Installation & Operation Manual
The Copper-fin II - How it works...
1.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.
2.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.
3.Blower
The blower pulls in and injects air into the individual burners along with gas from the gas manifold where the mix is burned inside the combustion chamber.
4.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.
5.System / tank temperature sensor (not shown)
When connected, this sensor can be used as a system sensor or a tank sensor.
6.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.
7.Inlet temperature sensor
This sensor monitors inlet water temperature. If selected as
the | controlling 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.
8.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.
9.Electronic display
The electronic display consists of 6 buttons and a
10.Burner
The burner is a 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.
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 provides a location to connect all of the line voltage (120 VAC) contact points to the unit.
17.Low voltage connection board(s)
The low voltage connection board 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.
18.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.
19.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.
20.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.
21.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.
22.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.
23.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 pressure and are shipped standard as 150 PSI and 210°F (98.9°C).
24.Power switch
The power switch is used to engage and disengage power to the appliance on the 120 VAC circuit.
25.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.
11.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 #26), a relief valve (see #23), and a temperature and pressure gauge (boilers only) (see #8).
12.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.
26.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 is discontinued during operation for any reason the flow switch will break the control circuit and the unit will shut down.
27.Drain port(s)
The drain ports are located underneath the front header.
13.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.
28.Manual shutoff valve (not shown)
Manual valve used to isolate the unit from the gas supply.
14. 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. |
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