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497 - 2067 service manual Connection diagram continued, Installation & Service Manual
Models:
497 - 2067
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Specs
Install
Pressure Drop Chart
Placement of sensors
Warranty
Maintenance
Connecting to gas supply
8_Optionaloutdoor reset control
Diagnostic Status Indication
Setup procedure
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Image 67
Installation & Service Manual
10
Diagrams
(continued)
Connection diagram
(continued)
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Contents
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CBX-CWX-I-SRev A
Installation & Service Manual Models: 497 -
WHAT TO DO IF YOU SMELL GAS
DANGER
Hazard definitions
NOTICE
Contents
Special instructions
Warranty –
Installation & Service Manual
Please read before proceeding
Codes –
Safety information
Owner warning –
Prevention of freezing –
Installation & Service Manual
The Copper-fin- How it works
Models 497 - 747 Left Side inside unit
Models 497 - 747 Front View
Models 497 - 747 Rear View
Models 497 - 747 Right Side inside unit
Models 987 - 2067 Right Side inside unit
The Copper-fin- How it works... continued
Models 987 - 2067 Front View
Models 987 - 2067 Rear View
Notes
Other Specifications
Ratings
Copper-fin I=B=R Rating
Installation & Service Manual
Copper-finSpecifications
Notes
Indoor clearances from combustible construction
Installation
1 Determine unit location
Locating the unit
Freeze protection
Outdoor boiler installation
1 Determine unit location continued
Shut-downand draining
1 Determine unit location
TABLE 1B
Combustion and Ventilation Air
Installation & Service Manual
Installation & Service Manual
Figure 1-3 Combustionair filter Models
Figure 1-4 Combustionair filter Models
Combustion air filter
1. Outside Combustion Air, No Ducts
2. Outside Combustion Air, Using Ducts
Figure 1-7_Outsidecombustion air, using ducts
Combustion Air Options
Installation & Service Manual
Exhaust Fans
3. Combustion Air from an Interior Space
Figure 1-8_Combustionair from an interior space
Vertical vent termination clearances and location
2 Venting
General information
Venting support
Vent system options
TABLE 2A
Barometric damper location
Common venting systems
1.Conventional negative draft venting
Negative draft
Flue outlet piping
Vertical vent termination clearances and location
Masonry chimney installation
Inspection of a masonry chimney
Installation & Service Manual
2 Venting
2. Outdoor installation venting
Outdoor vent/air inlet location
Installation & Service Manual
TABLE 2B
Figure 2-6_Outdoorvent cap installed on Models
Figure 2-7_Outdoorvent cap installed on Models
Outdoor vent kit
Gas pressure test
Connecting to gas supply
3 Gas connections
Gas piping
TABLE 3C
3 Gas connections continued
Gas connection
TABLE 3B
Checking gas supply pressure
Combination gas valves
TABLE 3D
Venting of combination gas valves
NOTICE
Gas manifold pressure adjustment
Installation & Service Manual
3 Gas connections continued
Installation & Service Manual
TABLE 3E Net Manifold Pressure
Regulator Pressure Less Front Chamber Pressure
Figure 3-4_Measuringmanifold gas pressure
Inlet and outlet connections
Water flow switch
Heating boiler installations
4 Water connections
Water connections heating boilers only
Pressure Drop Chart
Circulator pump specifications
Pump delay operation
Installation & Service Manual
Minimum boiler water temperatures
Low system water volume
4 Water connections continued
Radiant floor and snow melt heating systems
Low temperature return water systems
TABLE 4A
TABLE 4B
NOTICE
Installation & Service Manual
4 Water connections continued
COMMON MANIFOLD SIZE Min Models: 497 -
NOTICE
Installation & Service Manual
4 Water connections
3 1/2
TO FLOOR DRAIN
Figure 4-7_Boilerwith low temperature bypass
Installation & Service Manual
4 Water connections continued
NOTICE
Installation & Service Manual
1 TEMPERATURE AND PRESSURE GAUGE AUTOMATIC AIR
4 Water connections
TABLE - 4C
Installation with a chilled water system
Typical heating boiler installations
Boiler flow rate
Water treatment
Temperature / pressure gauge
Boiler bypass requirements
Filling the system
Figure 5-1_Controlpanel location
Connecting to electrical supply
5 Electrical connections
TABLE 5A
Terminal strip connection options
ENABLE
Figure 5-5_Fieldinstallation safety devices
burners
Figure 5-7_Temperaturecontrol setting knobs
Temperature adjustment
Locating the temperature control
Temperature control settings
Differential
Outdoor reset option
Figure 5-8_Optionaloutdoor reset control
Setpoint
Outdoor air temperature sensor
Temperature control sensors
Inlet water temperature sensor
Multi-purposetemperature sensor
Hot surface igniter and ignition control module
Hot surface ignition system
TABLE 5C
Remote mounting of a sensor
Installation & Service Manual
Diagnostic Status Indication
Ignition and control timings
Figure 5-12_Hotsurface ignition control module
TABLE 5D
Operation and diagnostic lights
Figure 5-13_Operation /diagnostic lights
TABLE 5E
Figure 6-1_Operatinginstructions
6 Startup
Installation & Service Manual
Purge air from water system
Freeze protection when used
Check/control water chemistry
Fill and test water system
Start the boiler
Check for gas leaks
Check thermostat circuits
Check vent and air piping
Water velocity control
7 Domestic water heaters
TABLE - 7A
TABLE 7B
BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK-TEMP
7 Domestic water heaters continued
Installation & Service Manual
NOTICE
BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK-TEMP
Installation & Service Manual
7 Domestic water heaters
NOTICE
NOTICE
Installation & Service Manual
7 Domestic water heaters continued
COMMON MANIFOLD SIZE Min
BUILDING HOT WATER SUPPLY RELIEF VALVE
Installation & Service Manual
7 Domestic water heaters
NOTICE
Models 987 - 1/2 HP, 120 VAC, 7.4 Amps
Required temperature rise
TABLE 7C
Models 497 - 1/4 HP, 120 VAC, 5.8 Amps
Minimum pump performance
Potable hot water temperature control settings
Domestic water temperature
TABLE 7D
NOTICE
Location of cold water supply piping connections
Installation & Service Manual
7 Domestic water heaters continued
Cathodic protection
High water temperature limit control
Optional relief valve
Thermal expansion
Appliance area
8 Maintenance
Flue gas passageways cleaning procedure
Burner removal and cleaning
Adjusting air pressure
Heat exchanger cleaning
Fan cleaning
Combustion air fan adjustment
Figure 8-2_Airpressure switch
8 Maintenance continued
Adjustment procedure Models 497 -
Adjustment procedure: Models 1437, 1797 and
Overview
Figure 8-6_Adjustingthe air shutter
Sequence of operation
Ignition system checkout
Installation & Service Manual
Heat transfer process
End of sequence
8 Maintenance continued
Safety Device Terminals
Power Supply AC120VAC/60Hz
ON/OFF Rocker Switch
Manual Reset High-LimitThermostat
Hi-LoFire Relay
Pump Delay Electronic Thermostat Function
Trial for Ignition Ignition Module Function
Igniter Controlled by Ignition Module
Ladder diagram
10 Diagrams
Installation & Service Manual
10 Diagrams continued
Ladder diagram continued
0987-20670497-747
10 Diagrams
Connection diagram
Installation & Service Manual
Installation & Service Manual
Connection diagram continued
10 Diagrams continued
CBX-CWX-I-SRev A 3/11
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