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Lochinvar COPPER-FINN2 2072 User's Manual

1. Models 502 752 Front View Models 502 752 Rear View Models 502 752 Right Side inside unit Models 502 752 Left Side inside unit Em Installation amp Operation Manual Se z o 7 is 827 in h LI Models 992 2072 Front View Models 992 2072 Rear View Models 992 2072 Right Side inside unit Models 992 2072 Left Side inside unit 7 um Cem Installation amp Operation Manual Ratings CERTIFIED Specifications Model Number Air Vent Note Change N to Appliance Water Water Connections Gas Connections Sizes L for L P gas models Content Gallons NOTICE Maximum allowed working pressure is located on the rating plate Notes 1 Copper fin pool heaters require special gas venting Use only the vent materials and methods specified in the Copper Fin Pool Heater Installation and Operation Manual 2 The Copper fin is orificed for operation up to 2000 feet altitude a
2. 10 12 Service Indicator 40 2 VENTING 5 ELECTRICAL CONNECTIONS Before You 13 General Information cccccccceessseeesesseeeeeeeeeeseeeaeeeeeees 41 Vent System Options 14 3 Way Automatic Bypass Valve Wiring 41 General Venting Information 15 Pool Heater Operating Control Module 42 44 Conventional Negative Draft Venting 16 18 Wiring of the 44 Vertical DirectAire Venting 19 21 6 STARTUP Sidewall VJ 22 24 Pre Start Checklist esses 45 Horizontal DirectAire Venting 25 Starting the Filter System esses 45 Direct ali o RE E 26 29 Check for Gas Leaks 45 Outdoor Installation 30 Check Control Water 45 3 GAS CONNECTIONS Freeze 45 46 Connecting to Gas Supply 31 Check Thermostat Circuit S 46 Gas Pressure pinta oi se traen e 31 Placing the Pool Heater in Operation
3. 46 48 Checking Manifold Gas Pressure 31 7 OPERATING INFORMATION GaS 0 RR NT 91 E e Mr 49 Gas Connection 31 32 How the Control Module 49 51 Combination Gas 32 Sequence of Operation 52 Checking Gas Supply 5 33 Copper fin2 Control 53 54 Status Display 55 56 8 57 61 9 CONNECTION 62 63 10 LADDER 64 65 Revision Notes CEN Back Cover Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER eg indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING A indicates a potentially hazardous situation which if not avoided could result in death or serious
4. amp 0 YINYOISNVYL 0 OS TDO 20342 mI ad S lt oo 5 SISSVHO 702 24503 2 20 O LIZOZO L DIOL cx L ZX dl nd N X 200 lt 0 2 ISH SOVLS OFInS LLI OL LX 1X UZEO ZL XOY Z lt 437 08 ISH 15 gt gt OO 2205 L TOFUW MHA OOSIU 58555 o 58 0 45 gt C iS o IN ry OS dNNd nr 120 41415 41415 25 Qu TWNINNSL Narsis TYNINHEL qup a Q 0 o e o 522 LINN Uo ae OVA OZ C LA 93398 W 5 1 MOT 3 AV 134 H3M018 I SAA D E 31 VHOHALNI 03395 mne q33ads OTIH N HOLIMS LINN 440 NO 4 23345 W134 NE 5 _ H3MO18 41915 T TWNIWYAL J NOTE Not all connections features apply to pool heaters 64 Eh c 0 2 2 og E 0 v 10 Ladder diagram continued auvog SAOVAYALNI SNAdaVON 8 gt t gt NLH 3 SNEON 02 8 V L HX OL 8X L LNO 9 vX 8 9 8L 8X GA I3IHS davosvo YS YOSNAS 9 9 21 8 L
5. Rev B Installation amp Operation Manual Models 502 2072 WARNING Ifthe 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 f 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 This manual supplies information for the installation operation and servicing of the CERTIFIED appliance It is strongly recommended that this manual and the Copper fin Pool Heater 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 High Efficiency Water Heaters Boilers and Pool Heaters Contents HAZARD 2 4 WATER CONNECTIONS PLEASE READ BEFORE PRO
6. NOILOANNOO L L 8X 6S HOSNHS 19 ANZ 8 8X LS HOSNZS 19 cS YOSNAS 141 2 amp 15 HOSN3S 9 LNO L 8X 100d WALSAS 2 S LNO 8 95 YOSNAS 100d WALSAS 100d 8S HOSN3S 6L 8X Alddns 100d ANZ LL 8x GS HOSN3S agog 1 c NOILOANNOO SLOVLNOO INILNNEY 9 VNO c EX S VNO L X 22 2 11 4 L 9X S GNO L NOILOANNOO O Nav E AW 138 Wav IV SIOVINOO L NOILOANNOO G 8X 9 HP SNO LL 9X CVL SNO SL 9X OL GNO 9 9X SNO L ELX 6 SNO c 9x 8 9L 9X 6 1 9 L GNO 9X HOLIMS MO 14 v er Y3LNANOD AV 1dSIG oL ex S AN d33ds WALSAS 9 8 Z LNO c QHVOS NOILOJINNOO A LL 8X 9NO davosvo 9 1 8 1 9 LAdLNO v 2X OL 9NO ALVY gt lt AOL O 8 2 S 9NO gt lt 10 GL 8X 6 9NO gt lt AOL O YSANOT C pg 17181 MNV L C AOVLS C 15 C e 2 ADVLS 1 15 9 GNO V
7. Combustion air openings are not obstructed in any way N A PB Q N Ensure all air is purged from the water piping Starting the filter system Verify proper installation of the pool heater temperature controls and the installation of the 110 F auxiliary limit and pool supply sensor in the mixed discharge water from the filter piping to the pool Clean the filter Start the filter pump Be sure all air is out of all the lines including the pressure connection Ensure that the pool heater is not air bound by manually opening the temperature and pressure relief valve Leave the valve open until a steady flow of water is observed at the discharge from the valve Close the valve and complete filling the system Note Backwash the filter when the G P M filtration rates are too low to meet local codes or state code A high temperature rise across the pool heater is also an indication of low flow in the filter system Sustained low flow to the pool heater will result in cycling of the heater on the limit controls and possible opening of the relief valve Check for gas leaks Before starting the unit and during initial operation smell near the floor and around the unit for gas odorant or any unusual odor Remove the front access panel and smell the interior of the pool heater enclosure Do not proceed with startup if there is any indication ofa gasleak Use an approved leak detection solution Repair any leaks at once
8. 59 8 Maintenance Perform start up and checks Start appliance and perform checks and tests specified in Section 6 Start up of the Copper fim Installation and Operation Manual Check burner flame Visually check main burner flames at each start up after long shutdown periods or at least every six months burner viewport is located on the burner mounting flange A WARNING Lhe area around the burner viewport is hot and direct contact could result in burns Figure 8 1 Flame Pattern Illustration __________ YELLOW PEN MNA NORMAL YELLOW FLAME FLAME LIFT Normal Flame normal flame at 100 of burner input is blue with slight yellow tips a well defined flame and no flame lifting Yellow Tip Yellow tipping can be caused by blockage or partial obstruction of air flow to the burner Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner or excessive gas input This condition MUST be corrected immediately Lifting Flames Lifting flames can be caused by over firing the burner excessive primary air or high draft If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 60 COPPER EIN Installation amp Operation Manual Check flue gas passageways Any sign of soot around the inner jacke
9. Gas pressure test 1 The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5 kPa 2 The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa 3 The appliance and its gas connection must be leak tested before placing it in operation Checking manifold gas pressure Reference the Copper fin Pool Heater Service Manual for information regarding manifold gas pressure Gas piping To safely operate this pool heater you must properly size the gas supply piping See Tables 3B through 3D for piping and fiting requirements Gas pipe size may be larger than pool heater connection On Models 502 752 the gas connection to the pool heaters are I 1 4 NPT and on Models 992 2072 the gas connections to the pool heaters are 2 NPT For ease of service install a union Cor Installation amp Operation Manual Install manual main gas shutoff valve outside of the unit gas connection within six feet of the unit in accordance with the requirements of the National Fuel Gas Code ANSI Z223 1 You must provide sediment trap drip leg in the inlet of the gas connection to the unit NOTICE CAUTION It is the installer s responsibility to supply the sediment trap
10. NOILOANNOO HOLIMS SS34d L 9X SVO H9IH SSdHd SVO arri JYNSSIXYd HIV as d l AAOLND ar Y3LvM MOT 1541 g er 2 9 LBL20083 REV Notes 66 Notes 67 Revision Notes Revision A ECO C08226 initial release High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 as result of questions requests from the field 615 889 8900 Fax 615 547 1000 CPX I O Rev www Lochinvar com 7 11
11. indicate need performance Clean heat exchanger with a stiff bristle brush Remove and clean burners using water Dry before re assembling Clean the blower wheel with a brush and vacuum Do not let dirt from cleaning get pulled into the blower Owner maintenance Check appliance area Check pressure temperature gauge Check vent piping Check air piping Monthly Check relief valve e Replace combustion air filter Note More frequent replacement may be necessary in dirty environments Test low water cutoff if used Periodically Reset button low water cutoff Check appliance piping gas and water for leaks Every 6 months Operate relief valve e Shut appliance down End of season months 57 EAN Installation amp Operation Manual 8 Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING shipped with the appliance Failure to perform the service and maintenance could result in damage to 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 A WARNING The appliance should be inspected annually only by qualified service technician In addition the maintenance and care of the appliance designated in Table 8A and explained on the following pages must
12. A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage CAUTION NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage NOTICE Installation amp Operation Manual Please read before proceeding Special instructions This is gas appliance and should be installed NOTICE by licensed electrician and or certified gas supplier Service must be performed by qualified service installer service agency or the gas supplier A WARNING If the information in these instructions 18 not followed exactly fire or explosion may result causing property damage personal injury or death This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or additional information consult qualified installer service agency or the gas supplier A WARNING Checking equipment Upon receiving equipment check for signs of
13. EXCHANGER Figure 8 2_Location of the Heat Exchanger Inside Jacket Review with owner 1 Review the Copper fin2 Installation and Operation Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in this manual 3 Remind the owner of the need to call a licensed contractor should the appliance or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Oiled bearing circulators Inspect the pump every six 6 months and oil as necessary Use SAE 30 non detergent oil or lubricant specified by the pump manufacturer CIA Installation amp Operation Manual O Connection diagram COPT ALARM HARNESS ALARM CONTACTS RUNTIME CONTACTS z DIGITAL HARNESS 1 EE m loool mM M STAGING am gt gt gt gt LOUVER PROVING SWITCH TANK AQUASTAT er 22 ae SENSOR TN 24 SHIELD luus 2549 EE e 9 0 10V DC IN BMS L 0 10V DC OU BMS L COMMON 0 10V RATE OUT FERGE 4 Y 52 SHIELD 1m Bus I DEE B
14. also use 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 Q 4 Ensure that the air inlet pipes are properly supported Properly seal all joints and seams in the inlet vent piping system Failure to do so may result in flue gas A WARNING em recirculation spillage of flue products and carbon monoxide emissions Carbon monoxide poisoning can cause severe personal injury or death Vertical and sidewall combustion air inlet NOTICE To prevent recirculation of flue products into the combustion air inlet follow all instructions in this section Locate and install the combustion air inlet termination correctly Failure to do so can allow the discharge of flue products to be drawn into the combustion process This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning You must locate the combustion air cap and the flue gas outlet on the same rooftop surface vertical direct vent system or sidewall surface horizontal direct vent system and in the same pressure zone as the vent termination Follow all clearance requirements listed on this page Purchase
15. will adjust the position of the 3 way valve to maintain the inlet water temperature above the minimum allowable inlet temperature Electronic display The electronic display consists of 6 buttons and a two line 16 character liquid crystal display used to monitor the operation of the heater as well as enter and view the programming of the main control board Burner The burner is a ported stainless steel construction which uses a gas air mix to operate at a fixed input Banks of burners turn on or off to vary the firing rate Pool supply limit sensor not shown This 4 wire limit rated sensor monitors the temperature of the water being supplied to the pool to ensure safe operation The appliance will shut down if the maximum allowable pool supply temperature is exceeded Pool return sensor not shown This 2 wire sensor is the controlling sensor and it monitors the temperature of the pool water The appliance will stage to maintain pool temperature set point and turn off when set point 15 met Gas supply pipe The gas supply pipe on this appliance is 1 1 4 or 2 depending on model diameter NPT Please reference the National Fuel Gas Code charts for connection details SMART SYSTEM Control Module The SMART System Control Module is the main control for the appliance This module contains the programming that operates the blower gas valve and pumps in addition to other programmable features Air intake Fresh air for combustio
16. BUS SHIELD POOL SAFETY Comme f SUPPLY DOOR EL 66 AR Pa 10K R GAL SYS SUPPLY 10K 20K 4 SENSOR POOL BOILER 10K FROM 0 PUMP J OUTPUT I ege SAFETY 10K 20K 220708 OUTLET W S OUTLET ops BOG INLET 10K Fr SENSOR 24V COM MAIN POWER HARNESS 8 NE mes 24V OPT MODBUS HARNESS CONTROLLER GROUND Or I poe XEM IND DHW PUMP RELAY 5 120V SYSTEM PUMP RELAY con 1422229522222 120V 60Hz NEUTRAL GO SUPPLY LINE EE CHASSIS ON OFF PUMP RELAY GROUND SWITCH 120VAC COIL GROUND MAIN UNIT NOTE Not all connections features apply to pool heaters 62 EE Installation 4 Operation Manual 9 Connection diagram continued Notes L HARNESS 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 1054 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to trouble shoot unit ALARM 5 LOW VOLTAGE 5 T TEST HARNESS CHASSIS GROUND NO AIR PROV
17. 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 Vent installations for connection to gas vents or chimneys must be in accordance with Venting of Equipment of the above mentioned standards NOTICE Examine the venting system at least once each year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration If you find any problems correct them at once Venting support Support horizontal portions of the venting system to prevent sagging Provide an upward slope of at least 1 4 inch per foot 21mm m on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting installations Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney The weight of the venting system must not rest on the unit Provide adequate support of the venting system Follow all local and applicable codes Secure and seal all vent connections Follow the installation instructions from the vent material manufacturer Barometric damper location Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the unit s flue outlet The barometric damper M
18. DV venting termination Horizontal venting uses the unit s internal combustion air blower to force the flue products out of the horizontally terminated flue You must purchase a horizontal direct vent kit from the appliance manufacturer to ensure proper operation When installing the vent cap the wall opening must provide an air space clearance of 2 inches 5 1 cm around the flue pipe The diameter of the opening for installation of the sidewall cap will be 4 inches 10 2 cm larger minimum than the nominal diameter of the installed vent pipe to the horizontal vent cap Install the horizontal vent cap from the outside Mount the vent cap to the wall using four screws or wall anchors Seal under the screw heads with caulking Install the Category IV vent pipe from the unit to the vent cap See detailed instructions packed with the horizontal direct vent kit Horizontal Vent Termination Clearances and Location Follow all sidewall venting termination information for clearances and location under Sidewall Vent Termination Clearances and Location page 22 TABLE 2E DIRECT VENT KITS HORIZONTAL VERTICAL HORIZONTAL VERTICAL 502 DVK3004 VDK3026 1262 DVK3001 VDK3024 652 DVK3005 VDK3027 1442 DVK3001 VDK3024 752 DVK3005 VDK3027 1802 DVK30000 VDK3024 992 DVK3000 VDK3023 2072 DVK30000 VDK3024 These kits include DV box adapter air inlet cap and sidewall vent termination The VDK kits include DV box adapter and an air inlet cap Comb
19. GROUND L N 120V SUPPLY Figure 5 2 Line Voltage Field Wiring Connections Installation amp Operation Manual 5 Electrical connections continued Low voltage connections 1 Route low voltage wires through the knockouts on the left side of the heater as shown in FIG 5 3 2 Connect low voltage wiring to the low voltage connection board as shown in FIG 5 5 on page 44 of this manual and the heater wiring diagram LINE VOLTAGE KNOCKOUTS Figure 5 3 Routing Field Wiring EMS or remote thermostat connection An EMS remote thermostat or other remote temperature control may be connected to the pool heater see FIG 5 4 Follow the manufacturer s instructions supplied with the remote temperature control for proper installation and adjustment Connection of a set of dry switching contacts or a remote on off thermostat to the low voltage connection board will allow the unit to be switched on and off by making or breaking a 24 VAC control circuit Remove the factory jumper between the Staging S1 terminals on the low voltage connection board and connect the remote temperature control in its place see FIG 5 5 on page 44 Terminals S2 53 and S4 are not used Ensure that all wiring used to connect the switching contacts of the remote temperature controller to the connection board are a minimum of 18 gauge and have a maximum installed length of 300 feet 91 4m Set the SMART SYSTEM control to a set point temper
20. WALLS i OR PARAPETS IS MORE THAN 10 CHIMNEY WALL OR CHIMNEY l CHIMNEY Figure 2 3_Vent Termination from Flat Roof 10 ft Figure 2 4_Vent Termination from Flat Roof 10 ft or or Less From Parapet Wall More From Parapet Wall 18 Installation amp Operation Manual 2 Ve nting continued Vertical DirectAire venting see page 14 NOTICE Before installing venting system follow requirements found in the General Venting section The Vertical DirectAire vent system is the same as the Conventional Negative Draft vent system except it pulls combustion air from the outdoors through separate air inlet pipe Follow all requirements in the Conventional Negative Draft Venting section on page 16 M The Vertical DirectAire vent system requires you to install two pipes directly to the unit one vertical pipe with rooftop termination for the flue products and one pipe for combustion air For this venting option you must purchase the DV box adapter from the appliance manufacturer The DV box attaches to the air inlet of the unit The pipe for combustion air attaches to the DV box see FIG 2 11 on page 28 Reference page 28 for a list of approved air intake materials Combustion air inlet piping Locate and install the combustion air inlet cap correctly Failure to do so can allow the discharge of flue products to be drawn into the combustion process This can result in in
21. Water Chemistry on page 45 Figure 4 1_Water Connections Models 502 752 3 Lubricate the pump to the manufacturer s recommendations Pump damage due to inadequate aa lubrication is non warrantable Use SAE 30 non detergent INLET oil or lubricant specified by the pump manufacturer 2 1 2 NPT_ WATER 4 Standard pool heaters are furnished with the following circulating pump mounted in the factory supplied pool loop OUTLET 502 752 Models 1 4 HP 120 VAC 5 8 Amp 992 1442 Models 1 2 HP 120 VAC 7 4 Amp 1802 2072 Models INSPECTION 3 4 HP 120 VAC 8 8 Amp PLUGS Figure 4 2_Water Connections Models 992 2072 This pump is sized based on installation of a single pool heater in close proximity with the system If the number of fittings and straight pipe exceeds the quantities shown in this section a larger pump will be required As an alternative to changing the pump in these circumstances the piping can be changed to a sub loop Check pump for correct pump rotation The standard pump selection is based on the following pipe and 34 fittings from the pool heater to the system 4 Water connections continea 6 90 elbows 2 unions 2 ball valves 1 cold water tee Not more than 45 feet of straight pipe NOTICE For every elbow and tee in excess of those shown above deduct 5 feet from the maximum allowable straight pipe in the pool heater to the system circulating loop Minim
22. and all appliances are shut off Sequence of the cascade To equalize the run time of all appliances on the Cascade the firing sequence will automatically be changed at set intervals For the first 24 hours after initializing the Cascade the sequence will be changed every hour After that the sequence will be changed once every 24 hours SWITCHING ON SEQUENCE 1 1 2 3 4 5 6 7 M1 M2 M3 M4 M5 M6 M7 L M2 M3 M4 M5 M6 M7 L M1 Night Setback operation of the pool heater within the Cascade is available Programming of the Space Heating SH Night Setback will be done through the Leader heater Refer to the Copper fin Service Manual for information regarding Night Setback Ramp Delay operation of the pool heaters as described in the Copper fin Service Manual is available when the pool heaters are part of a Cascade system Night setback The controller may be programmed to reduce the pool water heating during a certain time each day A start and stop time can be programmed for each day of the week 51 Installation amp Operation Manual T Operating information Sequence of operation OPERATION DISPLAY The high limit may require reset through the display before Standby any action will take place 123 8F 78 Upon a call for heat the control turns on the unit pump The Standby flow switch and low water cutoff if equipped must close 123 8F 78 f the unit is equipped with a proof of
23. and assemble the combustion air inlet cap to protect the air inlet from wind and weather Alternatively assemble the combustion air inlet cap for vertical rooftop air inlet from items purchased locally The air inlet cap consists of two 90 elbows installed to the air inlet pipe see FIG 2 13 Install the first 90 elbow on the rooftop at the highest vertical point of the air inlet pipe Install the second 90 elbow on the horizontal outlet of the first elbow The outlet of the second 90 elbow will be pointing down You may use a 90 elbow and a 90 straight elbow to make this assembly If you use a straight piece of pipe between the two 90 elbows it should not exceed 6 51 mm in length For horizontal direct vent termination of combustion air you must use the termination cap from the appliance manufacturer The sidewall air inlet cap 1s available as part of a direct vent kit See Table 2E page 27 for Horizontal Direct Vent Kits Vertical Combustion Air Inlet Clearances You must locate the air inlet termination elbow at least 12 30 cm above the roof or above normal snow levels If the air inlet cap is within a 10 foot 3 05 m radius of the flue outlet the point of termination for the combustion air inlet cap must be at least 3 feet 0 91 m below the point of flue gas termination vent cap bba Do not install the combustion air inlet cap closer than 10 feet Figure 2 13_Vertical Rooftop Air Inlet 3 05 m from an inside cor
24. be performed to assure maximum appliance efficiency and reliability Failure to service and maintain the appliance and system could result in equipment failure Electrical shock hazard Turn off power to the appliance before any service operation on the appliance except as A WARNING FG noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems Flue vent system and air piping 1 Inspect any problems reported by the owner and correct 1 Check for gastight seal at every connection seam of before proceeding air piping and vent piping periodically inspected by a qualified service agency Inspect appliance area 1 Verify that appliance area is free of any combustible A WARNING Venting system must be sealed gastight materials gasoline and other flammable vapors and liquids to prevent flue gas spillage and carbon monoxide emissions which will result in Inspect appliance interior severe personal injury or death 1 Remove the outer access panels and inspect the interior of the appliance 2 Vacuum any sediment from inside the appliance and components Remove any obstructions Check all piping for leaks Eliminate all system or appliance leaks Continual fresh makeup water will reduce appliance life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causin
25. display Status Display Screens screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Display Shows Description The unit has been turned OFF by the Enter Reset button on the SMART SYSTEM display panel HTR OFF The unit s water temperature set point has been met and there is HTR STAND BY no call for heat demand being received from either the external thermostat or the BMS HTR SETPOINT MET The unit s water temperature set point has been met but is still receiving a call for heat from either a remote thermostat or a BMS The unit has initiated the combustion air purge cycle upon a call for heat HTR PRE PURGE Screen 1 Line 1 The unit has begun the igniter heatup cycle prior to the trial for HTR IGNITER ON ignition Display will show IGNITER A or IGNITER B depending on which stage has priority The unit has fired and is running at the displayed number of stages 1 2 3 4 HTR POST PURGE The call for heat has been satisfied and the unit runs the fan to clear the combustion chamber and vent system of residual flue products HTR SERVICE MODE The unit has been placed in temporary mode that will allow the unit to fire for the purpose of combustion analysis Screen 1 OUT F The outlet temperature is displayed by the control Line 2 OUT OPEN The control does not detect the outlet sensor OUT SHORTED The outlet
26. ensure proper operation Make all draft readings while the unit is in stable operation approximately 2 to 5 minutes Connect the flue vent directly to the flue outlet opening on the top of the unit No additional draft diverter or barometric damper is needed on single unit installations with a dedicated stack and a negative draft within the specified range of 0 02 to 0 08 inches w c If the draft in a dedicated stack for a single unit installation exceeds the maximum specified draft you must install a barometric damper to control draft Multiple unit installations with combined venting or common venting with other Category I negative draft appliances require each pool heater to have a barometric damper installed to regulate draft within the proper range Do not connect vent connectors serving appliances vented by natural draft negative draft to any portion of a mechanical draft system operating under positive pressure Connecting to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury Flue outlet piping With this venting option you must use Type B double wall vent materials Vent materials must be listed by a nationally recognized test agency for use as vent materials Make the connections from the unit vent to the outside stack as direct as possible with no reduction in diameter Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connect
27. located at the combustion air inlet This filter helps ensure clean air is used for the combustion process Check this filter every month and replace when it becomes dirty The filter size on Models 502 752 is 12 x 12 x 1 30 5 cm x 30 5 cm x 2 5 cm and 16 x 16 x 1 40 6 cm X 40 6 cm x 2 5 cm on Models 992 2072 You can find these commercially available filters at any home center or HVAC supply store For convenience and flexibility you can direct the combustion air inlet from either the back or right side of the unit To arrange the combustion air inlet for side entry follow the steps below 1 Remove the metal panel from the unit s side wall see FIG 1 6 2 Remove screws from the air filter bracket assembly 3 Move the filter bracket assembly from the rear of unit to the side opening see FIG 1 7 4 Attach filter bracket assembly to the unit s side using the pre drilled screw holes 5 Attach the metal panel to the rear combustion air opening to seal it off Figure 1 6 Metal Panel Covering Side Combustion Air Inlet Figure 1 7 Moving Air Filter Bracket Assembly from Rear of Unit to Side During construction the air filter should be checked more frequently to ensure it does not become clogged with NOTICE combustion dirt and debris Sustained operation of an appliance with a clogged filter may result in nuisance operational problems bad CAUTION combustion and non warrantable component fai
28. m radius of the termination The vertical termination must be a minimum of 3 feet 0 91 m above the point of exit A vertical termination less than 10 feet 3 05 m from a parapet wall must be a minimum of 2 feet 0 61 m higher than the parapet wall Keep the vent cap clear of snow ice leaves and debris to avoid blocking the flue 17 Cems Installation amp Operation Manual 2 Venting 10 OR LESS RIDGE CHIMNE Figure 2 2 Vent Termination from Peaked Roof 10 ft Figure 2 1 Vent Termination from Peaked Roof 10 or More From Ridge or Less From Ridge NOTICE Vent terminations are not shown in FIG s 2 1 thru 2 4 Make sure all vertical vents are installed with vent terminations recommended by the vent manufacturer S OS OS EN Z l 10 ORLESS 10 OR LESS 10 OR MORE I 1 aM 2 MIN 2 MIN 3 MIN 3 MIN l l l waLLOR NOTE NO HEIGHT PARAPET ABOVE PARAPET REQUIRED WHEN DISTANCE FOR
29. manifold pressure is preset at the factory and adjustment is not usually required If you must adjust regulator pressure follow the instructions in the Copper fin Service Manual Venting of combination gas valves The combination gas valve regulator used on all units is equipped with an integral vent limiting orifice per ANSI Z21 78 The vent limiter ensures that the volume of gas emitted from the valve in the event of a failed gas diaphragm does not exceed the maximum safe leakage rate allowed by agency requirements 3 Gas connections continued 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 Checking gas supply pressure Use the following procedure to check gas supply pressure 1 Turn the main power switch to the OFF position 2 Turn gas valve knobs to the OFF position 3 Shut off gas supply at the field installed manual gas cock in the gas piping to the unit If fuel supply is L P gas shut off gas supply at the tank 4 Remove the 1 8 hex plug located on the inlet side of the gas valve You may also use a tapping on the field installed main manual gas cock or gas piping Install a fitting in th
30. must be installed as the first fitting after the horizontal ell on the top of the unit see FIG 2 9 Plastic drain tubing sized per the vent manufacturer s instructions shall be provided as a drain line from the tee The drain tubing must have a trap provided by a 3 7 6 cm diameter circular trap loop in the drain tubing Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use caution not to collapse or restrict the condensate drain line with the nylon wire ties The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material Figure 2 9 Sidewall Vent Models 502 752 Only 23 Cems Installation amp Operation Manual 2 Ventin g Do not combine the flue from this unit with the vent from any other appliance Do not combine flues from A WARNING 2 multiple appliances into common vent The flue from this unit must 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 Provide adequate clearance to combustibles for the vent connector and fires
31. option All dimensions are based on net free area in square inches Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 2596 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the equipment room Each opening must have a minimum net free area as specified in TABLE 1C this page Single openings shall be installed within 12 30 cm of the ceiling A caution 1 combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as Freon trichlorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the heat exchanger finned tubes headers flue collectors and the vent system The result is improper combustion and a non warrantable premature unit failure TABLE 1C MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Outside Air from 2 Openings Directly from Outside Air from Outdoors 1 Opening Directly Opening in Opening in 2 502 652 722 92 Opening in 125 125 167 250 250 500 500 806 cm 1077 cm 1613 cm 1613
32. others would be designated as Member controls The set point or firing rate can be controlled by the 0 10V input as well Once the Leader appliance receives call for heat from BMS or external thermostat the control will determine what the set point will be A fixed temperature set point can be programmed into the control See Copper fin Service Manual to program the set point If the pool water temperature is less than the set point the off differential then the control will initiate a call for heat on the Cascade The appliance will fire and will then stage its firing rate to maintain the set point If the first appliance reaches 10096 of its firing rate the Leader will calculate at what point the second appliance could fire at its minimum firing rate At this point the Leader will fire the second appliance on the Cascade For a new startup this would be the first Member appliance The appliance will fire and will then stage its firing rate to maintain the set point If the set point still cannot be met the Leader will continue firing more Members until either the heat demand is met or all appliances on the Cascade are firing As the heat demand decreases the last appliance on will stage down to its minimum firing rate Once the demand for that appliance is 0 it will shut down As the heat demand decreases further the second to last appliance will stage down and shut off This will continue until the demand 15 satisfied
33. outlet sensor If this difference exceeds the first limit the control will turn off stages If the temperature difference exceeds a second limit the control will shut the unit down The unit will restart automatically once the temperature difference has dropped 10 F 6 C and the minimum off time has expired RISE LIMITING Outlet Temperature Up to 180 F 82 C Full Fire 180 F 82 to 185 F 85 C Above 185 F 85 C Freeze protection DO NOT install the appliance in a room likely to freeze The following integral feature of the SMART SYSTEM control module provides some protection for the appliance only not for the system The SMART SYSTEM control module provides freeze up protection as follows when the appliance water temperature drops below 45 F 7 2 C Below 45 F 7 2 C the appliance and system pumps operate constantly Below 37 F 2 7 C the appliance turns on Appliance and pumps turn off if appliance water temperature rises above 45 F 7 2 C A CAUTION This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing The installer must still use recognized design installation and maintenance practice to prevent freeze potential for the appliance and system High limit operations When outlet temperature exceeds 210 F 99 C high limit action occurs The appliance shuts down until the outlet water cools down and the RESET button on the Operator
34. shipping damage Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on packing slip with those actually received In case there is damage shortage immediately notify the carrier Do not use this appliance if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced NOTICE The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guides REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS BI Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent airborne dust Remove the combustion chamber lining from the
35. the gas supply to the pool heater and verify minimum gas supply pressure as the burner fires at 100 of rated input 7 Verify operation of safeties as necessary low water cutoff high limit gas pressure etc 8 Verify that all adjustable points in the Operator Interface are set as required 9 Once the pool heater analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the pool heater shuts down and registers an alarm Open the manual shutoff valve and reset the control 10 Place the pool heater back into normal operation Pool heater operation 11 The pool heater should begin the start up process for the sequence of operation 12 The pool heater will ignite at the proper ignition speed and will stage to meet the system demand 13 Ensure that inlet water temperature does not fall below the specified minimum for the pool heater 14 Based on system demand pool heaters may run for an extended period of time at a reduced rate of input to maximize efficiency 15 As system demand is satisfied the burner will cycle off and the combustion air blower will run for a post purge operation before the pool heater shuts down Start the pool heater Read and follow the Lighting Instructions in FIG 6 2 on page 47 1 pool heater does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Isthe unit in lockout Is the pool he
36. unit so that high winds can deflect off of adjacent walls buildings or shrubbery causing recirculation Recirculation of flue products may cause operational problems bad combustion or damage to controls Locate unit at least 3 feet 0 91 m from any wall or vertical surface to prevent wind conditions from affecting performance Multiple unit outdoor installations require 48 1 22 m clearance between each vent cap Locate outdoor cap at least 48 1 22m below and 48 1 22 m horizontally from any window door walkway or gravity air intake Locate unit at least 10 feet 3 05 m away from any forced air inlet Locate unit at least 3 feet 0 91 m outside any overhang Clearances around outdoor installations can change with time Do not allow the growth of trees shrubs or other plants to obstruct the proper operation of the outdoor vent system Do not install in locations where rain from building runoff drains will spill onto the unit Do not install outdoor units on stack frames Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building or unit surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate The outdoor vent cap kit The optional outdoor vent cap kit is available from the appliance manufacturer The outdoor cap part numbers are listed by mod
37. venting termination information for clearances and location under the Vertical Vent Termination Clearances and Location section on pages 17 18 26 GOAL Installation amp Operation Manual 2 Ventin Q continued Masonry chimney installation Do not use standard masonry chimney to directly vent the combustion products from this unit To use masonry chimney the chimney must use sealed corrosion resistant liner system Sealed corrosion resistant liner systems single wall double wall flexible or rigid must rated for use with high efficiency positive pressure vent system Corrosion resistant chimney liner systems are typically made from a high grade stainless steel such as AL29 4C The liner must be properly sized and fully sealed throughout the entire length Both the top and bottom of the masonry chimney must be capped and sealed to provide dead air space around the liner Do not vent this unit into masonry chimney without sealed stainless steel liner system Any breaks leaks A WARNING or damage to the masonry flue tile will allow the positive pressure flue products to leak from the chimney and into occupied living spaces This could cause serious injury or death due to carbon monoxide poisoning and other harmful flue products NOTICE Check with local code officials to determine code requirements or the advisability of using masonry chimney with sealed corrosion resistant liner system Horizontal
38. water going out to the pool could result in higher temperature water than desired being discharged to the pool If an external thermostat or BMS is being used to enable or disable the cascaded heaters the external thermostat or BMS should be connected to the Leader heater s S1 input located on the low voltage terminal board see FIG 5 5 Jumpers on all Member heaters should be left in place Communication between the Leader and the Member heaters is accomplished by using shielded 2 wire twisted pair communication cable Connect one of the twisted pair wires to terminal A on each of the low voltage connection boards and the other wire of the twisted pair to terminal B on each of the low voltage connection boards Connect the shield wire to the shield ground terminal on all of the heaters If more than two heaters are on the Cascade daisy chain the wiring from the Cascade terminals on the second heater to the Cascade terminals on the third heater then from the third to the forth and so on The connections can be made in any order regardless of the addresses of the heaters Try to keep each cable as short as possible 44 COPRER EINZ Installation amp Operation Manual Figure 5 5 Low Voltage Field Wiring Connections TO MONITORING DEVICE ALARM CONTACTS TO MONITORING DEVICE THREE WAY VALVE LOUVER PROVING SWITCH LINE RUN TIME CONTACTS OPEN CLOSE 3 WAY VALVE
39. 3 THERMOSTAT REMOTE 5 __ f 1 COM S1 S1 52 52 53 53 54 54 STAGING TO LOUVER PREVIOUS HEATER TO NEXT HEATER EXTERNAL SEQUENCER BUILDING AUTOMATIC CONTROL POOL SAFETY SUPPLY 10K 20K POOL BOILER o9 LOUVER RELAY 24VAC COIL FIELD PROVIDED as OPTIONAL MODBUS 1 So SHIELD OPTIONAL gt B r SHIELD TO NEXT BOILER 4 A UJ 30203584 10 LOUVER PROVING SW LOUVER RELAY COIL TANK AQUASTAT 2009000000000000000000 CASCADE SHIELD 0 10V BMS IN 0 10V RATE OUT SHIELD MODBUS 2 SUPPLY SENSOR POOL RETURN SENSOR NOT USED oN Do A N T g 1 1 D T 6 Startup Pre start checklist Before attempting to start the pool heater verify that the following items have been checked Verify proper location and installation of the pool heater Check gas piping and ensure the gas line is purged of all air Ensure that the pool is properly filled DO NOT operate pool heater if improperly filled Check to ensure that all water connections are tight Relief valve has been piped to a suitable floor drain
40. 9 Line 1 UNIT PUMP DELAY Press the Next P arrow key on the SMART SYSTEM display to access Screen 10 FLM SIG A The control displays the igniter flame signal of igniter A in microamps Ine reen 1 gr 2 FLM SIG B The control displays the igniter flame signal of igniter B in microamps Ine Press the Next arrow key on the SMART SYSTEM display to access Screen 11 reen 11 BE IGN AMPS A The control displays the current of either igniter Line 1 reen 11 ie 2 MIX VAL POS 96 The control displays the mixing valve percentage open to the system ine 56 8 Maintenance Installation amp Operation Manual Maintenance and annual startup Table 8A 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 Check system water pressure system piping expansion tank Check control settings Check igniter Check wiring and connections Check flue gas passageways gt H lt o lt lt Flame inspection stable uniform Inspect and clean the burner Check manifold gas pressure Perform start up checkout performance verification per Section 6 in the Copper fin2 Installation and Operation Manual If combustion
41. AUTION Failure to remove power from the actuator prior to attempting to manually operate the valve can result in irreparable damage to the actuator mechanism 39 4 Water connections Relief valve This pool heater is supplied with a relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section IV The relief valve s is installed in the vertical position and mounted in the hot water outlet Place no other valve between the relief valve and the pool heater To prevent water damage pipe the discharge from the relief valve to suitable floor drain for disposal when relief occurs Do not install any reducing couplings or other restrictions in the discharge line The discharge line will allow complete drainage of the valve and line Manually operate the relief valves at least once a year A CAUTION Avoid contact with hot discharge water Automatic chlorinator and chemical feeders All chemicals must be diluted into the pool water being circulated through the pool heater Any concentration of chlorine in the pool heater can cause damage to the pool heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concentrations will result when the pump is not running Chlorinator must feed downstream of the pool heater and have an anti siphoning device to prevent chemical back up in the pool heater when the pump is shut off NOTICE High chemical concentrations from improperly adjuste
42. CEEDING 9 PUND S Ei 34 SAFETY INFORMATION eeeeneennennm 4 Minimum Pump Performance 35 THE COPPER FIN HOW IT WORKS 5 7 Feat gt 019 EE 35 SATEN er 8 Auxiliary Mixed Water Limit 99 1 DETERMINE UNIT LOCATION Piping 36 38 Location of Unit 9 Pumped Automatic 39 Indoor Clearances from Combustible Construction 9 Outdoor Operation 3 Way Valve Cover 39 Non Combustible Combustible Flooring 9 Automatic Bypass Valve Cover Installation 39 Freeze Protection ERR 9 Manual Operation of the 3 Way Automatic Bypass 39 110 10 Relief 40 Hydronic Systems 10 Automatic Chlorinator and Chemical Feeders 40 Outdoor Pool Heater Installation 10 Water Flow SIGN escaso ai tessstu s noi Mesas dua 40 Combustion and Ventilation 10 Pump Purge Delay irent 40 Combustion
43. E bo COM SWTICH SILENCING ALARM ALARM RELAY SWITCH BELL 120VAC COIL 0202000000000000000000000000000000000000000000000000 900000 0090009000000oo9 4 228 GROUNDING AUXILLIARY DIGITAL gl or GS Exp lt OPTION HI LIMIT HARNESS 3 6 JUMPER IDENTIFICATION PLUG MODEL SPECIFIC CONSULT FACTORY 220000000000000000 2 SPD BLOWER EE LOW GAS SWITCH STAGE 1 2 STAGE 3 STAGE 3 STAGE 4 BURNER BURNER 1 HSI GROUND 2HSI GROUND BLOWER RELAY SPEED RELAY 120VAC 120 COIL 1 CIRCUIT BREAKER MAIN UNIT HARNESS Len Zn PR PURPLE BR BROWN DAN R BL BLUE G GREEN P PINK GY GRAY TO PREVENT ELECTRICAL SHOCK R RED YIG YELLOW WITH GREEN STRIPE THIS HEATER MAY BE CONNECTED TO MORE THAN ONE BRANCH CIRCUIT MORE THAN ONE DISCONNECT SMTCH MAY BE REQUIRED TO DEENERGIZE THE EQUIPMENT FOR SERMCING LBL20082 REV A GAS VALVE XFMR 63 19589 gt lt GLX INWASVDEIDVIS _ lt 9 0LX JAIWASVOZADVLS EOLX SOLX AAWASVD 3015 COIX L OLX QHVO8 YINYOAISNVEL DEE LINDYID Eh 43 fa
44. ER ON OFF SWITCH LWCO SWITCH LOCATION WIRE HARNESS CONNECTIONS BREAKER LOCATION OPTIONAL AUXILIARY HIGH LIMIT LOCATION 41 5 Electrical connections Pool heater operating control module The operating control for the appliance is the SMART SYSTEM control module It is located on the inside of the control panel behind the front access door Access to adjust the temperature set point and other user adjustable points is made through the Operator Interface located on the front access door The exact temperature set point is based on the system s requirements Set the control set point s to the desired operating water temperature The maximum temperature set point that can be programmed into the control module from the Operator Interface on a pool heater is 105 F 40 5 C The manual reset high limit control for a pool heater is adjustable up to a fixed maximum setting of 200 F 93 C TABLE 5C AMP DRAW DATA 502 652 732 992 1262 5 5 5 7 7 1442 7 8 6 v 8 4 3 4 8 4 3 4 8 25 Oe A 7 3 2 2 4 2 6 7 4 7 3 6 7 8 7 3 6 7 8 With standard factory supplied pump A WARNING ELECTRICAL SHOCK HAZARD For your safety turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard Failure to do sO can cause severe personal injury or death NOTICE Wiring must be N E C Class 1 If original wiring as supplied with t
45. F GAS TO 1 Turn off all electric power to the appliance 3 Push in gas control knob slightly and if service is to be performed turn clockwise to OFF Do not force ON 2 Open control access panel 4 Replace control access panel LBL2084 REV D 47 6 Startup Set clock The SMART SYSTEM control has built in clock that it uses for its night setback feature and for logging events This clock must be set when the appliance is installed and anytime the appliance has been powered off for more than one month Use the following procedure to set the clock 1 Press and hold the MENU key FIG 7 1 for at least 5 seconds 2 The display changes to ready ENTER MENU CODE with four 4 zeros below it 3 Change the zeros to match the user code factory set at 70704 Use the UP and DOWN keys to increment or decrement the flashing digit and the NEXT and PREVIOUS keys to select which digit flashes 4 Press the ENTER key 5 The display changes to read USER CODE for a few seconds then displays a menu 6 Press the ENTER key 7 Press the UP key twice to display DATE AND TIME Press the ENTER key once 9 The date and time are displayed as YY MM DD W hh mm where mm minutes hh hour 24 hour time e g 2 00 PM 14 00 W day of the week 1 Sunday 2 Monday 3 Tuesday etc po YY year MM month DD date The internal clock does not adjust for NOTICE Daylight Sa
46. Gas and 0 60 3000 8 300 7 690 7 380 6 870 6 150 5 640 5 130 4 720 Specific Gravit EE Installation amp Operation Manual 4 Water connections Install piping from the filter system to the pool heater as shown in the pool heater piping diagrams See Figures 34 38 TABLE 4 Minimum pipe diameter to and from the installed pool heater Pipe Sizing Chart to the filter system piping on models 502 752 is 2 and on 502 752 Models Common Pipe Size models 992 2072 Btu hr the minimum is 2 1 2 The piping Number of units Min from the filter system to the pool heater may be PVC CPVC or Copper Pipe The piping from the pool heater back to the filter system will carry water with temperatures in excess of 110 F and must be CPVC or Copper Pipe The temperature of the heated water from the pool heater will be substantially cooled as it is mixed back into the pool water from the filter system and returned to the pool The mix of heated water and pool water from the filtration system should only be slightly ____ 6 ______ ___ warmer than pool water before the connections from the 992 2072 Models Common Pipe Size pool heater Number of units Min MATER WATER 5 OUTLET Circulating pump 1 This pool heater is factory supplied with a properly sized pump that circulates water between the pool heater and system INSPECTION 2 The pump is sized to pool heater input and water PLUGS hardness See
47. Interface is pressed Low water cutoff protection 1 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 This along with the flow switch ensures appliance shutdown in the event of low water or low flow conditions 2 Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff Consult local jurisdiction to determine Contact manufacturer for low water cutoff kit availability 50 Installation amp Operation Manual Monitor external limits Connections are provided on the connection board for external limits such as a louver proving switch The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The appliance provides dry contacts for indicating when the appliance is running and when it is unable to operate Run time and cycle counting The control uses two timers to monitor the total hours of burner operation One timer monitors the time the appliance is firing under 5096 of rate The other timer monitors the time the appliance is firing over 50 rate The control uses four 4 ignition counters to monitor the amount of appliance cycles The first counter counts all ignitions of t
48. LOCATION SHOWN ON THE PIPING DIAGRAM THE UNIT PUMP MUST MODEL NO BYPASS PIPE SIZE RUN CONTINUOUSLY TO ENSURE CP N L 502 752 2 MIN THE WATER FLOW PAST THE CP N L 992 2072 2 1 2 MIN SENSOR 15 MAINTAINED NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 37 EA Installation amp Operation Manual 4 Water connections Figure 4 7 Multi stack frame Cascaded heaters beyond 15 feet of pool piping MODEL NO BYPASS PIPE SIZE CP 502 752 2 MIN CP N L 992 2072 2 1 2 MIN POOL RETURN SENSOR LOCATION PRIMARY 4 PVC LOCATION POOL SUPPLY SENSOR FLOWMETER POOL AUTOMATIC BYPASS VALVE RECOMMENDED ISOLATION VALVE TABLE 4A PIPE SIZING CHART COPPER COMMON PIPE SIZE MIN OR PVC F UNITS MODELS 502 752 MODELS 992 2072 SEE TABLE 2 2 1 2 3 4 3 1 2 4 4 5 5 6 5 6 Please note that these illustrations are meant to show system piping concept only the installer is responsible for NOTICE all equipment and detailing required by local codes 38 4 Water connections continea Pumped Automatic Bypass This 1s a high efficiency pool heater which requires a special pumped bypass for proper operation The bypass assembly supplied with the pool heater includes a pump and a 3 way mixing valve All piping to connect the filter
49. Sidewall air inlet The sidewall air inlet cap is supplied in the Sidewall Air Inlet Kit Order the kit from the appliance manufacturer This sidewall cap supplies combustion air for a single unit only See Table 2B page 21 for kit numbers Locate the unit as close as possible to the sidewall where you will install the combustion air supply system Figure 2 5 Sidewall Combustion Air Inlet Figure 2 6 Air Inlet Cap for Sidewall Termination 19 Coes Installation amp Operation Manual 2 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 Clearances You must install the combustion air inlet cap at least one foot 0 30 m above ground level and above normal snow levels The point of termination for the combustion air inlet cap must be at least 3 feet 0 91 m below the point of flue gas termination if it is located within 10 feet 3 05 m of the flue outlet Make sure to properly install the air inlet cap assembly on the air inlet pipe Do not install the combustion air inlet cap closer than 10 feet 3 05 m from an inside corner of an L shaped structure Vertical Rooftop Air Inlet Use the vertical air inlet terminations available from th
50. The venting system must be installed so that it will prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death A WARNING Check control water chemistry A CAUTION Salt levels above 5000 ppm can cause corrosion damage to heat exchangers Factors which affect pool water and more importantly the efficiency of your new pool heater are 1 Proper Filtration 2 Proper Circulation Installation amp Operation Manual 3 Disinfection and Oxidation 4 pH Control and Total Alkalinity 5 Algae Control 6 Water Balance The water chemistry of your pool changes daily due to natural evaporation of the water and the addition of chemicals Chemicals are used to sanitize and control algae growth in the pool Their addition must be carefully monitored The accumulation of minerals or scale in the pool heater due to a chemical imbalance will cause a non warrantable failure of the heat exchanger and its components pH is an important factor in maintaining proper balance in your pool water pH is the measurement of the acidity or alkalinity of water The following chart shows the recommended pH range and what can happen when the pH increases or decreases from the ideal of 7 2 to 7 8 Figure 6 1 pH Scale pH Scale CORROSION SCALING HEAT HEAT EXCHANGERS EXCHANGERS DESTROYED DESTROYED LOW pH HIGH pH ALKALINE If the pH becomes too high it lowers the ability of chlorine to
51. 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 In User Mode the following parameters can be viewed but not changed Pool water target temperature Appliance model number Software version Total operating hours Total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code see the Copper fin Service Manual Saving parameters reference the Parameter Table in the Copper fin Service Manual To save parameters and exit programming Press the ENTER RESET button then the MENU EXIT button 3 times To keep parameter settings only for a current operating cycle Press the MENU EXIT button 3 times after making all desired parameter changes To enter a parameter and continue programming Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings Remember to press the ENTER RESET button when finished programming in order to save the changes made See the Copper fin Service Manual for a detailed description of parameters and access modes 54 COPEER EIN Installation amp Operation Manual T Operating information continued Status display screens By using the Previous Next 4 gt arrow keys on the SMART SYSTEM display panel you can navigate through the 11
52. UST NOT be installed in a bull head tee installed on the unit s flue outlet The tee or collar containing the barometric damper should be approximately three feet vertically above the connection to the unit s flue outlet This location ensures that any positive velocity pressure from the unit s internal combustion fan is dissipated and the flue products are rising due to buoyancy generated from the temperature of the flue products Adjust the weights on the damper to ensure that draft is maintained within the specified range TABLE 2A FLUE AND AIR INLET PIPE SIZES MODEL FLUE SIZE AIR INLET SIZE MODEL FLUE SIZE AIR INLET SIZE 52 e 1262 6m 8 S 04 759 8 8 180 2072 Minimum diameter for air inlet pipe Installer may increase diameter one pipe size for ease of installation if needed 15 EE Installation amp Operation Manual 2 Venting 16 Conventional negative draft venting see page 14 NOTICE Before installing a venting system follow requirements found in the General Venting section 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 to
53. Use a vacuum to remove loose soot from surfaces and inner chamber 7 If necessary the heat exchanger can be removed Once the heat exchanger is removed from the unit a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces Note Do not wet the unit s refractory 8 Ensure that all burner ports are cleaned to remove any soot See Burner Removal and Cleaning page 60 9 Carefully reinstall the heat exchanger V baffles and frame runners if removed from the unit Note Make sure frame runners seal securely where they contact the front and rear compartment refractory 10 Carefully reinstall inner jacket panels burners manifolds wires and hoses Use new gasket material to ensure a proper air seal 11 Reassemble all gas and water piping Test for gas leaks Upon completion of any testing on the gas system leak test all gas connections with a soap and water solution while main burners are operating Do not spray soap and water solution on the SMART SYSTEM control module housing The use of an excessive amount of soap and water solution can damage the control Immediately repair any leak found in the gas train or related components Do not operate an appliance with a leak in the gas train valves or related piping 12 Reassemble outer jacket panels 13 Cycle unit and check for proper operation Installation amp Operation Manual HEAT
54. a flue products with air supplied by a pipe from the separate combustion air pipe to the outdoors sidewall or rooftop see page 19 This system terminates both the flue and combustion air inlet in the same pressure zone VERTICAL DIRECTAIRE VENTING see page 26 This option uses a powered vent assembly This option uses the installation of a special air C to exhaust the flue products out a sidewall inlet vent cap on top of the unit see page 30 vent termination with air supplied from the equipment room see page 22 SIDEWALL VENTING OUTDOOR VENTING p NOTE CAT I B VENT MATERIALS MAY BE USED WHEN THE POWERED VENT IS CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP IF THE POWERED VENT IS NOT CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP THEN CAT IV AL29 4C VENT MATERIALS MUST BE USED FROM THE POWERED VENT TO THE OUTSIDE VENT CAP 14 Cees X Installation amp Operation Manual 2 Ventin Q 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
55. al 13 Remove the manometer and related fitting from the inlet side of the gas valve replace 1 8 hex plug in gas valve and tighten 14 Turn on gas supply at the manual valve turn on L P gas at the tank if required 15 Turn the power switch to the position 16 Turn the gas valve knob to the position 17 Set the electronic temperature control or thermostat to call for heat A WARNING After completing any testing on the gas system leak test all gas connections Apply soap water solution to all gas connections while main burners are operating Bubbles forming indicate leak Repair all leaks at once Do not operate this unit with a leak in the gas train valves or related piping Check burner performance by cycling the system while you observe burner response Burners should ignite promptly Flame pattern should be stable see Burner Flames in the Copper fin Service Manual Turn system off and allow burners to cool then cycle burners again to ensure proper ignition and flame characteristics SUPPLY INLET INLET PRESSURE TAP GAS OUTLET VALVE CONTROL KNOB Figure 3 3 Measuring Gas Supply Pressure Combination Gas Valve Maximum Capacity of Pipe in Thousands of Btu hr per hour for gas pressures of 14 Inches ET Water Column 0 5 PSIG or less and pressure drop of 0 5 Inch Water Column Based on NAT 3 000 2 720 2 500 2 340 per Cubic Foot of
56. appliance and place it in a plastic bag for disposal NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines Warranty Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 Excessive water hardness causing a lime scale build up in the copper tube is not the fault of the equipment and is not covered under the manufacturer s warranty see Water Treatment and Water Chemistry 2 Excessive pitting and erosion on the inside of the copper
57. ater outlet temperature exceeding 200 F 93 3 C 3 Is the thermostat set below pool water temperature 4 Is gas turned on at meter or pool heater 5 Is incoming gas pressure less than 4 5 water column If none of the above corrects the problem refer to the Troubleshooting Section of the Copper fin Service Manual A WARNING The venting system must be installed so that it will prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Installation amp Operation Manual 6 Startu P continued Figure 6 2 Operating 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 f you cannot reach your gas supplier device which automatically lights the burner call the fire department Do not try to light the burner by hand B BEFORE OPERATING smell all around the C Use only your hand to turn the gas appliance area for gas Be sure to smell next control knob Never use tools If the to the floor because some gas is heavier knob will not turn by hand don t try to than air and will settle on the floor repair it call a qualified service tech nician Force or attempted repair may FOR YOUR SAFETY result in a fire or explosion WHAT TO DO IF YOU SMELL GAS D Do not use this applia
58. ature slightly higher than the setting of the remote temperature control This will ensure that the remote temperature controller functions as the operating control for the heater REMOTE ON OFF CONNECTION Figure 5 4 Remote ON OFF Wire Connection Louver relay When the heater is to control combustion air louvers a field provided 24VAC louver relay must be installed Connect the Louver Relay Coil terminals to the louver relay coil Louver proving switch The operation of a louver proving switch needs to be verified before the pool heater fires Remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch FIG 5 5 Pool return sensor 2 wire The pool return sensor should be installed into the return of the primary loop making sure it is immersed in the water flow The SMART SYSTEM control regulates the pool heater firing rate to maintain the system return temperature to the desired set point for the pool Pool supply limit sensor 4 wire The pool supply limit sensor should be installed into the supply of the primary loop making sure it is immersed in the water flow The SMART SYSTEM control limits the pool heater firing rate to maintain the system supply temperature Factory default for the limit temperature is 110 F 43 C Runtime contacts SMART SYSTEM control closes a set of dry contacts whenever the burner is running This is typically used by Buildi
59. burner ignition devices have a minimum clearance of not less than 18 46 cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present The appliance must be installed on a level floor Combustible floor installation a Models 502 752 require an approved floor kit for installation on combustible flooring reference Table 1A b Models 992 2072 are approved for installation on combustible flooring without a floor kit Note Concrete block over wood flooring is not considered non combustible DO NOT install this appliance directly on carpeting or other combustible material Maintain required clearances from combustible surfaces reference the Indoor Clearances from Combustible Construction Section this page For outdoor models you must install an optional vent cap Instructions for mounting the vent cap are included in the venting section of this manual Do not install outdoor models directly on the ground You must install the outdoor unit on a concrete brick block or other non combustible pad Outdoor models have additional special location and clearance requirements See Outdoor Installation Venting page 30 wind proof cabinet protects the unit from weather clearances from combustible construction COPPER FIN Maintain mini
60. closure valve the proof of closure switch must be closed The proof of closure valve is then energized The gas pressure switch es if equipped must close Standby If the contact for the louvers is closed the louver proving 123 8F 78 inputs must close If the air pressure switch is open the prepurge cycle then begins by starting the combustion blower Once started the air pressure switch must close After the 15 second prepurge the blower slows down and the hot surface igniter HSI is energized The HSI is heated for at least 20 seconds PREPURGE 123 9F 78 Once the HSI is hot the trial for ignition begins with the IGNITION opening of the gas valve 123 9F 78 If the SMART SYSTEM control does not sense flame then POSTPURGE LOCKOUT it will lock out 123 9F 78 If the SMART SYSTEM control senses flame it will fire the burner to maintain the set point The firing rate will stage as required to hold the actual temperature at the set point If the RUN STG 1 pool heater lights due to a space heating call for heat and the 124 8F 78 ramp delay function is active default is disabled the staging will be held to a series of increasing limits after the burner has lit Once a call for heat is satisfied the control will turn off the burner The blower will remain on for the 30 second POSTPURGE postpurge cycle The pump will continue to run for the 127 4F 78 respective pump delay
61. cm 3226 cm 3226 cm 163 217 325 325 650 650 1052 cm 1052 cm 1400 cm 2097 cm 2097 cm 4194 cm 4194 cm 188 188 250 375 375 750 750 1213 cm 1213 1613 cm 2420 cm 2420 cm 4839 cm 4839 cm 9 248 248 330 495 495 990 990 1600 cm 1600 cm 2129 cm 3194 cm 3194 cm 6388 cm 6388 cm Inside Air from 2 Ducts Delivered from Interior Space Opening in Opening in Inside Air from 2 Ducts Delivered from Outdoors Bottom Opening in 2 360 360 480 720 720 1440 1440 2323cm 2323cm 3097 cm 4646 cm 4646 cm 9291 cm 9291 cm 450 600 900 900 1800 1800 2903cm 2903cm 3871 cm 5807 cm 5807 cm 11614 cm 11614 cm 518 690 1035 1035 2070 2070 3342cm 3342cm 4452 cm 6678 cm 6678 cm 13356 cm 13356 cm Outside air openings shall directly communicate with the outdoors When combustion air is drawn from the outside through a duct the net free area of each of the two openings must have twice 2 times the free area required for Outside Air 2 Openings The above requirements are for the pool heater only additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances 315 315 420 630 630 1260 1260 2032cm 2032cm 2710 cm 4065 cm 4065 cm 8130 cm 8130 cm 11 1 Determine unit location Exhaust fans Any fan or equ
62. complete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning The sidewall or vertical rooftop DirectAire combustion air supply system has specific material and installation requirements The air inlet pipe connects directly to the unit to supply combustion air In most installations the combustion air inlet pipe will be a dedicated system with one air inlet pipe per unit You can combine multiple air inlets if the guidelines in Combined Air Inlet Points page 20 are followed The air inlet pipe will be connected to a combustion air inlet cap as specified in this section For normal installations this system uses a single wall pipe to supply combustion air from outdoors directly to the unit In cold climates use a Type B double wall vent pipe or an insulated single wall pipe for combustion air This will help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe 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 2 m Subtract 5 feet 1 5 m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7 m of equivalent length for each 45 elbow Do not exceed the limits for the combustion air inlet piping lengths
63. d feeders and Chlorinator can cause rapid corrosion to the heat exchanger This damage is non warrantable Water flow switch water flow switch is standard equipment The wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition The standard flow switch is installed in the outlet side of the piping loop when shipped from the factory These pool heaters require a sufficient flow of 26 GPM to make the flow switch and start burner operation Ensure that the pump installed on the pool heater will supply adequate flow to make the flow switch contacts and operate the pool heater water flow switch meets most code requirements for a low water cut off device on appliances requiring forced circulation for operation 40 COPRERTEINZ Installation amp Operation Manual Pump purge delay Pump purge pre running delay The controller provides a pump purge or pre running feature This feature is used whenever the pump has been off for extended periods of time to conserve energy causing air to become entrapped in the pool system piping The pump purge pre running feature delays pool heater operation until the pump has been on for a sufficient amount of time to remove air from the piping Both the inactivity time and pump purging pre running time are adjustable PH Pump Off Inactivity timer is adjustable from 0 to 99 hours Selection of time between 4 to 8 hours is recomm
64. ded for the system low ambient temperature alarm is recommended for the equipment room Damage to the pool heater by freezing is non warrantable 1 Pump Operation MOST IMPORTANT This pool heater is designed for continuous operation of the filter system pump when the burners are firing If the system pump does not run continuously an interlock mechanism should be provided to disable when if the system pump turns off The constant flow of warm pool water can help prevent freezing 2 Anytime the temperature measured at the sensor drops below 45 F the temperature control turns on the pump to circulate the water if the pump option is installed 3 Location Indoor pool heaters must be located in a room having a temperature safely above freezing 32 F 0 C 4 Outdoor Pool Heater Installation Use extreme caution to prevent freezing snow screen should be installed to prevent snow and ice accumulation around the pool heater Or its venting system 5 Shut Down and Draining If for any reason the pool heater is to be shut off the following precautionary measures must be taken a Shut off gas supply b Shut off water supply c Shut off electrical supply Drain the pool heater completely Remove the threaded drain plugs from the inlet and outlet sides of the front header on the heat exchanger see FIG s 4 1 and 4 2 Blow all water out of the heat exchanger Leave drains open until Spring e Drain pump and pip
65. destroy bacteria and algae water can become cloudy filter elements may become blocked and scale formation will occur in the pool and heat exchanger If the pH becomes too low the water becomes acidic You can have eye burn and skin irritation etching of the plaster corrosion of metal fixtures and the resulting stains on the plaster degradation of sand and gravel filters and corrosion of the copper tubes in the heat exchanger Damage to the pool heater including the pumped bypass due to improper chemical water balance is non warrantable Proper chemical water balance as indicated by use of the calcium saturation and Ryznar indexes is required to maintain warranty status of the pool heater and its components These indexes are designed to help prevent scaling and corrosive damage to the pool and all associated equipment We recommend the use of a commercial or professional grade test kit to maintain chemical water balance See your local pool professional for assistance Freeze protection Although this pool heater is CSA design certified for outdoor installations such installations are not recommended in areas where the pool heater will be operated in the winter months and the danger of freezing exists Proper freeze protection must be provided for outdoor installations pool heaters installed in unheated equipment rooms or where temperatures may drop to the freezing point or lower 45 6 Startup If freeze protection is not provi
66. drip leg Do not block access to the electrical cover plate when installing the sediment trap The sediment trap must be minimum of 12 inches from the appliance The combination gas valves have an integral vent limiting device and do not require venting to atmosphere outside the building The unit will not operate properly if the reference hose is removed or vent to atmosphere is installed Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes Gas connection All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum L P and natural gases All piping must comply with local codes and ordinances Piping installations must comply with approved standards and practices 1 Make sure gas line is a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier USE WRENCH TO HOLD SUPPLY PIPE UNION MANUAL MAIN SHUTOFF VALVE NIPPLE CAP Figure 3 1 Gas Line Connection NOTICE If an inline high gas pressure regulator is used it MUST BE of the lockup type and be located minimum of 10 feet from the appliance Failure to do so may result in insufficient gas volume supplied to the appliance 31 3 Gas connections 2 Use new properly threaded black iron pipe free from chips If you use tubing make sure the ends a
67. e The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded Pool heaters operate on temperature and pressure and are shipped standard as 150 PSI and 210 F 98 990 Power switch The power switch is used to engage and disengage power to the appliance on the 120 VAC circuit Air pressure switch The air pressure switch is a safety device which ensures proper blower operation The air pressure switch is wired in series with the low voltage control circuit in such a way that if the fan does not engage or shuts down prematurely the device will break the control circuit and the unit will shut down Flow switch The flow switch is a safety device that ensures flow through the heat exchanger during operation This appliance is low mass and should never be operated without flow The flow switch makes contact when flow is detected and allows the unit to operate If flow is discontinued during operation for any reason the flow switch will break the control circuit and the unit will shut down Drain port s Location from which the heat exchanger can be drained The drain ports are located underneath the front header Manual shutoff valve not shown Manual valve used to isolate the unit from the gas supply Installation amp Operation Manual The Copper fin How it works NC 6 20 A
68. e inlet pressure tapping suitable to connect to a manometer or magnehelic gauge Range of scale should be 14 w c or greater to check inlet pressure 5 Turn on gas supply at the manual gas cock turn on L P gas at the tank if required Turn the power switch to the ON position Turn the gas valve knobs to the ON position Set the electronic temperature control or thermostat to call for heat 8 Observe the gas supply pressure as all burners are firing Ensure that inlet pressure is within the specified range See Connecting To Gas Supply page 31 for minimum and maximum gas supply pressures 9 If gas pressure is out of range contact gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control 10 If gas supply pressure is within normal range turn the power switch to the OFF position 11 Turn gas valve knobs to the OFF position 12 Shut off gas supply at the manual gas cock in the gas piping to the unit If fuel supply is L P gas shut off gas supply at the tank Nominal Iron Pipe Qo sls e d H N d NG 974 ON N N 2 150 1 500 1 4 100 2 820 2 6 460 4 460 3 610 7 900 6 400 5 400 N O NIDN 60 Em c COPPER FINS Length of Pipe in Straight Feet Installation amp Operation Manu
69. e appliance manufacturer recommended and or supplied by the vent manufacturer or use two 90 elbows as described on page 29 sm You must locate the air inlet termination elbow at least 12 TIL 30 cm above the roof or above normal snow levels EX If the air inlet cap 1s within a 10 foot 3 05 m radius of the flue outlet the point of termination for the combustion air inlet D cap must be at least 3 feet 0 91 m below the point of flue gas termination vent cap Do not install the combustion air inlet cap closer than 10 feet 3 05 m from an inside corner of an L shaped structure Combined air inlet points The air inlet pipes from multiple pool heaters can be combined to a single common connection if the common air inlet pipe has cross sectional area equal to or larger than the total area of all o 1 air inlet pipes connected to the common air inlet pipe Example Two 10 air inlet pipes 78 5 in area each have a total area of 157 in and will require a 15 176 7 in area common air inlet pipe Figure 2 7 Rooftop Combustion Air Inlet The air inlet point for multiple pool heater air inlets must be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet This exterior opening for combustion air must con
70. e other appliances remaining connected to the common venting system are not in operation 1 Sealany unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch Make sure there is no blockage or restriction leakage corrosion and other unsafe conditions 3 If possible close all building doors and windows Close all doors between the space in which the appliances remaining connected to the common venting system are located and other building spaces EL Installation amp Operation Manual 2 Ventin 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 summer exhaust fan Close fireplace dampers 6 Place in operation the unit being inspected Follow the lighting instructions Adjust thermostat so unit will operate continuously 7 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of match or candle or smoke from a cigarette cigar or pipe 8 After making sure that each appliance remaining connected to the common venting system properly vents when tested as above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use 9 Correct any improper operation of the common ventin
71. e pool heater ae overheating occur or the gas supply ail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the pool heater Installation amp Operation Manual Initial set up of maximum water flow On initial start up of the Copper Fin pool heater the maximum water flow to the heat exchanger must be checked and manually limited with a valve or bypass before normal operation begins An appliance allowed to operate at return temperatures below the specified minimum setting may experience problems with the operating controls safety switches obstruction of the flue gas passages on the heat exchanger incomplete combustion and possible flue gas spillage Sustained operation at lower than specified water temperatures 140 F may cause hazardous conditions that may result in personal injury or non warrantable damage to the appliance Auxiliary Mixed Water Limit Control Pool return and pool supply mixed water limit sensors reference FIG 4 3 page 36 Ensure pool return and pool supply mixed water limit sensors are both installed in the system piping The return sensor should be installed in the upstream of the feed water to the pool heater The supply sensor limits the temperature of the water going back to the pool factory adjusted to lt 110 F The supply sensor may be installed in the filtration system piping be sure to keep it at
72. e vent kit Sidewall vent termination clearances and location Locate the bottom of the vent terminal at least 12 inches 30 cm above grade and above normal snow levels Locate the bottom of the vent terminal at least 7 feet 2 13 m above grade when located adjacent to public walkways Do not terminate directly above a public walkway Do not terminate the venting system in a window well stairwell alcove courtyard or other recessed area Do not terminate the venting system below grade Locate vent termination at least 3 feet 0 91 m from an inside corner of an L shaped structure Provide a minimum clearance of 4 feet 1 2 m horizontally from electric meters gas meters regulators and relief equipment Never locate vent cap above or below electric meters gas meters regulators and relief equipment unless a 4 foot 1 2 m horizontal clearance 18 maintained CaA Installation amp Operation Manual 2 Ventin Q continued Terminate the venting system at least 3 feet 0 9 m above any forced air inlet within 10 feet 3 05 m Terminate the venting system at least 4 feet 1 2 m below 4 feet 1 2 m beside or 1 foot 30cm above any door window or gravity air inlet into any building Locate vent termination at least 8 feet 2 4 m horizontally from any combustion air intake located above the sidewall termination cap Units which are shut down or will not operate may experience freezing due to convective air flow in the flue pipe
73. ed for the system low ambient temperature alarm is recommended for the mechanical room Damage to the unit by freezing is non warrantable 9 1 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 first stage will fire Location Locate indoor pool heaters in a room having a temperature safely above freezing 32 F 0 C A mechanical room operating under a negative draft pressure may experience a down draft in the flue of a pool heater when it is not firing The cold outside air pulled down the flue may freeze a heat exchanger This condition must be corrected to provide adequate freeze protection Hydronic systems anti freeze Freeze protection for a pool heater using an indirect coil can be provided by using hydronic system antifreeze Follow the appliance manufacturers instructions Do not use undiluted or automotive type antifreeze see page 40 Outdoor pool heater installation snow screen should be installed to prevent snow and ice accumulation around the unit or its venting system Combustion and ventilation air Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances a
74. een under water must be replaced Do not alter this pool heater in any way Any change to this pool heater or its controls can be dangerous The Copper fin How it works 1 10 11 12 13 14 Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer The glass lined 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 heat exchanger from inside the combustion chamber Blower The blower pulls in and injects air into the individual burners along with gas from the gas manifold where the mix is burned inside the combustion chamber Gas valve The referenced gas valves have a dual purpose changing the gas supply pressure to manifold pressure and the reference side of the gas valve is designed to allow chamber pressure to change the volume of gas through the valve This is not a design to compensate for gas supply pressure issues Outlet limit temperature sensor This 4 wire limit rated sensor monitors the outlet temperature to ensure safe operation The appliance will adjust its firing rate to maintain water temperatures below the maximum allowable outlet temperature Inlet temperature sensor This 2 wire sensor monitors the inlet temperature The appliance
75. el number See Table 2F for kit numbers Install the outdoor vent cap on the rear of the unit Complete installation instructions are included with the outdoor vent cap kit Figure 2 14 Outdoor Vent Cap Installed TABLE 2F OUTDOOR VENT CAP KITS MODEL OUTDOOR VENT KIT MODEL OUTDOOR VENT KIT ODK3075 1262 ODK3078 ODK3076 1442 ODK3079 3 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 The pressure tap is located upstream of the combination gas valve s See Table 3A for maximum and minimum inlet pressures Do not exceed the maximum Minimum inlet pressure is for the purpose of input adjustment TABLE 3A INLET GAS PRESSURE NATURAL W W C W C W C Manifold pressure The gas regulator on the unit s combination gas valve is adjustable to supply proper manifold pressure for normal operation See the Copper Fin Pool Heater Service Manual for net manifold pressure settings If you must adjust regulator pressure follow the instructions under Gas Manifold Pressure Adjustment in the Copper Fi Pool Heater Service Manual Do not increase regulator pressure beyond specified pressure setting
76. ended PH Pump Purge Purge or pre running timer is adjustable from 0 to 60 minutes Selection of a time between 10 to 30 minutes is recommended Note To override the purge pre running feature press the PREV and NEXT buttons To disable the feature the purge pre running timer should be set to zero 5 Electrical connections General information A WARNING ELECTRICAL SHOCK HAZARD For your safety turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard Failure to do sO can cause severe personal injury or death A 120 VAC 15 Amp 1 ph 60 Hz circuit is required for operation of the appliance controls The appliance when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code Part I and or local Electrical Codes Multiple units connected in a Cascade must be grounded to the same ground connection 1 All wiring between the appliance and field installed devices shall be made with type T wire 63 F 35 C rise 2 All line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 The circulating pump must run continuously when the appliance is being f
77. ent material and installation requirements Only use listed sealed AL29 4C vent system materials Follow all installation requirements See Table 2A page 15 for proper pipe size for your unit Seal all vent joints and seams gas tight Drain tee installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee must be installed as the first fitting after the horizontal ell on the top of the unit see FIG 2 9 on page 23 Plastic drain tubing sized per the vent manufacturer s instructions shall be provided as a drain line from the tee The drain tubing must have a trap provided by a 3 7 6 cm diameter circular trap loop in the drain tubing Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use caution not to collapse or restrict the condensate drain line with the nylon wire ties The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material Do not combine the flue from this unit with the vent from any other appliance Do not combine flues from A WARNING 2 2 multiple appliances into common vent The flue from this unit must dedicated stack Connect the flue vent directly to
78. g heat exchanger failure Leaking water may also cause severe property damage Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 3 Gas Connections of the Copper fin2 Installation and Operation Manual 56 8 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 fin2 Installation and Operation Manual before proceeding further A WARNING Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the pool heater relief valve as directed could result in un
79. g system so that the installation conforms to the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment When resizing any portion of the common venting system resize to approach the minimum size as determined using the appropriate tables of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment Masonry chimney installations A masonry chimney must be properly sized for the installation of a high efficiency gas fired appliance Venting of a high efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems Exterior masonry chimneys with one or more sides exposed to cold outdoor temperatures are more likely to have venting problems The temperature of the flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft This will result in condensing of flue products damage to the masonry flue tile insufficient draft and possible spillage of flue products into an occupied living space Carefully inspect all chimney systems before installation Do not vent this unit into a masonry chimney without a sealed stainless steel liner system Any breaks leaks or damage to the masonry flue tile will allow the flue pr
80. gative 0 02 to 0 08 inches w c TABLE 2D HORIZONTAL DIRECTAIRE KITS MODEL KIT HDK3031 O HDK3031 HDK3027 HDK3027 HDK3028 992 HDK3028 These kits include barometric damper 25 EE Installation amp Operation Manual 2 Venting Direct venting see page 14 NOTICE Before installing venting system follow all requirements found in the General Venting section 22 This option uses sealed AL29 4C vent materials for the flue outlet piping and separate combustion air inlet piping T This system terminates both the flue and combustion air inlet in the same pressure zone The flue outlet and combustion air intake may terminate at either sidewall or the rooftop EL To use the optional Direct Vent system you must install specific vent kits and venting materials The following is a detailed explanation of Direct Vent installation requirements including the components used and vent kit part numbers reference Table 2E on page 27 for kit numbers Flue outlet piping Venting Guidelines If using this venting option a sealed AL29 4C venting system for flue products is required on all models of this appliance This venting system operates with a positive pressure in the vent The internal combustion air blower generates this positive pressure which operates the combustion process and also exhausts the flue products from the building This vent system has specific v
81. h do not use any telephone in your building Immediately call your gas supplier from neighbor s telephone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department This appliance is a high efficiency pool heater which has been designed to operate scale free and trouble free for many years Particular attention should be directed to the following items Correct piping to the pool filter system with specified pipe materials and size Electrical interconnection of the pool heater controls bypass pump and filter pump to ensure continuous circulation Proper venting Water chemistry Follow all clearances from combustibles contained in this manual Appliance surfaces become hot during operation Be careful not to touch hot surfaces Keep all adults children and animals away from an operating pool heater Severe burns can occur This pool heater must have an adequate supply of fresh air during operation for proper gas combustion and venting Make sure all exhaust venting is properly installed and maintained Improper venting of this pool heater could lead to increased levels of carbon monoxide Do not use this pool heater if any part has been under water Immediately call a qualified service technician to replace the pool heater The possible damage to a flooded pool heater can be extensive and present numerous safety hazards Any appliance that has b
82. he control The second counter counts only ignition attempts that have failed The third and fourth counters are the same as the first and second respectively but can be reset by the installer Service reminder The control can be programmed for service reminder notification This notification will become active when either a set time frame has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will alternate the standard text on the display screen with Service Due every 5 seconds The service reminder notification can be reset by the installer Error logging The control will hold in memory the last 10 error codes as well as the last 10 turn off functions The date and time of the occurrence will be recorded as well Only the 10 most current occurrences will be held in memory Pool heater temperature regulation Operating temperature target The SMART SYSTEM control module senses water temperature and regulates appliance firing rate to achieve a target temperature The target temperature can be set between 40 F 4 5 C and 105 F 40 590 CIF Installation amp Operation Manual T Operating information continued Cascade When multiple appliances are installed they can be wired together in cascade sequence maximum of eight appliances can be controlled from single control In this application one appliance would be designated as the Leader control and all
83. he pool heater must be replaced use only type 105 C wire or equivalent Pool heater must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition 36 27 58 ni gt 34 34 58 _ __ 54 58 __ _ 73 32 74 _ 73 32 74 179 __ _ 73 ez 74 __ 102 73 67 ss 28 2072 73 67 88 EE nstallation amp Operation Manual Label all wires prior to disconnection when A CAUTION servicing controls Wiring errors can cause improper and dangerous operation Installation must comply with 1 National Electrical Code and any other national state provincial local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connections 1 Connect 120 power wiring to the line voltage terminal strip in the junction box as shown in FIG 5 2 2 Provide and install fused disconnect or service switch 15 AMP recommended as required by the code see FIG 5 2 3 To activate the unit wire as shown in FIG 5 2 If the motor is larger than 1 HP you must install contactor 4 When connecting power to units which are to cascaded each unit must be connected to the same ground connection UNIT UNIT PUMP SUPPLY SUPPLY 4 0 22 000 0 5 T V PUMP GROUND SPLICE reete e CHASSIS
84. his opening within 12 30 cm of the top of the enclosure Figure 1 3 Outside Combustion Air Two Openings 2 Outside Combustion Air Using Ducts You can direct outside combustion air to this unit using two air ducts to deliver the air to the mechanical room see FIG 1 5 Each of the two openings must have minimum free area of one square inch per 2000 Btu input 11cm per kW 3 Combustion Air from Interior Space You can direct combustion air to this unit using air from an adjoining interior space You must provide two openings from the mechanical room to the adjoining room see FIG 1 4 Each of the two openings must have a net free area of one square inch per 1000 Btu input 22cm per kW but not less than 100 square inches 645cm d Figure 1 4 Combustion Air from Interior Space Installation amp Operation Manual 1 Determine unit location continued 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
85. include DV box adapter and a rooftop air inlet cap 21 EE Installation amp Operation Manual 2 Venting Sidewall venting see page 14 C 22 NOTICE Before installing venting system follow all requirements found in the General Venting section This option uses powered vent assembly which pulls the flue products out of the stack This fan generates negative draft at the unit Combustion air is drawn from the equipment room see Combustion and Ventilation Air on 10 Sidewall with fan The sidewall fan can be mounted on the inside outside depending upon model with sidewall vent hood installed on the exterior wall The sidewall fan and accessories are included in a venting kit provided by the appliance manufacturer See Table 2C on page 24 for kit numbers The venting kit includes the sidewall fan vent hood tapered vent adapter barometric damper 992 2072 Models proving switch and all necessary relays to interlock with the heaters control system The tapered vent adapter reduces the vent size at the inlet to the fan There should be no reduction in vent diameter from the unit s flue outlet to the sidewall fan The barometric damper must be installed on the flue and adjusted to supply a negative draft within the range of 0 02 to 0 08 inches w c while unit is operating Flue outlet piping With this venting option you must use Type B double wall or equivalent vent materials Vent material
86. ing 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 and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 voltage does occur under any condition check and correct the external wiring 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Allow the pool heater to cycle Check vent and air piping Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual 46 COPPER FIN2 Installation amp Operation Manual Placing the pool heater in operation Pool heater operational checks 1 Turn the pool heater main power switch to the ON position 2 Verify operation of the SMART SYSTEM control module and Operator Interface 3 Program the adjustable points from the Operator Interface 4 Push the reset for the low water cutoff if equipped 5 Ensure that flow requirements and approximate temperature rises shown in Table 4B on page 35 are met Verify by checking rises while the unit is at 100 of rated input 6 Installa manometer on
87. installing Damaged burners must be replaced When installed in a dusty and dirty location the burners may require cleaning on a 3 to 6 month schedule or as needed based on severity of contamination Contaminants can be drawn in with the combustion air Non combustible particulate matter such as dust dirt concrete dust or dry wall dust can block burner ports and cause non warrantable failure The standard inlet air filter will help eliminate dust and dirt from entering the unit Use extreme care when operating a unit for temporary heat during new construction The burners could require a thorough cleaning before the unit 15 placed in service 8 Maintenance continued Inspect and clean the heat exchanger 1 While burners are removed check the heat exchanger surface for sooting If present heat exchanger must be cleaned and problem corrected Proceed as follows 2 Remove gas manifold s orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning page 60 3 Disconnect wiring from the hot surface igniter and remove igniter from the door panel to prevent damage to the igniter 4 Remove inner jacket panel mounting screws and slide door assembly out toward front of the unit Use caution to prevent damage to the refractory 5 Check V baffles and frame runners along front and back edges of heat exchanger Remove and clean if necessary 6 Remove soot from heat exchanger with a stiff bristle brush
88. ion 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 vent system requires you to install two pipes directly to the unit one pipe for flue products and one for combustion air Install both pipes horizontally with a sidewall termination point For this HARE venting option you must purchase the DV box accessory from the appliance manufacturer The DV box attaches to the air inlet of the unit The pipe for combustion air attaches to the DV box see FIG 2 11 on page 28 Reference page 28 for a list of approved air intake materials Make vent connection directly to the top of the unit No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and a negative draft maintained between 0 02 to 0 08 inches w c The Horizontal DirectAire combustion air supply system has specific vent material and installation requirements The air inlet pipe connects directly to the pool heater to supply combustion air The combustion air inlet pipe is a dedicated system with one air inlet pipe per pool heater You must connect the air inlet pipe to a combustion air inlet cap as specified in this section Combustion air supplied from outdoors must be free of contaminants
89. ipment which exhausts air from the mechanical room may deplete the combustion air supply and or cause down draft in the venting system Spillage of flue products from the venting system into an occupied living space can cause very hazardous condition that must be immediately corrected If a fan is used to supply combustion air to the mechanical room the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the pool heater Vertical DirectAire Horizontal DirectAire and Direct Vent venting systems have specific requirements for combustion air ducts from the outside which are directly connected to the unit See the requirements for combustion air duct in the venting section NOTICE Use of filters having MERV Minimum Efficiency Reporting Value ratings higher than 4 is not recommended Higher efficiency low micron filters can limit combustion air leading to either nuisance problems or potential component damage if used over prolonged periods of time Filters having a MERV rating of 5 to 6 may be used on a limited basis during the construction phase of a project provided they are replaced once filter loading becomes apparent After the construction phase is completed it is recommended that the filter be changed to a 4 or lower MERV disposable type filter COPRER EIN Installation amp Operation Manual Combustion air filter This unit has a standard air filter
90. ired 4 To avoid serious damage DO NOT energize the appliance until the system is full of water Ensure that all air is removed from the heat exchanger and piping before beginning initial operation Serious damage may result if the appliance is operated without proper flow 5 Provide the appliance with proper overload protection NOTICE DO NOT block access to the electrical cover plate when installing electrical conduit Figure 5 1 Control Panel Component Location ICOPRER FIN Installation amp Operation Manual 3 way automatic bypass valve wiring If the piping loop was disassembled for shipping or needs to be fitted with an outdoor enclosure connection or disconnection of the 3 way automatic bypass valve will be required Wiring connections should be made to the appropriately numbered terminals on the 3 way automatic bypass valve as follows TABLE 5A 3 Way Automatic Bypass Valve Wiring FIELD FACTORY Color 3 Way Valve Low Voltage O Wire Board Note Orientation of the valve connections may vary from what is shown Care should be taken to ensure wires are connected to the appropriate terminals see FIG 4 8 on page 39 of this manual A WARNING Power must be removed and the clutch button must be depressed before attempting to manually operate the valve or damage to the 3 way valve may occur TABLE 5B Remote Wire Connection Wire Maximum Gauge Allowable Length MAIN CONTROL BOARD TRANSFORM
91. l Metal Fab Inc Corr Guard Vent with AL29 4C stainless steel Or other listed Category IV vent systems suitable for a condensing positive pressure gas fired appliance A Category IV flue MUST have all vent joints and seams sealed gastight and have provisions for a drain to properly collect and dispose of condensate that may occur in the venting system 13 eem Installation amp Operation Manual 2 Venting Ve nt syste m opt Ions Note Installations shown below are representative actual installations may vary from those shown This option uses a powered vent assembly to exhaust the flue products out a sidewall with air supplied by a pipe from the sidewall see page 25 This option uses a vertical rooftop flue termination with air supplied from the equipment room see page 16 HORIZONTAL DIRECTAIRE VENTING CONVENTIONAL NEGATIVE DRAFT VENTING NOTE CAT I B VENT MATERIALS MAY BE USED WHEN THE POWERED VENT IS CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP IF THE POWERED VENT IS NOT CONNECTED DIRECTLY TO THE OUTSIDE VENT CAP THEN CAT IV AL29 4C VENT MATERIALS MUST BE USED FROM THE POWERED VENT TO THE OUTSIDE VENT J MIN CE D Tu 3l This option uses a vertical conventional vent for This option uses a sealed AL29 4C flue and
92. lations are made In the absence of such requirements the installation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code All pool heater heat exchanger construction conforms to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Part HLW To minimize the possibility of serious personal injury fire or damage to your unit never violate the following safety rules 1 Pool heaters are heat producing appliances To avoid damage or injury do not store materials against the pool heater or the vent air intake system Use proper care to avoid unnecessary contact especially children with the pool heater and vent air intake components COPRERTEINZS Please read before proceeding 10 11 12 Installation amp Operation Manual Never cover your pool heater lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to your pool heater UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this pool heater vent air intake system or any location from which fumes could reach the pool heater or vent air intake system This pool heater is only for use with the type of gas indicated on the rating plate If smell gas shut off the gas supply Do not try to light any appliance Do not touch any electrical switc
93. least three 3 feet downstream from the point where the heated water from the pool heater is being added to the filtration system Note In order to accurately sense water temperatures both sensors need to be in the actual water flow Installation of return and supply sensors Both pool sensors are immersion type sensors with 1 4 NPT threads and may be installed directly into the system piping by drilling 7 16 pilot holes and tapping them with a 1 4 NPT tapered tap Apply a small amount of high quality RTV silicone sealant to the threads to prevent leaks and install the sensors into the threaded openings in the PVC pipe Over tightening can damage the parts and or strip the threads cut into the plastic pipe Sensor connections The sensors are connected to the pool heater from the factory The return sensor is a two wire sensor and the supply sensor is a four wire sensor Disconnects are provided for each sensor If disconnected to facilitate installation re connection is necessary after installation If sensors must be located further than allowed by the cables provided any extension cabling must be of equivalent type and wire gauge see Table 5B on page 41 of this manual for recommended gauges IMPORTANT If the unit is to be installed outdoors weatherproof connections must be provided over all sensor connections 35 4 Water connections Installation amp Operation Manual Figure 4 3 Heater Within 15 feet of Pool Pi
94. llage of flue products can cause personal injury or death due to carbon monoxide poisoning For single unit installations with sidewall air inlet you must order the sidewall air inlet kit from the appliance manufacturer The part number for each SVK kit is listed by unit size in Table 2B For single unit installations with rooftop air inlet see FIG 2 8 you must order the rooftop air inlet kit from the appliance manufacturer The part number for each VDK kit is listed by unit size in Table 2B Purchase the flue pipe rooftop flue termination and air inlet pipe locally There is no vent kit for combined air supply systems for multiple units Make sure the air inlet cap is properly sized You must purchase this cap locally Venting of flue products For venting flue products vertically to the outdoors follow all requirements in the installation instructions for conventional venting in this manual Follow all clearance requirements in Vertical Vent Termination Clearances and Location on page 17 A barometric damper is not required in the flue on Vertical DirectAire installations if the draft is within the negative 0 02 to 0 08 inches w c required for proper operation If the draft exceeds this range install a barometric damper DIRECTAIRE KITS SVK3040 VDK3023 1262 SVK3041 VDK3024 1442 SVK3041 VDK3024 1802 SVK3041 VDK3024 2072 SVK3041 VDK3024 The SVK kits include DV box adapter and sidewall air inlet cap The VDK kits
95. lling venting system follow all requirements found in the General Venting section 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 No additional vent piping is required A WARNING Only install outdoor models outdoors and only use the vent cap supplied by the appliance manufacturer Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors Properly install all covers doors and jacket panels to ensure proper operation and prevent hazardous condition Combustion air supply must be free of contaminants see Combustion and Ventilation Air page 10 To prevent recirculation of the flue products into the combustion air inlet follow all instructions in this section Outdoor vent air inlet location Keep venting areas free of obstructions Keep area clean and free of combustible and flammable materials Maintain minimum clearance of 3 76 mm to combustible surfaces and minimum of 36 915 mm clearance to the air inlet To avoid blocked air inlet or blocked flue condition keep the outdoor cap air inlet flue outlet and drain slot clear of snow ice leaves debris etc Do not install outdoor models directly on the ground You must install the outdoor unit on concrete brick block or other non combustible pad Do not locate
96. lures EH EAA Installation amp Operation Manual 2 Venting BEFORE YOU BEGIN 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 CP N L 0502 CP N L 0652 CP N L 0752 CP N L 0992 CP N L 1262 CP N L 1442 CP N L 1802 CP N L 2072 Venting options Direct Vent Options CAT IV Outdoor Vent Option Failure to use correct venting materials can result in loss of life from flue gas spillage into working or living A DANGER ice B Vent Material CAT Venting Category Definitions Reference National Fuel Gas Code ANSI 2223 1 CAT Negative pressure non condensing An appliance that operates with a non positive vent static pressure with a vent gas temperature that avoids excessive condensate production in the vent CAT IV Positive pressure condensing An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause excessive condensate production in the vent CAT IV Flue pipe materials The following manufacturers supply flue materials suitable for these models when installed as CAT IV All materials are made with AL29 4C stainless steel Heat Fab Inc Saf T CI Vent with AL29 4C stainless steel Protech Systems Inc Fas N Seal Vent with AL29 4C stainless stee
97. manufacturer s instructions A WARNING wl ade Failure to do so can result in property damage personal injury or death Mixing of venting materials will void the warranty and certification of this unit Sealing Type B double wall vent pipe or galvanized vent pipe Follow the steps below to properly seal Type B double wall vent pipe or galvanized vent pipe 1 Sealall joints and seams of the air inlet pipe using either aluminum foil duct tape meeting UL Standard 723 or 181 A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric 2 On horizontal runs do not install vent pipe with seams pointing down Position vent pipe so that the seams are on the top side of the vent pipe 3 Secure all joints with a minimum of three sheet metal screws or pop rivets Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe 4 Ensure that the air inlet pipes are properly supported Sealing PVC CPVC ABS dryer vent and flex duct vent pipe 1 Clean the PVC CPVC or ABS air inlet pipe using the pipe manufacturer s recommended solvents Seal the pipe joints using standard commercial pipe cement 28 HU Installation amp Operation Manual 2 Ventin continued 2 For ABS dryer vent or flex duct air inlet piping use silicone sealant to ensure proper seal at the unit inlet and the air inlet cap For Dryer vent or flex duct
98. mum specified clearances for adequate operation Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the unit See rating plate for specific service clearance requirements Installation amp Operation Manual Right Side 3 7 5 cm Rear 3 7 5 cm 3 min from any surface Left Side 6 15 24 0 61 m suggested for service Front Alcove 30 0 76 suggested for service Top 3 7 5 cm Flue 1 25 4 mm Hot Water Pipes 1 25 4 mm An Alcove is a closet without door Thirty six inches 36 to rear required for outdoor installation Note No additional clearance is needed on the right side of the unit for the observation port An observation port is located on both the right and left side of the unit Figure 1 1 Indoor clearances from combustible construction RIGHT SIDE TOP 30 MIN FRONT NOTICE TABLE 1A COMBUSTIBLE FLOOR KITS Clearances from combustible construction are noted on the appliance rating plate CFK3302 CFK3303 CFK3304 Freeze protection Although these units are CSA International design certified for outdoor installations such installations are not recommended in areas where the danger of freezing exists You must provide proper freeze protection for outdoor installations units installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower If freeze protection is not provid
99. n is drawn through a filter provided at the air intake located at either the rear or right side of the appliance Line voltage terminal strip The line voltage terminal strip provides a location to connect all of the line voltage 120 VAC contact points to the unit COPPER RINA 15 16 17 18 19 20 21 22 23 24 25 Installation amp Operation Manual Low voltage connection board The low voltage connection board provides location to connect all of the low voltage devices to the appliance This is where most of the external safety controls are connected Front doors upper and lower The front doors provide access to the gas train as well as the blower burners and other key components for service and maintenance Hot surface igniter HSI The hot surface igniter is a device that is used to ignite the air gas mixture as well as monitor the performance of the flame during operation This device acts as a flame sense electrode Flame inspection window sight glass The flame inspection windows located on either side of the appliance allow for visual inspection of the burners and flame during operation Manual reset high limit sensor This device monitors the outlet water temperature to ensure safe operation If the temperature exceeds its setting field adjustable it will break the control circuit shutting the appliance down Manual reset is performed through the display Relief valv
100. nce if any part has been under water Immediately call a qualified service technician to inspect Do not touch any electrical switch do not use the appliance and to replace any part any phone in your building of the control system and any gas con trol which has been under water Do not try to light any appliance Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information above on 5 Push in gas control knob slightly and this label turn clockwise to OFF 2 Turn off all electric power to the appliance 3 Open control access panel NOTE On the 36C valve knob cannot be turned to OFF unless knob is pushed in 4 This appliance is equipped with an ignition slightly Do not force device which automatically lights the burner Do not try to light the burner by hand Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Turn gas control knob counterclockwise to ON E Replace control access panel Turn on all electric power to the appliance If the appliance will not operate follow GAS CONTROL KNOB the instructions To Turn Off Gas To Appliance and call your service tech SHOWN IN THE ON POSITION 2 nician or gas supplier TO TURN OF
101. nd Equipment or applicable provisions of the local building codes Provide properly sized openings to the equipment room to assure adequate combustion air and proper ventilation when the unit 15 installed with conventional venting or sidewall venting Combustion air options A CAUTION Under no circumstances should the equipment room ever be under a negative pressure Particular should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the unit This unit has four combustion air options 1 Outside Combustion Air No Ducts You can direct outside combustion air to this unit using either one or two permanent openings One Opening The opening must have a minimum free area of one square inch per 3000 Btu input 7 cm per kW You must locate this opening within 12 30 cm of the top of the enclosure see FIG 1 2 10 COPRER FING Installation amp Operation Manual Figure 1 2_Outside Combustion Air Single Opening Two Openings The combustion air opening must have a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW You must locate this opening within 12 30 cm of the bottom of the enclosure see FIG 1 3 The ventilation air opening must have a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW You must locate t
102. nd including up to 4 500 feet with no field adjustments The appliance will de rate by 4 for each 1000 feet above sea level up to 4 500 feet Consult the factory for installations above 4 500 feet elevation 1 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 and ANSI Z21 10 3 CSA 4 3 latest edition 1 10 Indoor Maintain all clearances from combustible construction when locating appliance See Clearances from Combustible Construction this page Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that suitable drain pan adequately drained be installed under the unit The pan must not restrict combustion airflow Under circumstances is the manufacturer to be held responsible for water damage in connection with this unit or any of its components The appliance must be installed so that the ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and
103. nduit hose into the conduit fitting and reinstall the conduit cap Note If the wing nut underneath the valve actuator body is loose retighten 9 Reinstall the plastic actuator cover and secure with the screw loosened in Step 2 10 Place the valve cover JKD6652 over the 3 way automatic bypass valve Install the end caps JKD6653 and JKD6654 using the four screws provided in the kit BLT7901 as shown in FIG 4 9 11 Turn the power on to the unit and resume operation E un Installation amp Operation Manual Note The actuator handle is not used when the outdoor cover is installed The handle is attached to the underside of the actuator for storage Figure 4 8 3 Way Valve Cover Connection Diagram NOTE Refer to the numbers located next to the terminals when making wiring connections R TO TERMINAL 5 BK TERMINAL 6 TERMINAL 7 BL TO TERMINAL 19 LOW VOLTAGE BOARD FACTORY CONNECTIONS 3 WAY VALVE CIRCUIT BOARD FIELD CONNECTIONS Figure 4 9_3 Way Valve Cover END CAP JKD6654 VALVE COVER JKD6652 3 PLASTIC ACTUATOR COVER END CAP JKD6653 INSTALLED VIEW EXPLODED VIEW Manual operation of the 3 way automatic bypass valve actuator To manually operate the 3 way automatic bypass valve actuator 1 Power must be removed from the unit 2 Once power is removed the de clutch button located on the side of the valve actuator body can be pressed C
104. nect directly to the outdoors The total length of the combined air inlet pipe must not exceed a maximum of 50 15 2 m equivalent feet Subtract 5 feet 1 5 m for each 90 elbow in the air inlet pipe You must deduct the restriction in area provided by any screens grills or louvers installed in the common air inlet point These are common on the sidewall air inlet openings Screens grills or louvers installed in the common air inlet can reduce the free area of the opening from 2596 to 7596 based on the materials used You can terminate the combustion air pipe either horizontally with a sidewall air inlet or vertically with a rooftop air inlet The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet 15 2 m 20 2 Ventin Q continued EE Installation amp Operation Manual Only use sidewall air inlet cap supplied by the appliance A WARNING manufacturer or rooftop air inlet cap supplied by either the vent MIN Figure 2 8 Vertical DirectAire Installation w Rooftop Combustion Air Inlet or appliance manufacturer Using any other air inlet cap for single unit installations or using common air inlet cap for multiple units with insufficient free area and or protections from wind and weather may result in operational problems and the spillage of flue products Spi
105. ner of an L shaped structure Horizontal combustion air inlet clearances You must locate the horizontal air inlet termination point at least 12 30 cm above grade and above normal snow levels If the air inlet cap is within a 10 foot 3 05 m radius of the flue outlet the point of termination for the combustion air inlet cap must be at least 3 feet 0 91 m below the point of flue gas termination vent cap Do not install the horizontal combustion air inlet cap above the flue outlet Do not install the combustion air inlet cap closer than 10 feet 3 05 m from an inside corner of an L shaped structure Multiple sidewall direct vent installations You must locate the horizontal air inlet termination points at least 12 30 cm above grade and above normal snow levels The combustion air inlet caps for multiple appliance installations must maintain the same minimum clearance from the closest flue vent cap as specified in single appliance installations You may install multiple flue outlet caps side by side and multiple combustion air inlet caps side by side but the air inlet must always be at least 3 feet 0 91 m horizontally and 3 feet 0 91 m below the closest flue outlet Do not install combustion air inlet caps above the flue outlets Maintain all clearances and installation requirements for multiple appliance installations 29 EO Installation amp Operation Manual 2 Venting F Outdoor installation see page 14 NOTICE Before insta
106. ng Management Systems to verify that the pool heater is responding to a call for heat 3 way valve out An electric 3 way mixing valve is used to maintain 130 55 C temperature to the heater Connect the Open output to the Open terminal on the 3 way valve Connect the Close output to the Close terminal on the valve and the COM output to the 24VAC terminal on the valve Reference the wiring diagram on page 39 of this manual 0 10V rate out A 0 10VDC signal is available to allow a Building Management System BMS to monitor the firing rate of the heater Make sure the terminal is connected to the or common terminal of the external control and the 4 terminal 1s connected to the or terminal of the external control Building Management System BMS 1 An external control may be connected to control either the firing rate or the set point of the pool heater Connect the 0 10 VDC terminals to the 0 10 VDC output of the external control The SMART SYSTEM control can be programmed to use the enable output of the BMS or use the voltage signal to enable the heater A BMS or a remote thermostat can be connected to the S1 terminals to enable or disable the unit in place of the factory provided jumper wire 2 Make sure the ground terminal is connected to the ground output terminal of the external control and the 0 10 V BMS IN terminal is connected to the 0 10 VDC terminal of the external control 43 5 Elec
107. nput from appliance sensors and external devices The control module activates and controls the blower and gas valves to regulate heat input and switches the pool heater and system pumps on and off as needed The user programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and appliance operating modes Pool heater operation is based on pool heater return temperature Control inputs and outputs Staging S1 S4 The 51 input tells the pool heater to provide water for space heating The S2 S4 inputs are not used Remote Aquastat EMS This input can be used to remotely enable disable the pool heater SE E Installation amp Operation Manual Pool heater pump operation The pool heater s unit pump will turn on whenever there is a call for heat based on the set point of the pool return water and it will remain on as long as the unit is firing Once set point is achieved the pump will complete a purge cycle to remove any residual heat from the heat exchanger and will then turn off Note If the pump s pre running feature is active the pump will run for several minutes prior to the unit firing in order to purge any air from the pool system that may have become entrapped during extended periods of inactivity Pool return programmed as controlling sensor The pool heater controller is programmed from the factory to utilize the pool return sensor as the controlling sensor The p
108. o show system piping concept only the installer is responsible for Corr FINA 4 Water connections continea Installation amp Operation Manual Figure 4 5 Cascaded heaters Within 15 feet of Perpendicular Pool Piping COPPER OR CPVC SEE TABLE AUTOMATIC POOL PVC MIN BYPASS VALVE RETURN SEE TABLE SENSOR SECONDARY LOCATION RECOMMENDED ISOLATION VALVE COPPER OR CPVC SEE TABLE FROM POOL REQUIRED POOL RETURN SENSOR LOCATION MODEL NO BYPASS PIPE SIZE CP N L 502 752 2 MIN CP N L 992 2072 2 1 2 MIN POOL RETURN SENSOR PRIMARY LOCATION NOTE IF THE RETURN SYSTEM SENSOR IS LOCATED IN THE SECONDARY LOCATION SHOWN ON THE PIPING DIAGRAM THE UNIT PUMP MUST RUN CONTINUOUSLY TO ENSURE THE WATER FLOW PAST THE SENSOR IS MAINTAINED Figure 4 6 Cascaded Heaters Beyond 15 feet of Pool Piping POOL AUTOMATIC FROM RETURN BYPASS gx POOL SENSOR VALVE Er SECONDARY 1 POOL LOCATION 32 Y RETURN x SENSOR PRIMARY 2 LOCATION MG gt A 4 gt AJ sE FLOWMETER REQUIRED A BERE 27 Jd 3 SENSOR E LOCATION Pd RECOMMENDED 2 ISOLATION VALVE P4 MON I N PA CK 24 ae COPPER lt f a OR PVC PA gt d SEE A TABLE Fw P 4 NOTE IF THE RETURN SYSTEM SENSOR IS LOCATED IN THE SECONDARY
109. oducts to leak from the chimney and into occupied living spaces This could cause serious injury or death due to carbon monoxide poisoning and other harmful flue products NOTICE Check with local code officials to determine code requirements or the advisability of using a masonry chimney with a sealed corrosion resistant liner system Inspection of a masonry chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products A clay tile lined chimney must be structurally sound straight and free of misaligned tile gaps between liner sections missing sections of liner or any signs of condensate drainage at the breaching or clean out If there is any doubt about the condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system An unlined masonry chimney must not be used to vent flue products from this high efficiency unit An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner systems Type B double wall or flexible or rigid metallic liners are recommended Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney Vertical vent termination clearances and location The vent terminal should be vertical and exhaust outside the building at least 2 feet 0 61 m above the highest point of the roof within a 10 foot 3 05
110. ool return sensor is required to be the controlling sensor and CANNOT be changed by either the installer or the end user Anti cycling After the set point has been satisfied the control will delay the next burner cycle for a set time period time is adjustable by the installer The time delay will be bypassed if the system return temperature drops too far during the delay Firing rate Depending upon the model the Copper fin is capable of staging its firing rate from a minimum of 2596 to a maximum of 100 The firing rate is dictated by the call for heat 1 pool return temperature the heating load and various other temperature limitations Gradient limiting If during operation of the heater the outlet water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Night setback The controller may be programmed to reduce the set point during a certain time each day A start and stop time can be programmed for each day of the week Protection features Outlet temperature and temperature rise limiting The outlet temperature is monitored by the pool heater outlet temperature sensor When the outlet temperature exceeds 180 F 82 C the unit will reduce the firing rate If the outlet water temperature exceeds 200 93 C the control will shut the unit down until it cools off 49 T Operating information The control monitors the temperature difference between the inlet and the
111. ors and stacks Follow the vent manufacturer s instructions when installing Type B vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls ceilings and floors Locate the unit as close as possible to a chimney or gas vent Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and a negative draft maintained between 0 02 to 0 08 inches w c Common Venting Systems You can combine the flue with the vent from any other negative draft Category I appliance Using common venting for multiple negative draft appliances requires you to install a barometric damper with each unit This will regulate draft within the proper range You must size the common vent and connectors from multiple units per the venting tables for Type B double wall vents in the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Common venting systems may be too large when an existing unit is removed At the time of removal of an existing appliance the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation whil
112. ping AUTOMATIC BYPASS VALVE MODEL NO BYPASS PIPE SIZE N L 502 752 2 MIN CP N L 992 2072 2 1 2 MIN NOTE POOL RETURN SENSOR SECONDARY LOCATION PVC MIN SEE TABLE COPPER OR PVC SEE TABLE POOL REQUIRED POOL RETURN SENSOR LOCATION IF THE RETURN SYSTEM SENSOR IS LOCATED IN THE SECONDARY LOCATION SHOWN ON THE PIPING DIAGRAM THE UNIT PUMP MUST RUN CONTINUOUSLY TO ENSURE THE WATER FLOW PAST THE SENSOR IS MAINTAINED RECOMMENDED ISOLATION VALVE FROM POOL POOL RETURN SENSOR PRIMARY LOCATION Figure 4 4 Heater Beyond 15 feet of Pool Piping AUTOMATIC 4 BYPASS VALVE MODEL NO BYPASS PIPE SIZE CP N L 502 752 2 MIN CP N L 992 2072 2 1 2 MIN NOTICE 36 all equipment and detailing required NOTE IF THE RETURN SYSTEM SENSOR IS POOL RETURN SENSOR SECONDARY LOCATION PVC MIN SEE TABLE OR PVC SEE TABLE RECOMMENDED ISOLATION VALVE 12 REQUIRED POOL RETURN SENSOR LOCATION by local codes LOCATED IN THE SECONDARY LOCATION SHOWN ON THE PIPING DIAGRAM THE UNIT PUMP MUST RUN CONTINUOUSLY TO ENSURE THE WATER FLOW PAST THE SENSOR IS MAINTAINED FROM POOL POOL RETURN SENSOR MAX PRIMARY LOCATION OR 2 4X PIPE 3 DIAMETERS MIN Please note that these illustrations are meant t
113. re cut square deburred and clean Make all tubing bends smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide unit with proper volume of gas 3 Install a manual main gas shutoff valve at the unit s gas inlet outside of the unit 4 Run pipe or tubing to the unit s gas inlet If you use tubing obtain a tube to pipe coupling to connect the tubing to the unit s gas inlet 5 Install a sediment trap in the supply line to the unit s gas inlet see FIG 3 1 6 Apply a moderate amount of good quality pipe compound do not use Teflon tape to pipe only leaving two end threads bare 2 Remove seal over gas inlet to unit Connect gas pipe inlet of unit Use wrench to support gas manifold on the unit 9 For L P gas consult your L P gas supplier for expert installation 10 Ensure that all air is completely bled from the gas line before starting the ignition sequence Start up without properly bleeding air from the gas line may require multiple reset functions of the ignition control module to achieve proper ignition Do not have any open flame in proximity to A WARNING the gas line when bleeding air from the gas line Gas may be present Gas train and controls NOTICE The gas train and controls assembly provided on this unit have been tested under the applicable American National Standard to meet minimum safety and performance criteria such as safe ligh
114. repairs may create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty hot surface igniter or control module must be replaced with an identical part specification igniter and control module for this specific unit is available from your local distributor Do not use general purpose field replacement control modules or igniters Ignition system checkout 1 Turn off gas supply to unit 2 Turn electric power on 3 Adjust the set point on the temperature control to a setting above water temperature or to the highest safe setting 4 The igniter will cycle on trial for ignition 5 control module will lock out and turn the alarm light on 6 Adjust the Set Point Differential and High Fire Offset to the desired settings 7 Turn on gas supply 8 Press the RESET button at the electronic display panel to reset the control module 9 If ignition system fails to operate properly repair work must be performed by a qualified service person or installer Check all wiring 1 Inspect all wiring making sure wires are in good condition and securely attached Check control settings 1 Set the SMART SYSTEM control module display to Parameter Mode and check all settings Reference the Copper fin Service Manual for how to adjust settings and parameters Adjust settings if necessary 2 Check settings of external limit controls if any and adjust if necessary
115. rogram this into the control Press the MENU key twice to exit the control parameters Repeat this procedure for all appliances in the Cascade designating the Leader control and the Member controls T Operating information General How the appliance operates The Copper fin uses a copper finned tube heat exchanger to transfer heat from the flue products to the water An electronic control module monitors various inputs to initiate a call for heat The blower provides both primary and secondary air to the burner and forces the flue products out of the combustion chamber and into the vent system The control module regulates the blower speed and firing stages based upon the heat demand Gas valves regulate the amount of gas supplied for the firing stages which is then mixed with the combustion air supplied to the burner NOTICE If an inline high gas pressure regulator is used it MUST BE of the lockup type and be located a minimum of 10 feet from the appliance Failure to do so may result in insufficient gas volume supplied to the appliance If a pressure drop of more than 2 water column occurs between Standby static Mode and Operating dynamic Mode a gas volume problem exists Contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide the proper gas volume to the appliance NOTICE How the control module operates The SMART SYSTEM control module receives i
116. s must be listed by a nationally recognized test agency for use as vent materials Make the connections from the unit vent to the sidewall fan cap as direct as possible with no reduction in diameter Follow the vent manufacturer s instructions when installing Type B vents and accessories such as firestop spacers vent connectors thimbles caps etc When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls The maximum installed length of sidewall vent pipe with an induced draft fan must not exceed 100 feet 30 5 m Subtract 5 feet 1 5 m for each 90 elbow Subtract 2 5 feet 0 7 m for each 45 elbow Sidewall venting termination The sidewall vent cap must be installed on an exterior sidewall The sidewall fan powered sidewall vent cap and accessories are included in a venting kit which is furnished by the appliance manufacturer in accordance with CSA International requirements This venting kit includes the powered sidewall fan cap proving switch and all necessary relays to interlock with the heaters control system The sidewall fan powered vent cap must be interlocked with the units control system to start the fan on a call for heat and prove fan operation before the pool heater fires Plug in and terminal strip connections are provided on the unit for easy connection of the factory supplied vent kit and control package for the sidewall vent fan See the installation instructions provided with th
117. safe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the appliance until a new relief valve has been installed A WARNING 2 After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing COPPER EINE Installation amp Operation Manual Inspect replace hot surface igniter This unit uses a proven SMART SYSTEM control module and a hot surface igniter The SMART SYSTEM control module is not repairable Any modification or repairs will invalidate the warranty A WARNING Do not attempt to repair a faulty hot surface igniter or control module Any modification or
118. see the Combustion and Ventilation Air section on page 10 You must order the Horizontal DirectAire Vent Kit for sidewall installation from the appliance manufacturer See Table 2D for kit numbers Each kit includes a sidewall powered vent cap fan proving switch controls combustion air inlet cap to supply air to a single unit the transition adapter to attach the field supplied single wall air inlet pipe to the unit and installation instructions Purchase flue pipe and air inlet pipe locally The sidewall air inlet cap supplied in the Horizontal DirectAire Vent Kit is used to supply combustion air to a single pool heater Combustion air supply pipes from multiple units can not be combined into a single air inlet pipe and inlet point A WARNING Only use the sidewall air inlet cap recommended by the appliance manufacturer Using another sidewall air inlet cap may result in operational problems and the spillage of flue products Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning Venting of flue products For venting flue products horizontally follow all requirements in the installation instructions for sidewall venting Termination point for the flue products must follow the clearance requirements in the Sidewall Venting Termination section on page 22 For proper operation a barometric damper is provided for Horizontal DirectAire installations The damper will help to ensure a draft between ne
119. sensor wires or the sensor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 2 HTR RUN STG Screen 2 INLET F The inlet temperature is displayed by the control Line 1 INLET OPEN The control does not detect the inlet sensor INLET SHORTED The inlet sensor wires or the sensor itself has become shorted Screen 2 RISE OF The difference between the inlet temperature and the outlet temperature Line 2 is displayed Press the Next P arrow key on the SMART SYSTEM display to access Screen 3 SYSSUP F The system supply temperature is displayed by the control Screen 3 SYSSUP OPEN The control does not detect the system supply sensor Line 1 SYSSUP SHORTED The system supply sensor wires or the sensor itself has become shorted Installation amp Operation Manual T Operating information Status Display Screens cont d By using the Previous Next 4 gt 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 Display shows The system return sensor acts as the control sensor The control SYSRIN pU will display the system return temperature as well as the set point in Screen 3 parenthesis Line 2 SYSRTN OPEN The control does not detect the sy
120. stem return sensor SYSRTN SHORTED The system return sensor wires or the sensor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 4 N A Press the Next P arrow key on the SMART SYSTEM display to access Screen 5 y vidi STG DEMAND The control displays the number of stages firing based upon demand me Press the Next arrow key on the SMART SYSTEM display to access Screen 6 Screen 6 Line I The control will display either OFF LOW or HIGH depending upon FAN SPEED fan speed requirements of number of stages firing Screen 6 0 10V RATE V The control will display 0 to 10 volts based upon fan speed and unit Line 2 capacity Press the Next arrow key on the SMART SYSTEM display to access Screen 7 Screen 7 The control will display either ON or OFF based upon demand call for heat for heat Line 1 Press the Next P arrow key on the SMART SYSTEM display to access Screen 8 Screen 8 SYS PUMP Line 1 Press the Next P arrow key on the SMART SYSTEM display to access Screen 9 UNIT PUMP The control will display either ON or OFF based upon unit pump requirements upon demand The control will display delay in unit pump operation after the heat requirements have been satisfied The control will display either ON or OFF based upon system pump requirements upon demand Screen
121. system to the pool heater is made directly to the bypass piping on the pool heater Outdoor operation 3 way valve cover If the pool heater is to be installed outdoors the 3 way valve must be protected from the elements A cover for the 3 way valve is included with the outdoor vent kits for all models see Table 2F on page 30 Automatic bypass valve cover installation The pump supplied on the pool heater bypass has a sealed motor suitable for outdoor installations When installing the 3 way automatic bypass valve outdoors an outdoor valve cover is required outdoor valve cover is supplied with an optional outdoor vent kit see Table 2D page 25 of this manual To install the outdoor valve cover follow the steps below 1 Turn off power to the unit 2 Remove the plastic actuator cover from the 3 way automatic bypass valve by loosening the screw above the conduit fitting FIG 4 9 3 Grasp the cover on the screw side and lift the cover up and away from the valve 4 Disconnect the wires connected at the terminal block if 5 Unscrew the plastic conduit cap from the conduit fitting FIG 4 9 and pull the plastic conduit hose and wires from the valve 6 Feed the plastic conduit hose through the opening of the valve cover end cap JKD6654 see FIG 4 9 and slide the end cap approximately one foot up the conduit 7 Reconnect the wires to the 3 way valve circuit board as shown in FIG 4 8 8 Feed the co
122. t outer jacket flue pipe connections burner or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted units seldom need flue cleaning NOTICE All gaskets sealants on disassembled components or jacket panels must be replaced with new gaskets sealants on reassembly Gasket and sealant kits are available from your distributor When a Category IV vent system is A CAUTION 22 disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions Inspect and clean burner Turn off main power to unit Turn off main manual gas shutoff to unit Remove the front outer jacket panels ps aee Disconnect manifold from gas train using union s just below each gas valve s 5 Remove mounting screws from manifold mounting brackets Pull the manifold orifice assembly away from burners Repeat for each manifold assembly 6 Remove two mounting screws from burner and slide burner out toward front of unit Use caution to prevent damage to burners refractory hot surface igniter or wiring 7 Remove soot from burners with a stiff bristle brush Dirt may be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re
123. th the screw holes surrounding the air filter hanger Insert sheet metal screws and tighten firmly For venting versatility you can move the air filter assembly and DV box adapter to the right side of the unit Remove the metal panel on the unit s right side see FIG 2 12 Remove the filter bracket assembly from the rear of the unit Attach the filter bracket assembly and DV box adapter to the right side opening using the pre drilled screw holes Make sure you attach the metal panel to the rear combustion air opening of the unit The DV box adapter has an air inlet pipe mounting ring Connect combustion air inlet piping to the direct vent box mounting ring VERTICAL DV BOX ADAPTER HORIZONTAL DV BOX ADAPTER Figure 2 11 Attaching DV Box Adapter to Unit Figure 2 12 Moving Air Filter Assembly amp DV Box Adapter Air inlet piping materials The air inlet pipe s must be sealed Select air inlet pipe material from the following specified materials CPVC or ABS Dryer vent sealed flexible duct not recommended for rooftop air inlet Galvanized steel vent pipe with joints and seams sealed as specified below Type B double wall vent with joints and seams sealed as specified below Plastic pipe may require an adapter not provided to transition between the air inlet connection on the unit and the plastic air inlet pipe Use only vent or air intake materials specified in this manual Follow vent pipe
124. 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 Provide adequate clearance to combustibles for the vent connector and firestop Follow the vent manufacturer s instructions when installing sealed AL29 4C vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls ceilings and floors Locate the unit as close as possible to chimney or gas vent When a vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions The installed length of flue from the unit to the outside point of termination must not exceed 50 equivalent feet 15 2 m Subtract 5 feet 1 5 m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7 m of equivalent length for each 45 elbow Vertical DV venting termination Vertical venting uses the unit s internal combustion air blower to force the flue products out of the vertically terminated flue You must purchase a vertical direct vent kit from the appliance manufacturer to ensure proper operation You must use the vent termination recommended by the vent manufacturer for vertical direct vent terminations Follow all vertical
125. through the air inlet or from negative pressure in the equipment room In cold climates operate the pump continuously to help prevent freezing of pool heater water Provide proper freeze protection See Freeze Protection page 45 Sidewall venting without fan For Models 502 752 which are approved for sidewall venting without an external power vent fan you must install specific vent kits and venting materials reference Table 2C on page 24 for kit numbers The following is a detailed explanation of Sidewall Venting Without an External Power Vent Fan installation requirements Flue outlet piping Venting Guidelines If using this venting option a sealed AL29 4C venting system for flue products is required on all models of this appliance This venting system operates with a positive pressure in the vent The internal combustion air blower generates this positive pressure which operates the combustion process and also exhausts the flue products from the building This vent system has specific vent material and installation requirements Only use listed sealed AL29 4C vent system materials Follow all installation requirements See Table 2A for proper pipe size for your unit A list of sealed AL29 4C flue pipe manufacturers is located on page 15 Seal all vent joints and seams gas tight Drain tee installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee
126. times then turn off 52 T Operating information continued Copper fin control module SYSTEM SHANE Installation amp Operation Manual 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 DISPLAY SCREEN UP DOWN Press to change boiler water temperature and or tank water temperature set point during normal operation Press to change displayed data values in Menu Mode Press to navigate through menu listing in Menu Mode Press to turn heater off or back on Press to select menu item Press after parameter programming to store parameter data Press to exit Service Mode ENTER RESET PREVIOUS NEXT Press to toggle display during normal operation to show outlet and return temperatures fan speed flame signal etc Press to toggle between digits when entering access code or between hour minutes etc when entering date and time Press and hold both to enter Service Mode Installation amp Operation Manual T 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
127. ting combustion and safety shutdown operation 502 MODEL COMBINATION VALVE COMBINATION _ N 2072 MODEL DOWNSTREAM TEST VALVE TO BURNERS DOWNSTREAM TEST VALVE TO BURNERS Figure 3 2 Typical Pool Heater Gas Train Drawing 32 Installation amp Operation Manual TABLE 3B SUGGESTED GAS PIPE SIZE FOR SINGLE UNIT INSTALLATIONS Distance from Meter in feet MODEL 301 500 21128 24112 2 1 2 3 1 2 3 1 2 For each elbow or tee add equivalent straight pipe to total length from Table 3C TABLE 3C FITTINGS TO EQUIVALENT STRAIGHT PIPE Diameter Pipe 3 4 1 11 4 11 2 2 3 4 5 Equivalent length of Straight Pipe 2 2 3 4 5 10 14 20 feet inches 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 Each combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves The valve has a gas control knob that must remain in the open position at all times when the unit is in service The gas control valve has pressure taps located on the inlet and discharge sides of the valve Manifold pressure is adjusted using the regulator located on the valve A manifold gas pressure tap for each burner stick is located on the discharge side of the valve 201 300 2102 3 3 3 The
128. top Follow the vent manufacturer s instructions when installing sealed AL29 4C vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls ceilings and floors Locate the unit as close as possible to chimney or gas vent When a vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions The installed length of flue from the unit to the outside point of termination must not exceed 50 equivalent feet 15 2 m Subtract 5 feet 1 5 m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7 m of equivalent length for each 45 elbow Sidewall vent termination clearances and location Follow all sidewall venting termination information for clearances and location under Sidewall Vent Termination Clearances and Location on page 22 TABLE 2C SIDEWALL VENT KITS KIT MAX VENT SENI MAX VENT W POWER FAN ASSY LENGTH MODELS 502 752 LENGTH 2072 SVK3012 N A N A These kits include a barometric damper 24 EAA Installation amp Operation Manual 2 Ventin continued Horizontal DirectAire venting Powered Venting see page 14 NOTICE Before installing a venting system follow all requirements found in the General Venting sect
129. trical connections Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the heater is locked out or the power is turned off This can be used to turn on an alarm or signal Building Management System that the pool heater is down 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 48 Configuration of the Cascade for a detailed explanation of this procedure The return sensor of the Leader heater should be placed in the main system piping loop upstream of the water being supplied to all the heaters see FIG s 4 5 4 6 and 4 7 The return sensors on the remaining Member heaters may also be placed in the same location as the Leader or they can be placed in each Member s PVC piping loop in the Alternate sensor location using the tapped sensor hole FIG 4 3 Should the Leader heater ever need to be replaced with one of the Member heaters in the Cascade that Member s sensor should be relocated to the previous lead heater s supply sensor location for optimum operation of the cascaded units The supply limit sensors of all cascaded heaters MUST be placed downstream in the main system piping loop in the blended water going out to the pool FIG s 4 5 4 6 and 4 7 The supply limit sensor also serves as a high temperature limit for pool supply water and failure to locate all sensors in the blended
130. tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer s warranty see Pool heater Flow Rates and Temperature Rise for flow requirements 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 ee Fire Regulations and other Safety Codes that apply to this installation Consult local gas utility company to authorize and inspect all gas and flue connections A gas appliance that draws combustion air from the equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting A WARNING Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance Prevention of freezing Heat exchangers and headers damaged by freezing are not covered by warranty See Section 7 Operating Information Freeze Protection for more information Codes The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before instal
131. um Pump Performance Pump performance is based on providing adequate flow and temperature rise to prevent scale accumulation in the heat exchanger See Water Chemistry on page 45 TABLE 4B Minimum Pump Performance and Temperature Rise Temperature Rise 10 15 5 F 0 23 2 Heat exchanger This is a highly sophisticated heat exchanger designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build up of impurities The straight line two pass design of the tubes sends water into the headers at a properly rated velocity The configuration of the headers in turn creates a high degree of turbulence which is sufficient to keep all contaminants in suspension This scouring action provides greater cost savings for owners Tubes are always able to transfer heat at peak efficiency Every surface within this water containing section is of a non ferrous material providing clear clean rust free water Straight copper tubes finned on the outside for maximum heat transfer coated cast iron one piece cored headers make up an entirely rust proof pool heater provided water chemistry is maintained per the Water Chemistry requirements on page 45 ofthis manual A Cupro Nickel heat exchanger is standard on 1802 2072 models On all models header inspection plugs can be removed for field inspection and cleaning of copper tubes The entire heat exchanger may be easily removed from th
132. ustion air inlet piping The Direct Vent system requires the installation of pipe to supply combustion air from the outdoors directly to the unit Make sure the combustion air inlet is in the same pressure zone as the vent terminal In cold climates use Type B double wall vent pipe or an insulated single wall pipe for combustion air This will help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe A CAUTION Units that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe 27 02 59091 Installation amp Operation Manual 2 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 2 m Subtract 5 feet 1 5 m of equivalent length for each 90 elbow Subtract 2 5 feet 0 7 m of equivalent length for each 45 elbow Do not exceed the limits for the combustion air inlet piping lengths Connecting the air inlet pipe to the unit Connect the air inlet piping directly to the unit by attaching it to the DV box adapter The DV box adapter is included in the direct vent kits The combustion air inlet area of the unit 15 located at the right rear corner of the unit This unit uses a simple air filter to ensure clean air is used for the combustion process Attach the DV box adapter over the air filter see FIG 2 11 Align screw holes on the DV box adapter wi
133. vings Time and therefore will require a manual adjustment Use the UP and DOWN keys to increment or decrement the flashing number and the NEXT and PREVIOUS keys to select which number flashes 10 Press the ENTER key to save the setting 11 Press the MENU key twice to exit the Programming Mode 48 COPPER EIN Installation amp Operation Manual Configuration of the cascade When installed in a Cascade system the individual controls must be programmed for cascade operation This is accomplished by accessing the control parameters Input the Installer code as described in the Copper fin Service Manual Once the control parameters have been accessed use the DOWN arrow key to select the H Control Mode parameters Press the ENTER key to access these parameters Use the UP arrow key to access parameter H4 Cascade Press the ENTER key to access this parameter Use the DOWN arrow key to select Enable Press the ENTER key to program this into the control Press the EXIT key then press the DOWN key until I Cascade is selected Press the ENTER key to select the parameter I1 BLR Address Press the ENTER key to access this parameter Each unit in the Cascade system must be programmed with its own address The unit designated as the Leader will have an address of 0 The remaining units in the Cascade will be Members and have addresses from 1 7 Use the UP and DOWN arrow keys to select the appropriate address Press the ENTER key to p

Lochinvar COPPER-FINN2 2072 User's Manual

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