Lochinvar CF0502, Installation And Operation Manual

Page 1: ... Rev A 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 Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fi...

Page 2: ...as Pressure 31 Combination Gas Valves 32 Checking Gas Supply Pressure 33 4 WATER CONNECTIONS Inlet Outlet Connections 34 Relief Valve 35 Heating Boiler Installations 35 36 Low Temperature Return Water Systems 36 Low Temperature Bypass Requirements 36 Three Way Valves in System 37 Radiant Floor and Snow Melt Heating Systems 37 Typical Heating Boiler Installations 38 Installation with a Chilled Wate...

Page 3: ... replaced WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or additional information consult a qualified installer service agency or the gas supplier Special instructions REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust re...

Page 4: ... not covered by warranty See Section 7 Operating Information Freeze Protection for more information Safety information 1 This unit is only for use with the type of gas indicated on the rating plate 2 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 pho...

Page 5: ... 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 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 16 Line voltage terminal strip The line voltage terminal strip p...

Page 6: ...orks 18 18 13 13 27 27 18 18 Models 402 752 Front View Models 402 752 Left Side inside unit Models 402 752 Right Side inside unit Models 402 752 Rear View 15 15 23 23 26 26 4 25 25 24 24 16 16 14 14 3 17 17 10 10 19 19 21 21 2 7 12 12 8 6 22 22 11 11 20 20 1 9 ...

Page 7: ...tinued Models 992 2072 Left Side inside unit Models 992 2072 Right Side inside unit Models 992 2072 Rear View Models 992 2072 Front View 18 18 13 13 27 27 18 18 15 15 26 26 23 23 8 3 4 2 21 21 19 19 10 10 24 24 16 16 25 25 17 17 14 14 6 22 22 7 9 1 20 20 12 12 11 11 8 ...

Page 8: ...tallations above 4 500 feet elevation Copper fin II I B R Rating Model Number Note Change N to L for L P gas models Input MBH Note 4 Min Max Gross Output MBH Note 1 Net I B R Ratings Water MBH Note 2 CFN0402 250 399 339 295 CFN0502 250 500 425 370 CFN0652 250 650 553 481 CFN0752 250 750 638 555 CFN0992 360 990 842 732 CFN1262 360 1260 1071 931 CFN1442 360 1440 1224 1064 CFN1802 360 1800 1530 1330 ...

Page 9: ... DO NOT install this appliance directly on carpeting or other combustible material 9 Maintain required clearances from combustible surfaces reference the Indoor Clearances from Combustible Construction Section this page 10 For outdoor models you must install an optional vent cap Instructions for mounting the vent cap are included in the venting section of this manual Do not install outdoor models ...

Page 10: ...rect outside combustion air to this unit using either one 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 cm2 per kW You must locate this opening within 12 30 cm of the top of the enclosure Figure 1 2_Outside Combustion Air Single Opening Two Openings The combustion air opening must have a minimum free area of one ...

Page 11: ...MMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Model Number Outside Air from 2 Openings Directly from Outdoors Outside Air from 1 Opening Directly from Outdoors in2 Inside Air from 2 Ducts Delivered from Outdoors Inside Air from 2 Ducts Delivered from Interior Space Top Opening in2 Bottom Opening in2 Top Opening in2 Bottom Opening in2 Top Opening in2 Bottom Opening in2 402 100 645 cm2 100 645 cm2...

Page 12: ...n 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 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 ...

Page 13: ...e 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 ste...

Page 14: ...e products out a sidewall vent termination with air supplied from the equipment room see page 22 This option uses the installation of a special air inlet vent cap on top of the unit see page 30 NOTE CAT I B VENT MATERIALS MAY BE 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 MAT...

Page 15: ...ting system to prevent sagging Provide an upward slope of at least 1 4 inch per foot 21mm 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 supp...

Page 16: ... 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 electr...

Page 17: ...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 WARNING 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 pro...

Page 18: ...rtical vents are installed with vent terminations recommended by the vent manufacturer Figure 2 2_Vent Termination from Peaked Roof 10 ft or More From Ridge Figure 2 4_Vent Termination from Flat Roof 10 ft or More From Parapet Wall Figure 2 3_Vent Termination from Flat Roof 10 ft or Less From Parapet Wall 18 Installation Operation Manual 2 Venting ...

Page 19: ...ir 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 WARNING 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 hazardo...

Page 20: ... termination elbow at least 12 30cm above the roof or 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 stru...

Page 21: ...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...

Page 22: ...nnectors 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 Subtract 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 exteri...

Page 23: ...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 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 ...

Page 24: ...he 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 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 ...

Page 25: ...on page 10 NOTICE Before installing a venting system follow all requirements found in the General Venting section 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 adap...

Page 26: ...bing 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 condensa...

Page 27: ...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 u...

Page 28: ...VERTICAL DV BOX ADAPTER HORIZONTAL DV BOX ADAPTER Air inlet piping materials The air inlet pipe s must 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 ...

Page 29: ...et 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 Figure 2 13_Vertical Rooftop Air Inlet 6 MAX For horizontal direct vent termination of combustion air you must use the termination cap from the appliance...

Page 30: ...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 Locat...

Page 31: ...If you must adjust regulator pressure follow the instructions under Gas Manifold Pressure Adjustment in the Copper fin II Service Manual Do not increase regulator pressure beyond specified pressure setting 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 ordinanc...

Page 32: ...262 2 2 1 2 2 1 2 3 3 1442 2 1 2 2 1 2 3 3 3 1 2 1802 2 1 2 3 3 3 1 2 3 1 2 2072 2 1 2 3 3 3 1 2 4 For each elbow or tee add equivalent straight pipe to total length from Table 3C 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 lighti...

Page 33: ...imum gas supply pressures 9 If gas pressure is out of range contact gas utility gas supplier qualified installer or service agency to determine necessary 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 pi...

Page 34: ... 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 Water flow switch A water flow switch is factory installed in the outlet on all heating boilers and water heaters The flow switch must prove water flow before a trial for ignition can begin The flow sw...

Page 35: ...g 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 effi...

Page 36: ...the boiler to the primary system A larger diameter pipe reduces head loss and increases flow Low Temperature Return Water Systems Any non condensing boiler will develop operational problems when exposed to inlet water temperatures below 140 F Lochinvar offers a low temperature protection valve LTV that is factory preset to maintain 140 F inlet water to the boiler regardless of the system return wa...

Page 37: ...enation is non warrantable TABLE 4B MAXIMUM FLOW FOR HEATING BOILER The maximum flow rate through the boiler with a copper heat exchanger must not exceed the following Model Maximum Flow 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 ...

Page 38: ...talled 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 Typical heating boiler installations Genera...

Page 39: ... 1 55 2 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 1 90 2 1 2 TO FLOOR DRAIN HEATING SUPPLY LOOP TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING RETURN LOOP 12 MAX HOT WATER GENERATOR 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 NO...

Page 40: ... Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 2 180 4 3 270 5 4 360 6 5 450 6 6 540 6 7 630 8 8 720 8 MAKE UP WATER PRESSURE RELIEF VALVE EXPANSION TANK LOW WATER CUT OFF OPTIONAL SYSTEM PUMP TO SYSTEM 12 OR 4X PIPE DIAMETERS FROM SYSTEM SECONDARY BOILER PUMP AIR SEPARATOR Please note that these illustrations are meant to show system piping concept only the installer is respo...

Page 41: ...NIFOLD SIZE Min Models 402 502 652 752 Number of Units GPM Diameter in 1 55 2 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 1 90 2 1 2 HEATING SUPPLY LOOP MIXING VALVE TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING RETURN LOOP TO FLOOR DRAIN 12 MAX Please note that these illustrations are meant to show system piping concept only the installer is respons...

Page 42: ...ion on the side of the tank for pictorial purposes The standard location for the system tappings is 180 from the recirculation tappings COMMON MANIFOLD SIZE Min Models 402 502 652 752 Number of Units GPM Diameter in 2 110 3 3 165 3 1 2 4 220 4 5 275 5 6 330 5 7 385 6 8 440 6 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 2 180 4 3 270 5 4 360 6 5 450 6 6 54...

Page 43: ...Code Part I and or local Electrical Codes Multiple units connected in a Cascade must be grounded to the same ground connection 1 All wiring between the appliance and field installed devices shall be made with type T wire 63 F 35 C rise 2 All line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 The circulating pump must run continuously whe...

Page 44: ...Routing Field Wiring EMS or remote thermostat connection 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 and adjustment Connection of a set of dry switching contacts or a remote on off thermostat to the low voltage connection board will...

Page 45: ... heater Connect the Staging S1 or tank thermostat terminals to the enable output of the BMS when used 2 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 10VDC terminal of the external control Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running This ...

Page 46: ...on 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 o...

Page 47: ...rain and be seen b Close the boiler or system isolation valve between the purge valve and fill connection to the system c Close zone isolation valves d Open quick fill valve on cold water makeup line e Open purge valve f 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 is present Close the zone isolation valves an...

Page 48: ...ctly 1 Check for loose connections blown fuse or service switch off 2 Is external limit control if used open Is boiler water temperature above 200 F 93 3 C 3 Is thermostat 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 M...

Page 49: ...he safety information above on this label 2 Turn off all electric power to the appliance 3 Open control access panel 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Push in gas control knob slightly and turn clockwise to OFF NOTE On the 36C valve knob cannot be turned to OFF unless knob is pushed in slightly Do not...

Page 50: ...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 4 Press the ENTER key 5 The display changes to read USER CODE for a few seconds then displays a menu 6 Press the ENTER key 7 Press the UP key twice to display A3 DATE AND TIME 8 Press the ENTER key once 9...

Page 51: ...s 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 temperatur...

Page 52: ...ined 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 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 practi...

Page 53: ...e system s efficiency as the outdoor temperature warms up See the Copper fin II Service Manual to 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 A maximum of eight appliances can be controlled from a single control In this application one appli...

Page 54: ...will be changed once every 24 hours The switching on off sequence will be as follows DAY SWITCHING ON SEQUENCE Start L M1 M2 M3 M4 M5 M6 M7 1 hour M1 M2 M3 M4 M5 M6 M7 L 2 hour M2 M3 M4 M5 M6 M7 L M1 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 DH...

Page 55: ...int The firing rate will 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 HTR RUN STG 1 OUT 124 8F 129 8 If the space heating call for heat is active and a DHW call for heat becomes ac...

Page 56: ... 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 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 an...

Page 57: ...s 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 bu...

Page 58: ... heatup time prior to the trial for ignition Display will show IGNITER A or IGNITER B depending on which stage has priority HTR RUN STG Or HTR DHW STG The unit has fired and is running at the displayed number of stages 1 2 3 4 HTR POST PURGE The call for heat has been satisfied and the unit runs the fan for an additional 10 seconds to clear the combustion chamber and vent system of residual flue p...

Page 59: ...ure as well as the set point in parenthesis SYSSUP F If the system supply sensor has not been selected as the control sensor only the system supply temperature will be displayed 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 Screen 3 Line 2 SYSRTN F When the system return sensor has been selecte...

Page 60: ...RT SYSTEM display to access Screen 7 Screen 7 Line 1 SH CFH The control will display either ON or OFF based upon a demand call for heat for space heating Screen 7 Line 2 WHR CFH The control will display either ON or OFF based upon a demand call for heat for DHW domestic hot water Press the Next arrow key on the SMART SYSTEM display to access Screen 8 Screen 8 Line 1 SYS PUMP The control will displ...

Page 61: ...ms and what they can display Screen Display shows Description Press the Next arrow key on the SMART SYSTEM display to access Screen 10 Screen 10 Line 1 FLM SIG A µA The control displays the igniter flame signal of igniter A in microamps Screen 10 Line 2 FLM SIG B µA The control displays the igniter flame signal of igniter B in microamps Press the Next arrow key on the SMART SYSTEM display to acces...

Page 62: ...e heat exchanger must be manually set before normal operation begins 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 ...

Page 63: ...issolved solids water may require a larger circulating pump an optional Cupro Nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated 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 du...

Page 64: ...N MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 1 90 2 1 2 OUTLET COLD WATER SUPPLY BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK TEMP STORAGE TANK DRAIN BUILDING RETURN INLET RELIEF VALVE MIXING VALVE 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 code...

Page 65: ...AGE TANK DRAIN BUILDING RETURN INLET MIXING VALVE COMMON MANIFOLD SIZE Min Models 402 502 652 752 Number of Units GPM Diameter in 1 55 2 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 1 90 2 1 2 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 cod...

Page 66: ... TANK COMMON MANIFOLD SIZE Min Models 402 502 652 752 Number of Units GPM Diameter in 2 110 3 3 165 3 1 2 4 220 4 5 275 5 6 330 5 7 385 6 8 440 6 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 2 180 4 3 270 5 4 360 6 5 450 6 6 540 6 7 630 7 8 720 7 Please note that these illustrations are meant to show system piping concept only the installer is responsible...

Page 67: ...ORAGE TANK COMMON MANIFOLD SIZE Min Models 402 502 652 752 Number of Units GPM Diameter in 2 110 3 3 165 3 1 2 4 220 4 5 275 5 6 330 5 7 385 6 8 440 6 COMMON MANIFOLD SIZE Min Models 992 1262 1442 1802 2072 Number of Units GPM Diameter in 2 180 4 3 270 5 4 360 6 5 450 6 6 540 6 7 630 7 8 720 7 Please note that these illustrations are meant to show system piping concept only the installer is respon...

Page 68: ...ntrol 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 int...

Page 69: ...ety 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 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 Inte...

Page 70: ...e 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 Optional relief valve This water heater is normally supplied with a temperature and pressure relief valve ...

Page 71: ...rformance indicate need Clean heat exchanger with a stiff bristle brush 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 ANNUAL START UP Owner maintenance see the Copper fin II User s Information Manual for instructions Daily Check appliance area Check pressure temperature gauge Mon...

Page 72: ... Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 3 Gas Connections of the Copper fin II Installa...

Page 73: ...nstalled 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 WARNING WARNING Inspect replace hot surface igniter This unit uses a proven SMART SYSTEM control module and a hot ...

Page 74: ...n Properly installed and adjusted units seldom need flue cleaning All gaskets sealants on disassembled componentsorjacketpanelsmustbereplaced with new gaskets sealants on reassembly Gasket and sealant kits are available from your distributor NOTICE CAUTION When a Category IV vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s in...

Page 75: ... securely where they contact the front and rear compartment refractory 10 Carefully reinstall inner jacket panels burners manifolds wires and hoses Use new gasket material to ensure a proper air seal 11 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...

Page 76: ...BL R O R W 6 1 5 4 3 2 Y Y Y NEUTRAL UNIT PUMP SYSTEM PUMP RELAY COIL IND DHW PUMP RELAY COIL LINE GROUND 1 3 5 2 4 BK W G BK W BK R CONTR DISPLAY INLET SENSOR BR BR SAFETY OUTLET SENSOR ON OFF SWITCH BK BK BR BR CHASSIS GROUND W P W PR X3 1 2 3 4 P P PR PR 1 2 3 4 R W BK G 1 2 3 4 W Y W BK Y 1 7 2 5 6 8 Y BK P W R R BK BK R FIELD WIRING W BK G 3 1 BK W 2 G 3 2 Y BL 60VA 3 1 BK W 3 2 Y BL CONTROLL...

Page 77: ... BK W BK BK W HI LO SPEED RELAY 120VAC COIL W BK R BK W R BK NO COM NC COM O BK HSI 2 W BL R BL HI O O BK BL BL BL CIRCUIT BREAKER LO MAIN UNIT HARNESS 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 rep...

Page 78: ... F6 5A STAGE 1 HSI STAGE 3 HSI X1 12 X1 2 X1 3 X1 1 MODBUS INTERFACE BOARD CIRCUIT BREAKER OR FUSE TRANSFORMER INTERGRATED CONTROL BOARD X10 1 X12 1 X10 2 X10 3 X12 2 X12 3 STAGE 1 GAS VALVE STAGE 2 GAS VALVE STAGE 3 GAS VALVE STAGE 4 GAS VALVE X10 5 X10 6 X12 5 X10 4 X12 4 MANUAL RESET HIGH LIMIT X6 4 X12 6 CIRCUIT BREAKER INTERGRATED CONTROL BOARD TRANSFORMER WHERE POSSIBLE SWITCHES ARE SHOWN WI...

Page 79: ...SOR S5 2ND POOL SUPPLY SENSOR S8 SYSTEM POOL SUPPLY SENSOR S6 SYSTEM POOL RETURN SENSOR S7 CONNECTION BOARD 2 X8 3 X4 3 X4 1 X8 10 X4 2 X8 20 CN1 1 X6 3 CN1 3 X6 1 CN1 2 X6 2 X8 11 BOILER POOL A B SHIELD MODBUS RTU MODBUS INTERFACE BOARD DISPLAY BOARD COMPUTER X4 X11 CN4 1 CN4 4 CONNECTION BOARD 1 1 2 PROBE J3 6 J3 5 TEST RESET J2 1 J2 2 LOW WATER CUTOFF AIR PRESSURE LOW GAS PRESS HIGH GAS PRESS S...

Page 80: ...Revision Notes Revision A ECO C08226 initial release CFX CHX I O Rev A 6 11 ...