosion causing a sludge buildup This excessive corrosion will also damage the boiler and system components Sludge formed as the result of excessive oxygen in the system can restrict water flow resulting in a premature boiler failure Any boiler damage due to excessive oxygenation is non warrantable CorPER FIN Il Installation amp Operation Manual TABLE 4B MAXIMUM FLOW FOR HEATING BOILER The maximum flow rate through the boiler with a copper heat exchanger must not exceed the following 402 502 652 and 752 55 GPM 992 1262 1442 1802 and 2072 90 GPM If higher flow rates are required through the boiler an optional Cupro Nickel heat exchanger is available Consult the factory for specific application requirements Low system water volume System run time is very important to the overall operating efficiency of the boiler Short cycling of the boiler creates problems with condensation in the vent stack
159. ves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i If purge valves are not installed in the system open the manual air vents in the system one at a time beginning with the lowest floor Close the vent when water squirts out Repeat with remaining vents gt a Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 4 Refill to correct pressure Check for gas leaks A WARNING Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the front access panel and smell the interior of the boiler enclosure Do not proceed with startup if there is any indication of a gas leak Use an approved leak detection solution Repair any leaks at once A WARNING Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas 47 6 Start up Check thermostat circuit s
160. volts based upon the number of stages Line 2 firing Press the Next gt arrow key the SMART SYSTEM display to access Screen 7 Screen 77 Line 1 The control will display either ON or OFF based upon a demand call SH for heat for space heating Screen 7 Line 2 The control will display either ON or OFF based upon a demand call WHR for heat for DHW domestic hot water Press the Next arrow key the SMART SYSTEM display to access Screen 8 Screen 8 Line 1 The control will display either ON or OFF based upon system pump SYS PUMP requirements upon demand for space heating Screen 8 SYSPUMPSPD V The control will display the O 10V input voltage from the system Line 2 pump based upon system pump speed Press the Next arrow key the SMART SYSTEM display to access Screen 9 The control will display either ON or OFF based upon unit pump UNIT PUMP k requirements upon demand for space heating Screen 9 Line 1 M m UNIT PUMP DELAY The control will display delay in unit pump operation after the space heating requirements have been satisfied DHW PUMP The control will display either ON or OFF based upon unit pump Screen 9 requirements upon demand for DHW Line 2 DHW PUMP DELAY control will display delay in unit pump operation after the DHW requirements have been satisfied 60 Coprer Fin Ins
161. xpansion A relief valve that discharges periodically may be due to thermal expansion in a closed system water heater 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 Never 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 no smoking or open flames near the faucet at the time it is open Figure 8 6 Adjustable Auxiliary High Water Temperature Limit Control 70 9 Maintenance Maintenance and annual startup Table 9A_Service and Maintenance Schedules Service technician see the following pages for instructions 7 lt V lt 2 zZ lt General Address reported problems Inspect interior clean and vacuum if necessary Check for condens
162. y steps to provide proper gas pressure to the control 10 If gas supply pressure is within normal range turn the power switch to the OFF position 11 Turn gas valve knobs to the OFF position 12 Shut off gas supply at the manual gas cock in the gas piping to the unit If fuel supply is L P gas shut off gas supply at the tank CorPER FIN Il Installation amp Operation Manual 13 Remove the manometer and related fitting from the inlet side of the gas valve replace 1 8 hex plug in gas valve and tighten 14 Turn on gas supply at the manual valve turn on L P gas at the tank if required 15 Turn the power switch to the position 16 Turn the gas valve knob to the position 17 Set the electronic temperature control or thermostat to call for heat After completing any testing on the gas system leak test all gas connections Apply a soap water solution to all gas connections while main burners are operating Bubbles forming indicate a leak Repair all leaks at once Do not operate this unit 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 Burner Flames in the Copper fin II Service Manual Turn system off and allow burners to cool then cycle burners again to ensure proper ignition and flame characteristics SUPPLY INLET INLE
163. ypical bypass with a valve as shown in FIG 4 5 will allow control of boiler flow Temperature pressure gauge This boiler is equipped with a dial type temperature pressure gauge This gauge is factory installed in the outlet side of the boiler piping The gauge has one scale to read system pressure and a separate scale to read water temperature in degrees Fahrenheit The temperature pressure gauge is provided to meet code requirements Water temperatures can be more accurately monitored from the data provided in the digital display in the Operator Interface 38 Typical heating boiler installations General plumbing rules 1 Check all local codes 2 For serviceability of boiler always install unions 3 Always pipe pressure relief valve to an open drain 4 Locate system air vents at highest point of system Expansion tank must installed near the boiler on the suction side of the system pump 6 Support all water piping Installation with a chilled water system Pipe refrigeration systems in parallel Install duct coil downstream at cooling coil Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation the boiler piping system must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle The coil must be vented at the high po
164. ystem BMS to monitor the firing rate of the heater Make sure the terminal is connected to the or common terminal of the external control and the terminal is connected to the or Vdc terminal of the external control 0 10V system pump in 0 10VDC input is available so that the boiler can monitor the speed of a variable speed system pump This allows the boiler to anticipate changes in the heat load as the system flow changes Connect the terminal to the or common terminal on the system pump VFD drive and the terminal to the or 0 10VDC terminal on the system pump VFD drive A 0 020mA signal may also be used by adding a 500 ohm resistor between the and terminals Sequencer The individual stages in the heater can be controlled separately with an external sequencer Connect the Staging S1 terminals to the first stage contacts on the sequencer the Staging S2 terminals to the second stage contacts and so forth Note that the sequencer must enable the stages in order with Stage 1 first Stage 2 second and so on Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the heater is locked out or the power is turned off This can be used to turn on an alarm or signal a Building Management System that the boiler is down 45 5 Electrical connections Wiring of the cascade When wiring the heaters for Cascade operation select one heater as the Leader The rema

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