Watts AERCO CFR 3000 Installation And Start-Up Manual
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Watts AERCO CFR 3000 Installation And Start-Up Manual

Cfr boilers with edge@ controller
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  • Page 1 OMM-0163_A •...

  • Page 2: Table Of Contents

    CONTENTS TABLE OF CONTENTS SECTION 1: SAFETY PRECAUTIONS ................... 4 1.1 WARNINGS & CAUTIONS ....................4 1.2 EMERGENCY SHUTDOWN ....................5 1.3 PROLONGED SHUTDOWN ....................5 1.4 IMPORTANT REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS ..... 5 SECTION 2: INSTALLATION ....................6 2.1 RECEIVING THE UNIT ......................6 2.2 UNPACKING ........................
  • Page 3 FORWARD FOREWORD AERCO CFR boilers advance venting safety in the Category I boiler industry by always delivering dry flue gas. Designed for use in any closed-loop hydronic system, the CFR promotes application flexibility. Retrofit installations are reduced by accommodating a wide range of piping configurations, including primary- variable systems.

  • Page 4: Safety Precautions

    SECTION 1: SAFETY PRECAUTIONS SAFETY PRECAUTIONS SECTION 1: 1.1 Warnings & Cautions Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.

  • Page 5: Emergency Shutdown

    SECTION 1: SAFETY PRECAUTIONS 1.2 Emergency Shutdown If overheating occurs, or the gas supply fails to shut off, close the external gas shutoff valve (Figure 1-1). NOTE: Installer must identify the emergency shutdown manual gas valve to operating personnel. Valve Valve Open Closed Figure 1-1: Manual Gas Shutoff Valve...

  • Page 6: Installation

    SECTION 2: INSTALLATION SECTION 2: INSTALLATION 2.1 Receiving The Unit Each CFR system is shipped as a single crated unit. The shipping weight is approximately 1600 lbs. The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage. The unit should be inspected for evidence of damage and for shipment completeness at the time of receipt from the carrier and before the bill of lading is signed.

  • Page 7: Installation Clearances

    SECTION 2: INSTALLATION 2.3.1 Installation Clearances The unit must be installed with the minimum prescribed clearances for service listed below. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements. The minimum acceptable clearances required for the CFR 3000 are as follows: Front: 24 inches (61 cm) Sides: 24 inches (61 cm) Rear: 24 inches (61 cm)

  • Page 8: Anchoring The Unit

    SECTION 2: INSTALLATION 2.3.2 Anchoring the Unit If anchoring the unit, see below for anchor locations. • All holes are flush with the bottom surface of the frame. • All dimensions shown are in inches [millimeters] Figure 2-2: CFR 3000 Anchor Bolt Locations 2.3.3 Housekeeping Pad Requirements To ensure proper drainage the unit must be installed on a level concrete “housekeeping”...

  • Page 9: Lifting Provisions

    SECTION 2: INSTALLATION 2.4 Lifting Provisions ⚠ To avoid damaging the unit do NOT lift or move the boiler using the gas train or blower. Three lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-4. Remove the front top panel from the unit to provide access to the lifting lugs.

  • Page 10: Pressure Relief Valve Installation

    SECTION 2: INSTALLATION 2.6 Pressure Relief Valve Installation An ASME rated Pressure Relief Valve is supplied with each CFR Boiler. The pressure rating for the relief valve must be specified in the sales order. Available pressure ratings range from 30 to 160 psi (207 to 1103 kPa).

  • Page 11: Condensate Drain Installation Instructions

    SECTION 2: INSTALLATION 2.7.1 Condensate Drain Installation Instructions 1. Connect the condensate trap inlet to the exhaust manifold drain connection using the appropriate piping components (nipples, reducers, elbows, etc.). 2. Pipe the condensate outlet to a nearby floor drain using 3/4" NPT stainless steel or aluminum pipe. ⚠...

  • Page 12: Gas Supply Piping

    SECTION 2: INSTALLATION 2.8 Gas Supply Piping Consult TAG-0106, CFR Gas Supply Design Guide before designing or installing any gas supply piping. ⚠ Do NOT under any circumstances use matches, candles, flames, or other sources of ignition to check for gas leaks.

  • Page 13: Massachusetts Installations

    SECTION 2: INSTALLATION 2.8.3 Massachusetts Installations For Massachusetts installations, a mandatory external gas supply regulator must be positioned as shown above. The gas supply regulator must be properly vented to the outdoors. Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator. 2.8.4 Manual Gas Shutoff Valve A manual shut-off valve must be installed in the gas line upstream of the boiler as shown above.

  • Page 14: Electrical Power Panel Internal Components

    SECTION 2: INSTALLATION 2.9.3 Electrical Power Panel Internal Components Remove the front panel to access the Power Panel. Run the electrical service through the opening above the Power Panel and make the connections to the Power Breaker in accordance with the Power Panel cover label (see Figure 2-9, above).

  • Page 15: I/O Board Connections

    SECTION 2: INSTALLATION ⚠ DO NOT make connections to terminals labeled “NOT USED”. Attempting to do so may damage equipment. I/O BOARD POWER SPARK MONITOR HARNESS 63232 FROM SHELL CONNECTOR J24 HARNESS 63394-2 CONNECTOR J9 VALVE HARNESS INTERLOCK FROM SHELL HARNESS 63394-2 40 PIN RIBBON I/O J6 PINS 3 &...
  • Page 16 SECTION 2: INSTALLATION Connector Strip J3 Terminals Pin # Name Description Shield Connection to the shield from any cable. (NOT USED) (NOT USED) BLR V.S. Pump + Connection for a 0 – 10 V signal to drive a Boiler Variable Speed Pump if desired Main Menu →...
  • Page 17 SECTION 2: INSTALLATION Connector Strip J6 Terminals Pin # Name Description Remote Interlock Out Connection to an auxiliary device interlock - requires delay before firing. Remote Interlock Return Delayed Interlock 1 Out Connection to an auxiliary device interlock - requires delay before firing. Delayed Interlock 1 Return (NOT USED) (NOT USED)

  • Page 18: Flue Gas Vent Installation

    SECTION 2: INSTALLATION 2.11 Flue Gas Vent Installation The CFR gas-fired boiler is a fan-assisted, hydronic-heating unit with the following venting capabilities: 1. Room Combustion Air, Vertical Discharge 2. Ducted Combustion Air, Vertical Discharge It is critical that the flue gas vent be designed to prevent condensation in the flue gas vent for safe operation.

  • Page 19: Barometric Damper

    SECTION 2: INSTALLATION Barometric Damper Vent Increaser Vent Stater Section Figure 2-13: Vent Starter Section, Vent Figure 2-14: Installation Caution Label Increaser, Barometric Damper The supplied stack guard sensor must be field installed on the vent starter section. The sensor comes with a molex connector that must be connected to the mating wiring harness from the rear of the boiler.

  • Page 20: Combustion Air

    SECTION 2: INSTALLATION 2.12 Combustion Air Air supply is a direct requirement of ANSI 223.1, NFPA-54, and local codes. These codes should be consulted before a permanent design is determined. The combustion air must be free of chlorine, halogenated hydrocarbons, and other chemicals that can become hazardous when used in gas-fired equipment.

  • Page 21: Bst Sequencing Isolation Valve Installation

    SECTION 2: INSTALLATION 2.14 BST Sequencing Isolation Valve Installation All CFR units are pre-wired with a connection for an optional motorized external sequencing isolation valve (P/N 92084-TAB). This valve is an integral component of AERCO’s on-board Boiler Sequencing Technology (BST) solution. BST allows sites with multiple boilers to have one boiler, designated the “Manager,” manage the other boilers at the site, designated as “Clients”...

  • Page 22: Next Steps

    SECTION 2: INSTALLATION 2. Find the grey cable inside the unit’s enclosure with the unused Molex connector with a cap containing a jumper wire inserted in it (the jumper wire allows units that do not have a sequencing isolation valve to operate normally). The other end is connected to the I/O board and to a power supply.

  • Page 23: Appendix A: Dimensional And Clearance Drawings

    APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS CFR 3000 Dimension Drawing AP-A-1093 rev A • • •...
  • Page 24 APPENDIX A – DIMENSIONAL AND CLEARANCE DRAWINGS CFR 3000 Zero-Side Clearance Drawing SD-A-1283 rev A • • •...
  • Page 25 © AERCO International, Inc., 2023 • • •...

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