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)