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