CFA-I-SRev A
Installation & Service Manual
Models: 90,000 - 500,000 Btu/hr
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NOTICE
Hazard definitions
DANGER
Contents
Please read before proceeding
Warranty –
Installation & Service Manual
Checking equipment –
Please read before proceeding
Codes –
Installation & Service Manual
Copper-fin I=B=R Rating
Other Specifications
Ratings
Installation & Service Manual
Ratings
Copper-finSpecifications
Installation & Service Manual
Notes
The Copper-fin- How it works
6 7 8
Installation & Service Manual
The Copper-fin- How it works
13 12
7 23
The Copper-fin- How it works... continued
Installation & Service Manual
6 12 8 14
Installation & Service Manual
1Determine unit location
Location of unit
NOTICE
Figure 1-3_CombustionAir Direct from Outside
1Determine boiler location
Installation & Service Manual
Figure 1-4_CombustionAir Through Ducts
Installation & Service Manual
1Determine boiler location
AIR SUPPLY TO EQUIPMENT ROOM
1Determine boiler location continued
TABLE - 1B MINIMUM RECOMMENDED COMBUSTION
Installation & Service Manual
TABLE - 2A VENT PIPE SIZES
2Venting
A Conventional Negative Draft Venting System
Installation & Service Manual
Installation & Service Manual
2Venting continued
2Venting
Vertical Vent Termination Clearances
Installation & Service Manual
Figure 2-2_VentTermination from Peaked Roof 10 or
Input
Masonry Chimney Installation
TABLE - 7B VENT MATERIALS
Material
2Venting
Automatic Vent Damper
Installation & Service Manual
DANGER
Gas Pressure Test
3Gas connections
Gas Supply
Gas Connection
Installation & Service Manual
Gas Piping
TABLE - 3E
Install Piping to Control
Figure 3-3_ManifoldPressure Adjustment
Gas Manifold Pressure Adjustment Procedure
3Gas connections continued
Figure 3-2_Wrench
3Gas connections
Checking Gas Supply Pressure
Installation & Service Manual
Figure 3-4_GasSupply Pressure
3Gas connections continued
Combination Gas Valves
Installation & Service Manual
Figure 3-5_F1Gas Valve, standing pilot
Relief Valve
Water Flow Switch if equipped
4Hydronic piping
Installation & Service Manual
Low Water Cutoff if equipped
Typical Heating Boiler Installations
4Hydronic piping continued
TABLE - 4A MINIMUM REQUIRED FLOW
Based on Boiler Output in Btu/hr
TABLE - 4B SYSTEM TEMPERATURE RISE CHART
Piping of the Boiler System
Installation & Service Manual
Water Connections Heating Boilers Only
TABLE - 4C HEAT EXCHANGER PRESSURE DROP CHART
Circulator Pump Specifications
Circulator Pump Requirements
4Hydronic piping
Primary/Secondary Boiler Piping
Installation & Service Manual
NOTICE
Boiler Flow Rates
Low Temperature Bypass Requirements
Three Way Valves
4Hydronic piping continued
4Hydronic piping
Primary / Secondary Piping
Installation & Service Manual
NOTICE
Primary / Secondary Piping
Installation & Service Manual
4Hydronic piping continued
NOTICE
SYSTEM SUPPLY SENSOR WHEN USED
Installation & Service Manual
TEMPERATURE LOOP TEMPERATURE LOOP TEMPERATURE
TEMPERATURE / PRESSURE GAUGE TYPICAL
Power Venter Connection to Terminal Strip
TABLE - 5A TERMINAL STRIP WIRING
Boiler Operating Temperature Control
5Electrical connections
Operating Temperature Control
Temperature Adjustment
Pump Wiring for a Heating Boiler
TABLE - 5B
5Electrical connections continued
Locating Temperature Control
Temperature Control Settings
TABLE - 5C MAXIMUM SET POINT DETERMINATION
Inlet Water Temperature Sensor
Installation & Service Manual
Temperature Control Sensors
Multi-PurposeTemperature Sensor
Figure 5-5_Installationof Remote Sensors
Outdoor Air Reset Option
Installation & Service Manual
Figure 5-6_OptionalOutdoor Air Reset Control
Figure 5-7_OutdoorAir Control Example Chart
Additional Temperature Controls
Installation & Service Manual
Outdoor Air Shutdown Enable/Disable Switch
Figure 5-8_BlockedVent Switch Location
Installation & Service Manual
Manual Reset High Water Temperature Limit Control
5Electrical connections continued
6Start-up
FOR YOUR SAFETY READ BEFORE OPERATING
Pre-startChecklist
Initial Start-up
Figure 6-2_PilotLocation
Lighting Instructions
Installation & Service Manual
Figure 6-3_LightingWand
6Start-up
TO TURN OFF GAS TO APPLIANCE
Installation & Service Manual
Installation & Service Manual
Operating Instructions
FOR YOUR SAFETY READ BEFORE OPERATING
WHAT TO DO IF YOU SMELL GAS
To Turn Off Gas to Appliance
Intermittent Pilot Spark Ignition System F9/M9
Freeze Protection
Ignition and Control Timings
Water Treatment
Installation & Service Manual
7Domestic water heaters
TABLE - 7A REQUIRED TEMPERATURE RISE
Required Temperature Rise
Water Velocity Control
Water Chemistry
7Domestic water heaters continued
TABLE - 7B
Softened Water Systems
Figure 7-1_Singlewater heater_single tank
Installation & Service Manual
7Domestic water heaters
NOTICE
NOTICE
7Domestic water heaters continued
Figure 7-2 Singlewater heater multiple tank
COLD WATER SUPPLY
Figure 7-3_Multiplewater heater_single tank
Installation & Service Manual
7Domestic water heaters
NOTICE
Minimum Pump Performance
Remote Sensor Installation
Thermostat Settings
Heat Exchanger
7Domestic water heaters
Figure 7-5_DangerWarning
Thermal Expansion
Water Flow Switch if equipped
Pressure Only Relief Valve
Cathodic Protection
Owner maintenance
8Maintenance and annual startup
Service technician
see the following pages for instructions
Inspect appliance area
8Maintenance continued
Address reported problems
Inspect appliance interior
Check Relief Valve
8Maintenance
Check Expansion Tank
Installation & Service Manual
Combustion Air Adjustment
Check All Wiring
Check Control Settings
Perform Start-upand Checks
Inspection and Cleaning Procedure
Inspect and Clean Burner
Heat Exchanger / Burner Access
8Maintenance
Clear Area
8 Maintenance continued
Pilot Flame Adjustment Procedure
Inspection of Heat Exchanger Waterways
8Maintenance
Review with owner
Gas Train and Controls
Installation & Service Manual
Step3
9Troubleshooting
Step
Step
Step Step
Troubleshooting Guide
90,000 - 270,000 Btu/hr Models - Water Heaters F1
9Troubleshooting
Wiring Diagram - F1 Unit
10 Diagrams
Schematic Diagram - F1 Unit
90,000 - 270,000 Btu/hr Models
315,000 - 399,999 Btu/hr Models
Schematic Diagram - F9 Unit
Wiring Diagram - F9 Unit
10 Diagrams
Installation & Service Manual
Schematic Diagram - M9 Unit
Wiring Diagram - M9 Unit
10 Diagrams continued
500,000 Btu/hr Models
Schematic Diagram - F9/M9 Unit
Wiring Diagram - F9/M9 Unit 500,000 Btu/hr Models
10 Diagrams
Page
Revision A ECO #C06290 initial release
CFA-I-SRev A 09/10