Watts AERCO CFR 3000 Installation and operation manual

OMM-0163_A •

CONTENTS
• • •
TABLE OF CONTENTS
SECTION 1: SAFETY PRECAUTIONS................................................................................... 4
1.1 WARNINGS & CAUTIONS................................................................................................... 4
1.2 EMERGENCY SHUTDOWN................................................................................................ 5
1.3 PROLONGED SHUTDOWN................................................................................................ 5
1.4 IMPORTANT REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS..................... 5
SECTION 2: INSTALLATION .............................................................................................. 6
2.1 RECEIVING THE UNIT........................................................................................................ 6
2.2 UNPACKING........................................................................................................................ 6
2.3 SITE PREPARATION .......................................................................................................... 6
2.3.1 Installation Clearances .....................................................................................................................7
2.3.2 Anchoring the Unit ...........................................................................................................................8
2.3.3 Housekeeping Pad Requirements ....................................................................................................8
2.4 LIFTING PROVISIONS........................................................................................................ 9
2.5 SUPPLY AND RETURN PIPING.......................................................................................... 9
2.6 PRESSURE RELIEF VALVE INSTALLATION ....................................................................10
2.7 CONDENSATE DRAIN AND PIPING..................................................................................10
2.7.1 Condensate Drain Installation Instructions....................................................................................11
2.8 GAS SUPPLY PIPING ........................................................................................................12
2.8.1 Gas Supply Specifications...............................................................................................................12
2.8.2 External Gas Supply Regulator .......................................................................................................12
2.8.3 Massachusetts Installations ...........................................................................................................13
2.8.4 Manual Gas Shutoff Valve..............................................................................................................13
2.9 AC ELECTRICAL POWER WIRING....................................................................................13
2.9.1 Electrical Power Requirements ......................................................................................................13
2.9.2 Power Panel Locations ...................................................................................................................13
2.9.3 Electrical Power Panel Internal Components.................................................................................14
2.10 FIELD CONTROL WIRING –I/O BOARD.........................................................................14
2.10.1 I/O Board Connections .................................................................................................................15
2.11 FLUE GAS VENT INSTALLATION....................................................................................18
2.11.1 Exhaust Starter Kit and Stack Guard Sensor.................................................................................18
2.11.2 Barometric Damper......................................................................................................................19
2.12 COMBUSTION AIR...........................................................................................................20
2.12.1 Ducted Combustion Air ................................................................................................................20
2.13 CFR PUMP RELAY ..........................................................................................................20
2.14 BST SEQUENCING ISOLATION VALVE INSTALLATION................................................21
2.15 NEXT STEPS....................................................................................................................22
APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ............................................... 23

FORWARD
• • •
FOREWORD
AERCOCFRboilersadvanceventingsafetyintheCategoryIboilerindustrybyalwaysdeliveringdryflue
gas.Designedforuseinanyclosed-loophydronicsystem,theCFRpromotesapplicationflexibility.Retrofit
installationsarereducedbyaccommodatingawide rangeofpipingconfigurations,includingprimary-
variablesystems.Itcanachieveanindustry-bestupto3:1turndownratio,allowingforthereductionof
cycling losses in partial load conditions.
CFR models operate within the input and output ranges listed below.
CFR Boiler Intake and Output Ranges
MODEL
INPUT RANGE (BTU/HR.)
GROSS OUTPUT (BTU/HR.)
MINIMUM
MAXIMUM
CFR 3000
1,000,000
3,000,000
2,580,000
Theoutputoftheboilerisafunctionoftheunit’sfiringrate(valveposition)andreturnwatertemperature.
Wheninstalledandoperatedinaccordancewiththeseinstructions,theCFR3000complieswiththeBay
Area Air Quality Management District regulation 9, Rule 7.
Whetherusedinsingularormodulararrangements, CFRboilersoffermaximumventingflexibilitywith
minimuminstallationspacerequirements.TheseboilersareCategoryInegativepressureappliances.
Single and/or multiple breeched units are capable of operation in the following vent configurations:
•Room Combustion Air, Vertical Discharge
•Ducted Combustion Air, Vertical Discharge
CFR boilers may be vented with Type B gas vent and require careful attention to the exhaust and
combustionairsystemdesign.PleaseconsulttheCFRVentingandCombustionAirDesignGuide,TAG-
0105 for a list of allowable and preferred vent materials.

SECTION 1: SAFETY PRECAUTIONS
• • •
SECTION 1: SAFETY PRECAUTIONS
1.1 Warnings & Cautions
Installers andoperatingpersonnel MUST, at all times, observeall safetyregulations. Thefollowing
warningsandcautionsaregeneralandmustbegiventhesameattentionasspecificprecautionsincluded
intheseinstructions. InadditiontoalltherequirementsincludedinthisAERCOInstructionManual,the
installationofunitsMUSTconformwithlocalbuildingcodes,or,intheabsenceoflocalcodes,ANSIZ223.1
(NationalFuelGasCodePublicationNo.NFPA-54)forgas-firedboilers.Whereapplicable,theequipment
shall be installed in accordance with the current Installation Code for Gas Burning Appliances and
Equipment,andapplicableStateregulationsfortheclass,whichshouldbecarefullyfollowedinallcases.
Authorities having jurisdiction should be consulted before installations are made.
See section 1.4for informationregarding installation within the Commonwealth of Massachusetts.
Thismanualisanintegralpartoftheproduct.Itmustbemaintainedinasafeplaceinlegibleconditionand
given to the user by the installer for future reference.
⚠
●DoNOTunderanycircumstancesusematches,candles,flames,orothersourcesofignitiontocheckfor
gas leaks. Failure to heed this warning may result in property damage, death or serious injury.
●Fluidsunderpressuremaycauseinjurytopersonnelordamagetoequipmentwhenreleased.Besureto
shutoffallincomingandoutgoingwatershutoffvalves.Carefullydecreasealltrappedpressurestozero
before performing maintenance.
●Shut off all gas and electrical inputs to unit before performing any maintenance.
●Theexhaustventpipeoftheunitoperatesunderapositivepressureandthereforemustbecompletely
sealed to prevent leakage of combustion products into living spaces.
⚡ ⚡ ⚡ ⚡
●Electricalvoltagesupto480VACand24voltsACmaybeusedinthisequipment.Therefore,tooperate
safelythecoverontheunit’spowerbox(locatedbehindthefrontpaneldoor)mustbeinstalledatall
times, except during maintenance and servicing.
●A single-pole(120 VAC units) or three-pole(220+ VACunits)switchmust beinstalled ontheunit’s
electricalsupplyline.Theswitchmustbeeasilyaccessibletoquicklydisconnectelectricalservice.Donot
affix switch to unit sheet metal enclosures.
•Manysoapsusedforgaspipeleaktestingarecorrosivetometals.Thepipingmustberinsedthoroughly
with clean water after leak checks have been completed.
•DONOTusethisboilerifanyparthasbeenunderwater.Callaqualifiedservicetechniciantoinspectand
replace any part that has been under water.
ObservetheCAUTIONLABELontheexhaustmanifoldregardinginstallationofventstarter,ventincreaser,
stack guardsensor, barometric damper andcondensate trap. See sections2.7and 2.11fordetails.
Remove this label from the exhaust manifold before installation of the vent starter.

SECTION 1: SAFETY PRECAUTIONS
• • •
1.2 Emergency Shutdown
Ifoverheatingoccurs,orthegassupplyfailstoshutoff,closetheexternalgasshutoffvalve(Figure1-1).
NOTE: Installer must identify the emergency shutdown manual gas valve to operating personnel.
Figure 1-1: Manual Gas Shutoff Valve
An emergency shutdown procedure addressing the following points must also be implemented:
•For automatically operated unattended boilers located in a boiler room, provide a manually
operated remote shutdown switchor circuit breaker locatedjust insideoroutside eachboiler
roomdoor.Designthesystemsoactivationoftheemergencyshutdownswitchorcircuitbreaker
will immediately shut off the fuel supply to the unit(s).
•For automatically operatedunattendedboilersina location other thanaboilerroom, providea
manually operatedremote shutdownswitchorcircuitbreakermarkedforeasyidentificationata
location readily accessible in the event of boiler mis-operation.
•Design the system so activation of the emergency shutdown switch or circuit breaker will
immediately shut off the fuel.
•For boilersmonitored and/or operatedfrom acontinuouslyoccupiedcontrolroom,providean
emergencyshutdown switchinthecontrolroomthatishard-wiredtoimmediately shutoffthe
fuel upon activation.
1.3 Prolonged Shutdown
In an emergency, turn off the electrical power supply to the boiler and close the manual gas valve
upstream from the unit. The installer must identify the emergency shut-off device.
If the unit is being shut down for oneyear ormore,completethe instructionsinSection8.8:Shutting
Boiler Down for Extended Period in the CFR Operation-Maintenance Manual (OMM-0164). When
returningaunittoserviceafteraprolongedshutdown,itisrecommendedthattheinstructionsinSection
4:InitialStartupandSection5:SafetyDeviceTestingbeperformedtoverifyalloperatingparameters.
1.4 Important Requirements for Massachusetts Installations
•BoilersmustbeinstalledbyaplumberorgasfitterlicensedintheCommonwealthofMassachusetts.
•Beforeoperation,thegastrainandallconnectionsmustbeleaktestedusinganon-corrosivesoap.
•The vent termination must be located a minimum of 4 feet above grade level.
Valve Open
Valve
Closed

SECTION 2: INSTALLATION
• • •
SECTION 2: INSTALLATION
2.1 Receiving The Unit
Each CFRsystem is shipped asa single cratedunit. Theshipping weightisapproximately 1600lbs.
Theunitmustbemovedwiththeproperriggingequipmentforsafetyandtoavoidequipmentdamage.
Theunitshouldbeinspectedforevidenceofdamageandforshipmentcompletenessatthetimeofreceipt
from the carrier and before the bill of lading is signed.
C A U T I O N !
Whileinshippingcontainer,unitmustbemovedbypalletjackorforkliftfromthefrontonly.Failuretoabide
by this warning may result in death, serious bodily injury, and damage to property or the unit.
NOTE:AERCOisnotresponsibleforlostordamagedfreight.EachunithasaTip-N-Tellindicatorontheoutside
of the crate to indicate if the unit has been turned on its side during shipment. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Note the information on the carrier’s paperwork andrequest afreight
claim and inspection by a claims adjuster before proceeding. Any other visual damage to the packaging
materials should also be made clear to the delivering carrier.
2.2 Unpacking
Carefully unpack the unit taking care not to damage the enclosure. After unpacking, make a close
inspection of the unit to ensure that there is no evidence of damage not indicated bythe Tip-N-Tell
indicator. The freight carrier should be notified immediately if any damage is detected.
The following accessories come standardwitheach unit;theyarepackedseparately withintheunit’s
shipping container to be installed by the installer in the field:
•Pressure/Temperature Gauge
•ASME Pressure Relief Valve
•Condensate Drain Trap (P/N 24789)
•A 1”, 1-1/2”or 2”Natural Gas Supply Shutoff Valve
•Exhaust Starter Kit (vent starter section plus vent increaser) –see section 2.11.1 for details
•Stack guard sensor (see section 2.11.1 for details)
Whenoptionalaccessoriesareordered,theymaybepackedwithintheunit’sshippingcontainer,factory
installedontheunit,orpackedandshippedinaseparatecontainer.Anystandardoroptionalaccessories
shipped loose should be identified and stored in a safe place until ready for installation or use.
2.3 Site Preparation
Ensure that the site selected for installation of the boiler includes access to:
•AC Input Power, as specified in the CFR Electrical Power Design Guide (TAG-0108).
•Access to a natural gas supply that conforms to the pressures specified in the CFR Gas
Supply Design Guide, TAG-0106.
•To ensure proper condensate drainage, the unit must be installed on a level concrete
“housekeeping”pad. See Section 2.3.3 for pad requirements.

SECTION 2: INSTALLATION
• • •
2.3.1 Installation Clearances
Theunitmustbeinstalledwiththeminimumprescribedclearancesforservicelistedbelow.However,if
LocalBuildingCodesrequireadditionalclearances,thesecodesshallsupersedeAERCO’srequirements.
The minimum acceptable clearances required for the CFR 3000 are as follows:
Front: 24 inches (61 cm) Sides: 24 inches (61 cm)
Rear: 24 inches (61 cm) Top: 18 inches (46 cm)
Allgaspiping,waterpipingandelectricalconduitorcablemustbearrangedsoitdoesnotinterferewith
the removal of any panels or inhibit service or maintenance of the unit.
Inmultipleunitinstallations,itisimportanttoplanthepositionofeachunitinadvance.Sufficientspace
for piping connections and future service/maintenance requirements must also be taken into
consideration. All piping must include ample provisions for expansion.
NOTE: CFR units can be installed with zero side clearances in pairs only. See Appendix A.
IfinstallingaCombinationPlantusinganACSpanel,identifytheCombinationModeBoilersinadvance
and place them in the proper location. For more information refer to Section 6.5 of OMM-0164.
Figure 2-1: CFR 3000 Clearances (in Inches)
NOTE: Ensure condensate assembly is not located over housekeeping pad, so condensate can drain.
⚠
Keepareaclearandfreefromallcombustiblematerialsandflammablevaporsorliquidsatalltimes. Failure
toabidebythiswarningmayresultindeath,seriousbodilyinjury,anddamagetopropertyorequipment.
For Massachusetts installations, the unit must be installed by a plumber or gas-fitter licensed within the
Commonwealth of Massachusetts. The installationmustcomplywith allrequirements specifiedin Section1.4.

SECTION 2: INSTALLATION
• • •
2.3.2 Anchoring the Unit
If anchoring the unit, see below for anchor locations.
•All holes are flush with the bottom surface of the frame.
•All dimensions shown are in inches [millimeters]
Figure 2-2: CFR 3000 Anchor Bolt Locations
2.3.3 Housekeeping Pad Requirements
Toensureproperdrainagetheunitmustbeinstalledonalevelconcrete“housekeeping”pad,withthe
condensate assembly supported separately away from the pad, as shown below.
TheminimumpadthicknesswithoutaCondensateNeutralizertankis4inches(10.2cm)
1
.Ifusingan
AERCOCondensateNeutralizerTank(P/N89030),youmustensureenoughheightforthecondensateto
drain intothe condensatetrap, then into the neutralizertank, andthentothedrain.Thismayrequire
that a 1”pit be dug for the Neutralizer Tank. For more information on the Condensate Neutralizer
Tank, see Technical Instructions TID-0074.
NOTE: In all cases a 6” pad eliminates the need for a pit.
Figure 2-3: Condensate Neutralizer Tank Installation
1
Minimum pad height without pit: 5”

SECTION 2: INSTALLATION
• • •
2.4 Lifting Provisions
⚠
To avoid damaging the unit do NOT lift or move the boiler using the gas train or blower.
ThreeliftinglugsareprovidedatthetopoftheprimaryheatexchangerasshowninFigure2-4.Remove
the front toppanel from the unit to provide accessto the lifting lugs. Removethe four (4) lag screws
securingtheunittotheshipping skid.Lifttheunitofftheshippingskidandpositionitonthe4-inchto8-
inch (10.2 cm to 20.3 cm) housekeeping concrete pad (required) in the desired location.
Figure 2-4: Lifting Lug Locations
2.5 Supply And Return Piping
Whenconnectingthehotwateroutletandcoldwaterinlettobuildingpiping,makesurematingsurfaces
are thoroughly clean. Gaskets of appropriate size for the pipe flange must be provided in the field.
CFR units have the following inlets and outlets:
•4” (10.2 cm) 150# flange water INLET (supply) and hot water OUTLET (return) piping.
•2” (5.08 cm) gas inlet pipe. •8” (20.3 cm) Air Inlet adapter
Figure 2-5: CFR 3000 Supply and Return Locations
Lifting Lugs
2”NaturalGasInlet
AIR INLET
HOT WATER
OUTLET
(SUPPLY)
NATURAL GAS
INLET
EXHAUST MANIFOLD
WATER INLET (RETURN)
CONDENSATE DRAIN

SECTION 2: INSTALLATION
• • •
2.6 Pressure Relief Valve Installation
AnASMEratedPressureReliefValveissuppliedwitheachCFRBoiler.Thepressureratingfortherelief
valvemustbespecifiedin thesalesorder. Availablepressureratingsrangefrom30to160psi(207to
1103 kPa). The relief valve is installed on the hot water outlet of the boiler as shown in Figure 2-6.
Asuitablepipejointcompoundshouldbeusedonthethreadedconnections.Anyexcessshouldbewiped
offtoavoidgettinganyjointcompoundintothevalvebody.Thereliefvalvemustbepipedtowithin12
inches (30.5 cm) of the floor to prevent injury in the event of a discharge.
IMPORTANT: No valves, restrictions, or other blockages areallowed in the full port discharge line.
IMPORTANT: In multiple unit installations the discharge lines must NOT be manifolded together.
IMPORTANT: Each must be individually run to a suitable discharge location.
Figure 2-6: P&T Relief Valve Location
2.7 Condensate Drain and Piping
Theinstallationmusthaveprovisionsforsuitablecondensatedrainageorcollection.Thecondensatedrain
portlocatedontheexhaustmanifoldmustbeconnectedtothecondensatetrap(P/N24789).Itsinletand
outletconnectionscontaintapped3/4”NPTports.Asamplecondensatetrapinstallationisshownbelow.
The installation details for thetrap willvary depending on available clearances, housekeeping pad
dimensions and other conditions at the site.
NOTE: The following guidelines MUST be observed to ensure proper condensate drainage:
•The condensate trap inlet must be level with, or lower than exhaust manifold drain port.
•The base of the condensate trap must be supported to ensure that it is level (horizontal).
•Thetrapmustberemovableforroutinemaintenance.AERCOrecommendsthataunionbeutilizedbetween
the exhaust manifold condensate drain port and the trap inlet port.
•If the condensate trap does not connect directly to the exhaust manifold condensatedrain port,thepipe
between the drain and the trap must be stainless steel or aluminum.
•The concrete housekeeping pad must not extend under the condensate assembly.
PRESSURE
RELIEF VALVE
4” HOT BOILER
WATER OUTLET
INSTALL TRIDICATOR
GAUGE HERE
(P/N 123675-TAB)

SECTION 2: INSTALLATION
• • •
2.7.1 Condensate Drain Installation Instructions
1. Connectthecondensatetrapinlettotheexhaustmanifolddrainconnectionusingtheappropriate
piping components (nipples, reducers, elbows, etc.).
2. Pipethecondensateoutlettoanearbyfloordrainusing3/4"NPTstainlesssteeloraluminumpipe.
⚠
Usestainlesssteeloraluminumforcondensatepiping. DoNOTusecarbon,copper,PVC,orpolypropylene.
If a floor drain is not available, a condensate pump can be used to remove the condensate to an
appropriate drain. The maximum condensate flow rate is 13 gallons per hour.
Figure 2-7: Sample Condensate Trap Installation
EXHAUST
MANIFOLD
DRAIN PORT
COMBUSTION
ANALYZER
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLES
HOSE
CLAMP
CONDENSATE
TRAP (P/N 24441)
TOP
COVER
THUMB
SCREWS
(4 each)
1” (2.54 cm) DIAM.
HOSE
4”
(10cm)
4-8” (10-20 cm)
THICK
TRAP INLET
INTEGRAL ADAPTOR AND
THUMBSCREW
TO
CONDENSATE
NEUTRALIZER

SECTION 2: INSTALLATION
• • •
2.8 Gas Supply Piping
ConsultTAG-0106, CFRGasSupplyDesignGuidebeforedesigningorinstallinganygassupplypiping.
⚠
DoNOTunderanycircumstancesusematches,candles,flames,orothersourcesofignitiontocheckforgas
leaks.Failuretoheedthiswarningmayresultindeath,bodilyharm,ordamagetoequipmentorproperty.
C A U T I O N !
Manyofthesoapsusedforgaspipeleaktestingarecorrosivetometals.Therefore,pipingmustberinsed
thoroughly with clean water after leak checks have been completed.
NOTE: All gas piping must be arranged so that it does not interfere with removal of any covers, inhibit
service/maintenance, or restrict access to the unit.
TheCFR3000hasa2”(5.08cm)gasinletpipe.Priortoinstallation,allpipesshouldbede-burredand
internallyclearedofanyscale,metalchipsorotherforeignparticles.Donotinstallanyflexibleconnectors
orunapprovedgasfittings.Pipingmustnotbesupportedbytheunit.Useasuitablepipingcompound
approvedforuse with naturalgas.Anyexcessmust bewipedofftopreventcloggingofcomponents.
Toavoidunitdamagewhenpressuretestinggaspiping,theunitmustbeisolatedfromthegassupply
piping.Athoroughleaktestofallexternalpipingmustbeperformedusingasoapandwatersolutionor
suitable equivalent. The gas piping used must meet all applicable codes.
2.8.1 Gas Supply Specifications
CFRLowNOxseriesboilersrequirestablenaturalgasandpropaneinputpressure.Itmustcomplywith
the allowable gasinlet pressurerange specified in theCFR Gas SupplyDesign Guide, TAG-0106.
2.8.2 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions.
Regulators must conform to the specifications in the CFR Gas Supply Design Guide, TAG-0106.
NOTE: It is the responsibility of the customer to source and purchase the appropriate gas regulator as
describedabove.However,AERCOoffersforsaleanappropriateregulator,whichmaybeorderedatthetime
of unit purchase or separately. Contact your AERCO sales representative for more information.
It is strongly recommended that the pressure regulator be installed a minimum distance of 10 pipe
diameters betweenthe pressureregulatorandthenearestdownstreamfittings(anelbowortheunit
itself),andaminimumof5pipediametersbetweenthepressureregulatorandanyupstreamfitting,such
as elbow or shutoff valve, as shown below.
Figure 2-8: Gas Regulator and Manual Shut-Off Valve
GAS INLET
GAS PRESSURE
REGULATOR
MANUAL SHUT-OFF
VALVE
GAS INLET
MINIMUM 10 PIPE
DIAMETERS IN LENGTH
MINIMUM 5 PIPE DIAMETERS IN LENGTH

SECTION 2: INSTALLATION
• • •
2.8.3 Massachusetts Installations
For Massachusetts installations, a mandatory external gas supply regulator must be positioned
as shown above. The gas supply regulator must be properly vented to the outdoors. Consult the
local gas utility for detailed requirements concerning venting of the supply gas regulator.
2.8.4 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas line upstream of the boiler as shown above.
2.9 AC Electrical Power Wiring
AllelectricalpowerrequirementsarelistedinAERCO’sCFRElectricalPowerDesignGuide,TAG-0108.This
guide must be consulted prior to connecting any AC power wiring to the unit.
2.9.1 Electrical Power Requirements
CFR boilers are available with the following power options:
Model
Voltage
Phase
Amperage
CFR-03000
208 V
3/ 60 Hz
20
480 V
3/ 60 Hz
15
2.9.2 Power Panel Locations
ExternalACpowerconnectionsaremadetotheunitinsidethePowerBoxonthefrontoftheunit.Remove
the front panel to access the Power Box, which is mounted in the upper part of the unit.
Figure 2-9: Power Box with Closed Cover
Eachunitmustbeconnectedtoadedicatedelectricalcircuit.Nootherdevicesshouldbeonthesame
electrical circuit as the boiler.
Aswitchmustbeinstalledontheelectricalsupplyline,externaltotheunit,inaneasilyaccessiblelocation
toquicklydisconnectelectricalservice.DONOTattachtheswitchtosheetmetalenclosuresoftheunit.
Afterplacingtheunitinservice,theignitionsafetyshutoffmustbetested.Ifanexternalelectricalpower
source is used, the installed boiler must be electrically bonded to ground in accordance with the
requirementsoftheauthorityhavingjurisdiction.Intheabsenceofsuchrequirements,theinstallation
shall conform to the National Electrical Code (NEC) and ANSI/NFPA 70.
For electrical power wiring diagrams, see the CFR Electrical Power Design Guide, TAG-0108.
POWER BOX
FRONT COVER

SECTION 2: INSTALLATION
• • •
2.9.3 Electrical Power Panel Internal Components
RemovethefrontpaneltoaccessthePowerPanel.Runtheelectricalservicethroughtheopeningabove
thePowerPanelandmaketheconnectionstothePowerBreakerinaccordancewiththePowerPanel
cover label (see Figure 2-9, above).
⚠
ThepowerbreakerdoesNOTremovepowerfromtheterminalblocks.Whenservicingtheunit,powerdown
the external disconnect switch (see section 2.9.2) to ensure power is removed from the boiler.
Figure 2-10: CFR 3000 Power Box Internal Components
NOTE:AllcomponentsinthePowerBoxaremountedonaDINrail.Allelectricalconduitandhardwaremust
be installed so that it does not interfere with the removal ofanyunitcovers, inhibitservice/maintenance, or
prevent access between the unit and walls or another unit.
2.10 Field Control Wiring –I/O Board
Eachunitisfullywiredfromthefactorywithaninternaloperatingcontrolsystem.Nofieldcontrolwiring
is requiredfornormaloperation.However, theEdge Controllerallowsforsomeadditionalcontroland
monitoringfeatures.WiringconnectionsforthesefeaturesaremadeontheI/Oboardlocatedbehindthe
removablefrontpanel.Allfieldwiringisinstalledfromtherearofthepanelbyroutingthewiresthrough
one of the four bushings provided on the sides of the I/O board.
Figure 2-11: Input/Output (I/O) Location
I/O BOARD
(cover removed)
MAIN POWER PANEL
(cover removed)
3-PHASE CIRCUIT
BREAKER
6A FUSE
12VDC POWER
SUPPLY
6A FUSE
TERMINAL
BLOCKS
TERMINAL
BLOCKS

SECTION 2: INSTALLATION
• • •
⚠
DONOTmakeconnectionstoterminalslabeled“NOTUSED”. Attemptingtodosomaydamageequipment.
Figure 2-12: Terminal Block Terminal Strips
2.10.1 I/O Board Connections
The I/O board containstheterminallistedbelow,arrangedonremovable,namedconnectorstripsJ3
throughJ7andJ14,plusMolexconnectorsforunitharnesses. Themaximumgaugeofwiresconnecting
to the I/O board is 14.
NOTE:Tofacilitateconnections,thesestripscanbeliftedofftheI/Oboard.Theentirestripisthenremounted
ontheI/Oboardafterallconnectionshavebeenmade. Ifaconnectorstripisremoved,itmustbere-mounted
in its original orientation (connecting wires arranged around the outside perimeter of the I/O board).
Connector Strip J3 Terminals
Pin #
Name
Description
1
2
Outside Temp +
Outside Temp -
Connections to Outside Air Temperature (OAT) sensor (P/N 61048). Used on
Manager and Backup Manager units. Required for the OUTDOOR RESET mode of
operation. To enable this mode, go to the Controller’s Main Menu →Advanced
Setup →Unit →Application Configuration and set SH Operating Mode to
Outdoor Reset, then configure the related parameters.
3
Shield
Connection to the shield from any cable.
4
5
Supply Header +
Supply Header –
Connection to the Supply Header temperature sensor (2 wire sensor P/N 24410,
or 4 wire sensor P/N 61058) for:
•Main Loop (in a Variable-Primary application)
•Secondary Loop (in a Primary-Secondary application)
•Loop 1 (in a Multi-application)
Typically, used on Manager and Backup Manager units.
For more information, refer to the CFR Boiler Application Guide (TAG-0107)
6
Remote Analog In +
Connection to the Analog Remote Signal, if Operating Mode = Remote Setpoint.
Used on Manager and Backup Manager units.
7
Remote Analog In –
SPARK MONITOR
FROM SHELL
HARNESS 63394-2
CONNECTOR J9
I/O BOARD POWER
HARNESS 63232
CONNECTOR J24
VALVE HARNESS
INTERLOCK FROM SHELL
HARNESS 63394-2
J6 PINS 3 & 4
40 PIN RIBBON I/O
HARNESS 63220
CONNECTOR J1
30 PIN RIBBON I/O HARNESS 63221
CONNECTOR J2

SECTION 2: INSTALLATION
• • •
Connector Strip J3 Terminals
Pin #
Name
Description
8
Shield
Connection to the shield from any cable.
9
(NOT USED)
10
(NOT USED)
11
BLR V.S. Pump +
Connection for a 0 –10 V signal to drive a Boiler Variable Speed Pump if desired
when doing BST. To enable this feature, go to the Controller’s Main Menu →
Advanced Setup →BST Cascade →Cascade Configuration and set VSP Pump
Mode to Fire Rate, then configure the related parameters.
12
BLR V.S. Pump –
13
BST/WHM RS485 +
Dedicated to internal communication between units in a BST system. ACS (legacy)
panel should also be connected to this terminal.
14
RS485 Iso Gnd
15
BST/WHM RS485 -
Connector Strip J4 Terminals
Pin #
Name
Description
1
(NOT USED)
2
(NOT USED)
3
(NOT USED)
4
(NOT USED)
5
RTD Spare 1
Reserved. Spare temp sensor
6
Sensor Ground
Ground connection for RTD Spare 1
7
(NOT USED)
8
(NOT USED)
9
(NOT USED)
10
DHW Temp
Connect the DHW tank temperature or DHW Loop Supply Temperature sensor
11
Shield
Connection to the shield from any cable.
12
(NOT USED)
13
(NOT USED)
Connector Strip J5 Terminals
Pin #
Name
Description
1
(NOT USED)
2
(NOT USED)
3
Spare Analog In 1 +
Connection to one of the following signals:
•SmartPlate Valve input
•VS Pump Feedback (Variable Speed Pump Feedback)
•Remote Setpoint 2
To assign function, go to the Controller’s Main Menu →Advanced Setup →Ancillary
Devices →Analog Inputs, then set the Input parameter to Spare Analog In 1.
4
Spare Analog In 1 -
5
(NOT USED)
6
(NOT USED)
7
Spare Analog Out 1 +
Connection to one of the following signals: ● Fire Rate ● Cascade Valve
To assign/program function, go to the Controller’s Advanced Setup →Ancillary
Devices →Analog Outputs, then set the Output parameter to Spare Analog Out 1.
8
Spare Analog Out 1 -
9
(NOT USED)
10
(NOT USED)
11
(NOT USED)
12
(NOT USED)

SECTION 2: INSTALLATION
• • •
Connector Strip J6 Terminals
Pin #
Name
Description
1
Remote Interlock Out
Connection to an auxiliary device interlock - requires delay before firing.
2
Remote Interlock Return
3
Delayed Interlock 1 Out
Connection to an auxiliary device interlock - requires delay before firing.
4
Delayed Interlock 1 Return
5
(NOT USED)
6
(NOT USED)
Connector Strip J7 Terminals
Pin #
Name
Description
1
Spare 2 Relay N.O.
Connection to an auxiliary device enable/disable signal, such as:
•System Pump • Pump 2 • Louver
•Louver 2 • Damper • Other
To assign/program its function, go to the Controller’s Main Menu →
Advanced Setup →Ancillary Devices →Relays, then set the Relay to
Spare 2 Relay and the Name to one of the above devices.
2
Spare 2 Relay Com
3
DHW Pump Relay N.O.
Connection to a DHW Pump enable/disable signal.
4
DHW Pump Relay Com
5
V2/Spare 1 Relay N.O.
Connection to an auxiliary device enable/disable signal, such as:
•System Pump • Pump 2 • Louver
•Louver 2 • Damper • Other
To assign/program its function, go to the Controller’s Main Menu →
Advanced Setup →Ancillary Devices →Relays, then set the Relay to
V2/Spare 1 Relay and the Name to one of the above devices.
6
V2/Spare 1 Relay Com
7
Reserve Relay N.O.
Connection to a reserve/backup boiler enable/disable signal.
8
Reserve Relay Com
9
(NOT USED)
10
(NOT USED)
11
Fault Relay N.O.
Connection to a Fault/Remote Alarm enable/disable signal.
12
Fault Relay Com
13
Aux Relay N.O.
Connection to an auxiliary device enable/disable signal.
14
Aux Relay Com
Connector Strip J14 Terminals
Pin #
Name
Description
1
BAS RS485 +
Connection to the building automation system (BAS) network (Modbus RTU, BACnet
MSTP). For IP network, use the Ethernet port.
2
BAS RS485 -
3
(NOT USED)
4
(NOT USED)
5
(NOT USED)

SECTION 2: INSTALLATION
• • •
2.11 Flue Gas Vent Installation
TheCFRgas-firedboilerisafan-assisted,hydronic-heatingunitwiththefollowingventingcapabilities:
1. Room Combustion Air, Vertical Discharge
2. Ducted Combustion Air, Vertical Discharge
Itiscriticalthatthefluegasventbedesignedtopreventcondensationinthefluegasventforsafe
operation.CondensationcanoccurintheCFRboiler,soeachunitisfittedwithacondensateremovaltrap
(seeSection2.7).However,withitsadvancedtechnology,theCFRboileralwaysdeliversdryfluegasfor
safe exhaust into Category I venting. A stack guard sensor is supplied with each boiler.
TheCFRBoilerisaCategoryIlistedapplianceandmustbeventedwithTypeBgasventorapprovedmetal
pipe/masonrychimney. ExteriorMasonry Chimneys, definedasmasonrychimneysexposedtothe
outdoorsononeormoresidesbelowtheroofline, cannotbeusedduetohighflueheatlosswhichcan
affectthedraftproduced.Whenventingintointeriormasonrychimneys,referandadheretothelatest
publicationofNFPA54forchimneyliningmaterial,sizing,andterminationrequirements.Whenusingan
existingchimney,itmustbeapprovedforCatIappliance,andinspected/cleanedtoensureitisstructurally
sound and free of blockage for properoperation. If the condition of the existing chimney is deemed
unsuitable itmust be relined, repaired, or replacedto complywith the latest publication ofNFPA54.
Once you have selected the vent material, enter that material in the Edge Controller:
1. Go to: Advanced Setup →Unit →Unit Settings. Find the Vent Type parameter.
2. Set this parameter to match your vent material: Category I; this sets the exhaust temp limits.
Horizontalventrunsslopeupwardstowardsthedirectionoffluegaspathataminimumof¼” perfoot.
TheexhaustsystemshallbesizedinaccordancewiththelatestpublicationoftheNationalFuelGasCode
(ANSI Z223.1/ NFPA54) as a fan-assisted Category I appliance.
Forindividuallyventedunits,theexhaustsystemmustbedesignedsothatthepressuremeasuredat
every point is negative, within the range of -0.01 to -0.08" w.c.
Forcommonventedunits,theexhaustsystemmustbedesignedsothatthepressuremeasuredatevery
point is negative, within the range of -0.01 to -0.08" w.c.
PleaseconsulttheCFRVentingandCombustionAirDesignGuide,TAG-0105foradditionalventand
combustion air installation details.
2.11.1 Exhaust Starter Piece, Vent Increaser, and Stack Guard Sensor
Aventstartersection(P/N99324) andaventincreaserisprovidedbyAERCOtobefieldinstalled(see
Figure 2-13) based on the individual vent or connector size selected for the venting layout:
1. 8” x 10” vent increaser (P/N99325-10):UsethiswhenCategoryIventsizingfromNFPA54tables
require the following individual vent or connection size: 9", 10", 12" and 14".
2. 8” x 18” vent increaser (P/N99325-10):UsethiswhenCategoryIventsizingfromNFPA54tables
require the following individual vent or connection size: 16", 18", 20" and 22".
IMPORTANT: Forretrofitapplications,replacingasystemwiththesametotalBTUcapacitydoesnot
necessarilymeantheexistingventsizewillwork.SizetheventinaccordancewithNFPA54asafan-assisted
Category I appliance to determine the correct size.

SECTION 2: INSTALLATION
• • •
Figure 2-13: Vent Starter Section, Vent
Increaser, Barometric Damper Figure 2-14: Installation Caution Label
Thesuppliedstackguardsensormustbefieldinstalledontheventstartersection.Thesensorcomeswith
a molex connector that must be connected to the mating wiring harness from the rear of the boiler.
ObservetheCAUTIONLABELontheexhaustmanifold.Removethislabelfromtheexhaustmanifold
before installation of the vent starter.
2.11.2 Barometric Damper
Toensuretheproperpressurerangeismaintained,theCFRboilerrequiresa
barometricdampertobeinstalledimmediatelyafterthefactorysuppliedstarter
piece (see Figure 2-15). Do not use the appliance vent connection size to
determine the size of barometric damper. Refer to latest edition of NFPA
54/ANSIZ223.1forsizingCategoryIventingsystemstosizethevent.Thenuse
that same diameter to size a barometric damper that will be installed
immediatelyafterthefactoryprovidedstarterpiece.Refertothemanufacturer’s
instruction on barometricdamper installation, operation, and maintenance.
Figure 2-15: Stack Guard Sensor
Vent Increaser
Vent Stater Section
Barometric Damper

SECTION 2: INSTALLATION
• • •
2.12 Combustion Air
Air supplyis a directrequirement ofANSI 223.1,NFPA-54, andlocalcodes.Thesecodesshouldbe
consulted before a permanent design is determined.
Thecombustionairmustbefreeofchlorine,halogenatedhydrocarbons,andotherchemicalsthatcan
become hazardous when used in gas-fired equipment. Common sources of these compounds are
swimmingpools,degreasingcompounds,plasticprocessing,andrefrigerants.Whenevertheenvironment
containsthesetypesofchemicals,combustionairMUSTbesuppliedfromacleanareaoutdoorsforthe
protection and longevity of the equipment and warranty validation.
If combustion air is not supplied through air ducts, it must be supplied to the unit(s) through two
permanentopenings.Thesetwoopeningsmusthaveafreeareaofnotlessthanonesquareinch(6.5
cm2)foreach4000BTUs(1.17kW)inputforeachunit.Thefreeareamusttakeintoaccountrestrictions
such as louvers and bird screens.
2.12.1 Ducted Combustion Air
For ducted combustion air installations, the air ductwork must be attached directly to the air inlet
connectiononthesheetmetalenclosure.ConsulttheCFRVentingandCombustionAirGuide,TAG-0105
when designing combustion air ducting.
When usingtheunitinaductedcombustionairconfiguration,theminimumdiameterconnectionatthe
unit is 8-inches.
2.13 CFR Pump Relay
TheCFRpowerpanelincludesapumprelayterminalblockproviding120VACwithamaximumpilotduty
of3amps.Ifthepumppowerrequirementunderallconditionsisgreaterthan3amps,usethisrelayto
activate the pump through an intermediate relay with a higher power.
Figure 2-16: Pump Relay Terminal Block (in Red Rectangle)
The PumpDelayTimerfeatureallowspumptorunforupto30minutesaftertheboilerhasshutdown
andthedemandissatisfied.Toenable,gotoAdvancedSetup→AncillaryDevices→Relaysandsetthe
Pump Off Delay setting to the desired delays time.