Lochinvar COPPER-FIN II 402 - 2072 Installation And Operation Manual
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Lochinvar COPPER-FIN II 402 - 2072 Installation And Operation Manual

Lochinvar water heater user manual
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WARNING:
If the information in these instructions is not
followed exactly, a fire or explosion may result causing property
damage, personal injury or death.
-- 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 fire department.
-- Installation and service must be performed by a qualified
installer, service agency, or the gas supplier.
Installation & Operation Manual
Models: 402 - 2072
WARNING:
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual and the Copper-fin II Service Manual be
reviewed completely before proceeding with an
installation. Perform steps in the order given.
Failure to comply could result in severe personal
injury, death, or substantial property damage.
Save this manual for future reference.
CFX-CHX-I-O Rev A

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Summary of Contents for Lochinvar COPPER-FIN II 402 - 2072

  • Page 1 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. -- 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 •...

  • Page 2: Table Of Contents

    8. DOMESTIC WATER HEATERS Initial Setup of Maximum Water Flow ... 62 Water Chemistry... 63 Typical Water Heater Piping w/Storage Tank(s) ... 64-65 Multiple Water Heater Piping w/Storage Tank(s) ... 66-67 Pump Operation ... 68 Minimum Water Temperatures (domestic hot water) ... 69 9.

  • Page 3: Please Read Before Proceeding

    Please read before proceeding Special instructions This is a gas appliance and should be installed NOTICE by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier. WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

  • Page 4: Safety Information

    Please read before proceeding Safety information Owner warning – The information contained in this manual is intended for use by qualified professional installers, service technicians, or gas suppliers. Consult and follow all local Building and NOTICE Fire Regulations and other Safety Codes that apply to this installation.

  • Page 5: The Copper-Fin Ii - How It Works

    The Copper-fin II - How it works... Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. headers and copper fined tubing are encased in a jacket that contains the combustion process. Heat exchanger access cover The heat exchanger access cover is a galvanized steel door which allows access for service, maintenance, and removal of the...
  • Page 6 The Copper-fin II - How it works... Models 402 - 752 Front View Models 402 - 752 Right Side (inside unit) Models 402 - 752 Rear View Models 402 - 752 Left Side (inside unit) Installation & Operation Manual...
  • Page 7 The Copper-fin II - How it works... Models 992 - 2072 Front View Models 992 - 2072 Right Side (inside unit) (continued) Models 992 - 2072 Rear View Models 992 - 2072 Left Side (inside unit) Installation & Operation Manual...

  • Page 8: Ratings

    Ratings Copper-fin II I=B=R Rating Input Model Number (Note 4) Note: Change “N” to “L” for L.P. gas models. CFN0402 CFN0502 CFN0652 CFN0752 CFN0992 CFN1262 CFN1442 CFN1802 CFN2072 CHN0402 CHN0502 CHN0652 CHN0752 CHN0992 CHN1262 CHN1442 CHN1802 CHN2072 Maximum allowed working pressure is located on the rating plate. NOTICE Notes: 1.

  • Page 9: Determine Unit Location

    Determine unit location Location of unit This unit meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ANSI standards for gas-fired units, ANSI Z21.13/CSA 4.9 and ANSI Z21.10.3/CSA 4.3 - latest edition. 1.

  • Page 10: Non-Combustible / Combustible Flooring

    Determine unit location Anytime the inlet temperature drops below 45°F, the control turns on the pump contact. If the inlet temperature is below 37°F, and the unit is in the ON Mode, the fi rst stage will fi re. Location Locate indoor boilers and water heaters in a room having a tem- perature safely above freezing [32°F (0°C)].
  • Page 11 Determine unit location Figure 1-5_Outside Combustion Air Through Ducts 4. Outside Combustion Air - Using Direct Venting With this option, you can connect combustion air vent piping directly to the unit. See the information under Direct Venting starting on page 26 for specific information regarding this option.
  • Page 12 Determine unit location Exhaust fans Any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and/or cause a down draft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected.

  • Page 13: Venting

    Venting Identify your appliance’s vent system: This manual covers venting requirements for CAT I models and CAT IV vent materials. Be sure to correctly identify the type of vent system your appliance requires before proceeding. C(F,H) (N,L)0402 C(F,H) (N,L)0502 C(F,H) (N,L)0652 C(F,H) (N,L)0752 C(F,H) (N,L)0992 C(F,H) (N,L)1262...

  • Page 14: Vent System Options

    Venting Vent system options: This option uses a vertical rooftop flue termination with air supplied from the equipment room - see page 16. CONVENTIONAL NEGATIVE DRAFT VENTING This option uses a vertical conventional vent for flue products with air supplied by a pipe from the sidewall or rooftop - see page 19.

  • Page 15: General Venting Information

    Venting (continued) General information You must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable local building codes.

  • Page 16: Conventional Negative Draft Venting

    Venting Conventional negative draft venting Before installing a venting system, follow requirements found in the General Venting section. NOTICE This option uses Type-B double-wall flue outlet piping. The blower brings in combustion air. The buoyancy of the heated flue products cause them to rise up through the flue pipe. The flue outlet terminates at the rooftop. Negative draft The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c.

  • Page 17: Vertical Vent Termination Clearances And Location

    Venting (continued) 4. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. 5.
  • Page 18 Venting Figure 2-1_Vent Termination from Peaked Roof - 10 ft. or Less From Ridge Vent terminations are not shown in FIG.’s 2-1 thru 2-4. Make sure all vertical vents are installed with vent NOTICE terminations recommended by the vent manufacturer. Figure 2-3_Vent Termination from Flat Roof - 10 ft.

  • Page 19: Vertical Directaire Venting

    Venting (continued) Vertical DirectAire ™ venting - Before installing a venting system, follow requirements found in the General Venting section. NOTICE The Vertical DirectAire™ vent system is the same as the Conventional Negative Draft vent system, except it pulls combustion air from the outdoors through a separate air inlet pipe. Follow all requirements in the Conventional Negative Draft Venting section on page 16.

  • Page 20: Vertical Rooftop Air Inlet

    Venting To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable clearance requirements in the latest edition of the National Fuel Gas Code and/or CAN/CGA-B149 Installation Code and instructions in the Installation and Operation Manual.
  • Page 21 Venting (continued) 12" Figure 2-8_Vertical DirectAire™ Installation w/Rooftop Combustion Air Inlet MODEL 1262 1442 1802 2072 *The SVK kits include a DV box adapter and sidewall air inlet cap. The VDK kits include a DV box adapter and a rooftop air inlet cap. Installation &...

  • Page 22: Sidewall Venting

    Venting Sidewall venting - see page 14. Before installing a venting system, follow all requirements found in the General Venting NOTICE section. This option uses a powered vent assembly which pulls the flue products out of the stack. This fan generates a negative draft at the unit.
  • Page 23 Venting (continued) Terminate the venting system at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m). Terminate the venting system at least 4 feet (1.2m) below, 4 feet (1.2m) beside, or 1 foot (30cm) above any door, window, or gravity air inlet into any building.

  • Page 24: Sidewall Venting

    Venting Do not combine the flue from this unit with the vent from any other appliance. Do not combine flues from WARNING multiple appliances into a common vent. The flue from this unit must be a dedicated stack. Connect the flue vent directly to the flue outlet opening on the top of the unit. Make the connections from the unit vent to the outside stack as direct as possible with no reduction in diameter.

  • Page 25: Horizontal Directaire Venting

    Venting (continued) Horizontal DirectAire™ venting (Powered Venting) Before installing a venting system, follow all requirements found in the General Venting section. NOTICE The Horizontal DirectAire™ vent system is the same as the Sidewall Venting system, except it pulls combustion air from the outdoors through a sidewall air inlet. Follow all requirements in Sidewall Venting section on page 22. The Horizontal DirectAire™...

  • Page 26: Direct Venting

    Venting Direct venting - see page 14. Before installing a venting system, follow all requirements found in the General Venting section. NOTICE This option uses sealed AL29-4C vent materials for the flue outlet piping and separate combustion air inlet piping. This system terminates both the flue and combustion air inlet in the same pressure zone.
  • Page 27 Venting (continued) Masonry chimney installation Do not use a standard masonry chimney to directly vent the combustion products from this unit. To use a masonry chimney, the chimney must use a sealed, corrosion-resistant liner system. Sealed, corrosion-resistant liner systems (single-wall, double-wall, flexible, or rigid) must be rated for use with a high efficiency, positive pressure vent system. Corrosion-resistant chimney liner systems are typically made from a high grade stainless steel such as AL29-4C.
  • Page 28 Venting Length of air inlet pipe The installed length of air inlet pipe from the unit to the outside air inlet cap 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 equivalent length for each 45° elbow. Do not exceed the limits for the combustion air inlet piping lengths.
  • Page 29 Venting (continued) 2. For PVC, CPVC, ABS, dryer vent, or flex duct air inlet piping, use a silicone sealant to ensure a proper seal at the unit inlet and the air inlet cap. 3. For Dryer vent or flex duct, also use a screw-type clamp to attach the inlet vent material to the unit inlet and the air inlet cap. Properly sealing the air inlet pipe ensures that combustion air will be free of contaminates and supplied in proper volume.

  • Page 30: Outdoor Installation

    Venting Outdoor installation Before installing a venting system, follow all requirements found in the General Venting section. NOTICE Units are self-venting and can be used outdoors when installed with the optional outdoor cap. This cap mounts directly to the top of the unit and covers the flue outlet and combustion air inlet openings.

  • Page 31: Gas Connections Connecting To Gas Supply

    Gas connections Connecting to gas supply Verify that the appliance is supplied with the type of gas specified on the rating plate. This appliance is configured for operation up to 4,500 feet altitude. Consult factory for installations above 4,500 feet elevation. Inlet gas pressure: Measured at the inlet pressure tap on the appliance gas manifold.

  • Page 32: Combination Gas Valves

    Straight Pipe (feet) Water heater models do not have downstream test valves, but the rest of the gas train is represented by FIG. 3-2. Combination gas valves These units fire in multiple stages of burner input. Each stage of burner operation has a combination gas valve(s) to cycle the gas supply on and off and regulate gas to the burners.

  • Page 33: Checking Gas Supply Pressure

    Gas connections Combination gas valve/regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors. The termination of the vent limited opening on the combination gas valve/regulator complies with the safety code requirements of CSD-1, CF-190(a) as shipped from the appliance manufacturer without the installation of additional vent lines.

  • Page 34: Water Connections

    Water connections Inlet and outlet connections For ease of service, install unions on the water inlet and water outlet of the unit. The connection to the unit marked “Inlet” on the 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.

  • Page 35: Relief Valve

    Water connections Relief valve This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. No valve is to be placed between the relief valve and the unit.

  • Page 36: 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 water temperature. See Table 4A for available valve kits.

  • Page 37: Three Way Valves In System

    Water connections When a mixing valve is used, an optional system return sensor should be installed into the system return piping. This will allow the display of the actual system return temperature, and will also allow control of the system return temperature when the SMART SYSTEM control is programmed for inlet temperature control.

  • Page 38: Typical Heating Boiler Installations

    Water connections Temperature Rise and Head Loss Based on Boiler Output in Btu/hr 30°F T Btu/hr Input Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd 399,999 339,999 500,000 425,000 650,000 552,500 750,000 637,500 990,000 841,500 1,260,000 1,071,000...

  • Page 39: Primary/Secondary Piping Of A Single Boiler

    Water connections Figure 4-3_Primary/Secondary Piping of a Single Boiler w/DHW COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) HOT WATER GENERATOR Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.

  • Page 40: Primary/Secondary Piping Of Multiple Boilers

    Water connections Figure 4-4_Primary/Secondary Piping of Multiple Boilers COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) 3 1/2 PRESSURE RELIEF VALVE MAKE-UP WATER SEPARATOR 12" OR 4X PIPE DIAMETERS FROM SYSTEM SECONDARY BOILER PUMP Please note that these illustrations are meant to show system piping concept only, the installer is responsible for NOTICE...

  • Page 41: Boiler W/Low Temperature Bypass Piping

    Water connections Figure 4-5_Boiler with Low Temperature Bypass Piping - Using a Low Temperature Valve Required for Systems Operating at less than 140°F (60°C) Return Water Temperatures from the Heating Return Loop COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.)

  • Page 42: Primary/Secondary Piping With Buffer Tank

    Water connections Figure 4-6_Primary/Secondary Piping with Buffer Tank COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) 3 1/2 1" TEMPERATURE AND PRESSURE GAUGE AUTOMATIC AIR ELIMINATOR/VENT SYSTEM OUTLET SYSTEM SENSOR LOCATION SYSTEM INLET BUFFER TANK The Inlet/Outlet System tappings are shown in the optional location on the side of the tank for pictorial purposes.

  • Page 43: Electrical Connections

    230°F (110°C). The maximum temperature set point for a water heater is 190°F (88°C). The auto reset high limit is fixed at 200°F (93°C), and the adjustable manual reset high limit has a maximum setting of 230°F (110°C).

  • Page 44: Line Voltage Connections

    If a tank sensor is used, it must be connected to the tank sensor terminals on the low voltage connection board. The correct Lochinvar sensor (TST20015) MUST BE USED. Installation & Operation Manual Connection of a set of dry switching...

  • Page 45: Runtime Contacts

    1. An external control may be connected to control either the firing rate or the set point of the appliance (boiler or water heater). Connect the 0 - 10 VDC terminals to the 0 - 10 VDC output of the external control. The SMART...

  • Page 46: Wiring Of The Cascade

    Electrical connections Wiring of the cascade When wiring the heaters for Cascade operation, select one heater as the Leader. The remaining heaters will be designated as Members. See page 50 Configuration of the Cascade for a detailed explanation of this procedure. On boilers, connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler.

  • Page 47: Startup

    Start-up Check/control water chemistry Do not use petroleum-based cleaning or CAUTION sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard water areas (above 7 grains hardness).

  • Page 48: Check Thermostat Circuit(S)

    Start-up Check thermostat circuit(s) 1. Disconnect the two external wires connected to the enable terminals on the connection board. 2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

  • Page 49: Operating Instructions

    Start-up (continued) Figure 6-1_Lighting Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition device which automatically lights the burner.

  • Page 50: Set Dhw Operation

    Start-up Set DHW operation Verify DHW circulator mode (boiler only) The DHW Mode is programmed to heat an indirect domestic hot water tank. When the tank thermostat or tank sensor calls for heat, the SMART SYSTEM control will turn on the DHW pump and turn off the boiler pump (if running).

  • Page 51: Operating Information General

    Boiler operation can be based on boiler outlet water temperature, boiler inlet water temperature, system supply temperature, or system return temperature, depending on the parameter setting. Water heater operation can be based on a tank sensor or a tank thermostat. Control inputs and outputs Staging S1 - S4 The S1 input tells the boiler to provide water for space heating.

  • Page 52: Temperature Control

    Operating information Temperature control Firing rate Depending upon the model, the Copper-fin II is capable of staging its firing rate from a minimum of 25% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, ramp delay (if enabled), and various other temperature limitations.

  • Page 53: Cascade

    Operating information Low water cutoff protection The SMART SYSTEM control module uses temperature sensing of both inlet and outlet areas of the heat exchanger. If the flow rate is too low or the outlet temperature too high, the control module modulates and shuts the appliance down.
  • Page 54 Operating information The appliance will fire at its ignition speed and will then stage its firing rate to maintain the set point. If the first appliance reaches 100% of its firing rate, the Leader will calculate at what point the second appliance could fire at its minimum firing rate.

  • Page 55: Sequence Of Operation

    (if equipped) must close. • If the contact for the louvers is closed, the louver proving, and auto reset high limit (water heater only) inputs must close. • If the air pressure switch is open, the prepurge cycle then begins by starting the combustion blower.

  • Page 56: Copper-Fin Ii Control Module

    Operating information Copper-fin II control module Use the control panel (FIG. 7-1) to set temperatures, operating conditions, and monitor appliance operation. Figure 7-1_Control Panel - Operator Interface • Hold 5 seconds to enter code Input Mode (Menu Mode) • Press to move up one level in Menu Mode or to exit Menu Mode MENU/EXIT...

  • Page 57: Access Modes

    Operating information Access modes User The user can adjust the space heating target temperature and the tank target temperature (if a tank sensor is used) by using the UP and DOWN buttons (FIG. 7-1) at any time during normal operation. By entering the USER code (0704), the user can also change temperature units, time and date, and night setback settings.

  • Page 58: Status Display Screens

    Operating information Status display screens By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen # Display Shows...
  • Page 59 Operating information By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen # Display shows:...
  • Page 60 Operating information By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
  • Page 61 Operating information Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...

  • Page 62: Domestic Water Heaters

    TABLE - 8A MAXIMUM WATER FLOW CAUTION: The maximum flow rate through a Copper-fin II water heater with a copper heat exchanger must be set to provide and not exceed the following flow: Model 402, 502, 652, and 752...

  • Page 63: Water Chemistry

    If the temperature rise is too high, the water velocity is too low, adjust as follows: 1. Check for restrictions in the outlet of the water heater. 2. Be sure all valves are open between the water heater and the storage tank. Ensure that all ball valves are fully ported.

  • Page 64: Typical Water Heater Piping W/Storage Tank(S)

    Domestic water heaters Figure 8-1_Typical Water Heater Piping with Storage Tank COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK-TEMP DRAIN STORAGE TANK Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 65 Domestic water heaters Figure 8-2_Single Water Heater Piping with Two Storage Tanks COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) MIXING VALVE BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK-TEMP STORAGE TANK DRAIN Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.

  • Page 66: Multiple Water Heater Piping W/Storage Tank(S)

    Domestic water heaters Figure 8-3_Multiple Water Heater Piping with a Single Storage Tank COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) 3 1/2 BUILDING WATER SUPPLY RELIEF VALVE LOCK-TEMP STORAGE TANK DRAIN Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 67 Domestic water heaters Figure 8-4_Multiple Water Heater Piping with Multiple Storage Tanks COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Diameter Number of Units (in.) 3 1/2 BUILDING WATER SUPPLY RELIEF VALVE LOCK-TEMP STORAGE TANK DRAIN Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.

  • Page 68: Pump Operation

    6" 6" Pump operation 1. The water heater must have a properly sized circulating pump. This pump is sized to circulate water between the heater and the storage tank only. 2. The pump is sized to the heater input and water chemistry specifications noted in the Water Chemistry section on page 63.

  • Page 69: Minimum Water Temperatures (Domestic Hot Water)

    Minimum water temperatures (domestic hot water use) Domestic water temperatures: This high efficiency water heater should be operated at a temperature setting high enough to prevent condensing of the products of combustion on the unit’s heat exchanger or in the attached venting system. Use extreme caution when storing water at elevated temperatures.

  • Page 70: Optional Relief Valve

    210°F (99°C). This water heater also includes a fixed high water temperature limit control set to 200° (93.3°C). The RESET key on the display must be pushed whenever water temperature has exceeded the set point of the limit.

  • Page 71: Maintenance

    Maintenance Maintenance and annual startup Table 9A_Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check for leaks (water, gas, flue, condensate) • Examine venting system •...

  • Page 72: Flue Vent System And Air Piping

    Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the appliance. Failure to perform the service and maintenance could result in damage to the appliance or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

  • Page 73: Check Control Settings

    Maintenance (continued) Check relief valve 1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 4 - Water Connections of the Copper-fin II Installation and Operation Manual before proceeding further.

  • Page 74: Check Burner Flame

    Maintenance Perform start-up and checks 1. Start appliance and perform checks and tests specified in Section 7 - Start-up of the Copper-fin II Installation and Operation Manual. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. Check burner flame Visually check main burner flames at each start-up after long shutdown periods or at least every six months.

  • Page 75: Maintenance

    Maintenance (continued) Inspect and clean the heat exchanger While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows. Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning, page 74.

  • Page 76: Connection Diagram

    Connection diagram FIELD WIRING ALARM TO MONITORING DEVICE CONTACTS RUNTIME TO MONITORING DEVICE CONTACTS OPEN OPEN 3-WAY CLOSE CLOSE VALVE COMMON STAGE #1 CONNECT STAGE #2 TERMINAL STAGE #3 (LOUVER STAGE #4 RELAY) FIELD LOUVER PROVING SWITCH SUPPLIED PROVE WIRING LINE LOUVER RELAY COIL...
  • Page 77 Connection diagram W VOLT HARNESS GITAL HARNESS R/BK R/BK W/BK CONTROLLER O/BK IDENTIFICATION PLUG MODEL SPECIFIC CONSULT FACTORY NOTE: NUMBER OF GAS VALVES VARIES BY MODEL SPLAY R Y R R Y R LOW GAS STAGE #1 STAGE #1 SWITCH BURNER GROUND R/BK...

  • Page 78: Ladder Diagram

    Installation & Operation Manual Ladder diagram WHERE POSSIBLE, SWITCHES ARE SHOWN WITHOUT UTILITIES (GAS, WATER OR ELECTRICITY) CONNECTED TO THE UNIT. AS SUCH, ACTUAL SWITCH STATES MAY VARY FROM THOSE SHOWN ON DIAGRAMS DEPENDING UPON WHETHER UTILITIES ARE CONNECTED OR A FAULT CONDITION IS PRESENT.

  • Page 79: Ladder Diagram

    Installation & Operation Manual Ladder diagram (continued) LBL20083 REV B...

  • Page 80: Revision Notes

    Revision Notes: Revision A (ECO #C08226) initial release. CFX-CHX-I-O Rev A 6/11...

This manual is also suitable for:

Copper-fin ii 402-2072Copper-fin ii cfn0402Copper-fin ii cfn0752Copper-fin ii cfn0992Copper-fin ii cfn0652Copper-fin ii cfn1262 ... Show all

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