Manuals / Lochinvar / Household Appliance / Boiler

Lochinvar 000 through 2, 1 warranty Warranty, Special Instructions To Owner, Intelli-Fin

Models: 000 through 2 1

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INSTALLATION AND SERVICE MANUAL

IFB/IFW-i&s-05

INSTALLATION AND SERVICE MANUAL

Intelli-Fin®

Hot Water Heating Boilers

Domestic Hot Water Supply Boilers

1,500,000 — 1,700,000 — 2,000,000 Btu/hr Models

FIG. 1 Front View

FIG. 2 Rear View

Installation and service must be performed by a qualified service installer, service agency or the gas supplier.

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 tube may be caused by too much water

velocity through	the tubes and is not	covered by
the manufacturer’s	warranty (See Boiler	Flow Rates
and Temperature Rise for flow requirements).

SPECIAL INSTRUCTIONS

TO OWNER

NOTE:

Retain this manual for future reference.

This manual supplies information for the installation, operation and servicing of the appliance. It is strongly recommended that this manual be reviewed completely before proceeding with an installation.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT,

ALTERATION, SERVICE OR MAINTENANCE can cause injury or property damage. Refer to this manual. For assistance or additional information, consult a qualified installer, service agency or the gas supplier.

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Lochinvar 000 through 2, 1 warranty Warranty, Special Instructions To Owner, Installation And Service Manual, Intelli-Fin

Contents

SPECIAL INSTRUCTIONS TO OWNER WARRANTYINSTALLATION AND SERVICE MANUAL Intelli-FinWater Heater/Domestic Hot Water Supply Boiler TABLE OF CONTENTSDO NOT CHECKING EQUIPMENTWHAT TO DO IF YOU SMELL GAS OWNER WARNINGRECOMMENDED SERVICE CLEARANCES INSTALLATION PROCEDURE LOCATION OF UNITTABLE - A Clearances from Combustible ConstructionAPPLIANCES DRAWING AIR FROM THE EQUIPMENT ROOM COMBUSTION AND VENTILATION AIR REQUIREMENTS FORFIG. 5 Combustion Air Direct from Outside FIG. 6 Combustion Air Through DuctsAIR SUPPLY TO MECHANICAL ROOM TABLE - B Minimum Recommended CombustionFIG. 9 Construction Air Filter CONSTRUCTION AIR FILTERVENTING CONSTRUCTION AIR FILTER KITS TABLE - CTABLE - D The Category IV Flue Pipe Sizes InputCategory IV Venting A CATEGORY IV POSITIVE PRESSURE VENTING SYSTEMCategory IV Flue Pipe Materials Venting Guidelines for a Category IV VentGeneral Category IV Vent Termination Clearances Drain Tee InstallationFIG. 12 Drain Tee VERTICAL VENTING TERMINATIONS MASONRY CHIMNEY INSTALLATIONS10 OR LESS 2 MINTABLE - E Sidewall Vent Cap Kits SIDEWALL VENTING TERMINATIONSSidewall Vent Cap KitDIRECT VENT AND INTELLI-VENTSYSTEMS LOCATION OF A SIDEWALL VENT TERMINATION3 MIN 4 MINand Air Inlet Pipe Sizes TABLE - F Direct Vent and Intelli-VentFlueAir Inlet Length of Air Inlet PipeVERTICAL DIRECT VENT SYSTEMS DANGERCombined Combustion Air Inlet Points HORIZONTAL DIRECT VENT Multiple Vertical Direct Vent InstallationsVERTICAL COMBUSTION AIR INLET TABLE - G SIDEWALL COMBUSTION AIR INLETFlue Sidewall AirINTELLI-VENTSYSTEMS Multiple Horizontal Direct Vent InstallationsVERTICAL INTELLI-VENTWITH SIDEWALL COMBUSTION AIR TABLE - HCombined Air Inlet Points Maximum Length of an Intelli-VentSystemVERTICAL COMBUSTION AIR HORIZONTAL INTELLI-VENTWITHTABLE - VentHORIZONTAL INTELLI-VENT VERTICAL COMBUSTIONAIR INLET WITH SIDEWALL COMBUSTION AIRSIDEWALL COMBUSTION AIR INLET TABLE - JFlue Air InletGAS SUPPLY Settings at Full FireGAS PRESSURE TEST TABLE - K Inlet Gas PressureTABLE - M Recommended Gas Pipe Size Single Appliance InstallationsTABLE - N TABLE - OInstall Piping to Control GAS MANIFOLD PRESSURE ADJUSTMENTGAS PIPING CHECKING GAS SUPPLY PRESSURECHECKING MANIFOLD GAS PRESSURE MANIFOLD GAS PRESSURE WATER CONNECTIONS– – – – = FIELD CONNECTED AIR INLET GAS WATER OUTLET WATER INLETPRIMARY HEAT EXCHANGER SECONDARY HEAT EXCHANGERInlet and Outlet Connections Minimum Pipe Size RequirementsBYPASS VALVE - Synchronization INTEGRAL BYPASSINTEGRAL CIRCULATOR BYPASS PIPING ASSEMBLYOptional Intermittent Pump Operation BYPASS - Initial Set-upof Maximum Water FlowMINIMUM WATER TEMPERATURES TABLE - P Temperature Rise At Full Rate FireTemperature Rise Bypass Manually Fully ClosedWATER FLOW SWITCH TABLE - Q Minimum Inlet Water TemperaturesTemperature LOW WATER CUTOFF If EquippedDIAPHRAGM GAS VALVE RELIEF VALVERATIO GAS VALVE FIG. 43 Ratio Gas ValveVenting of Gas Valves and Pressure Switches JACKET ASSEMBLYELECTRICAL CONNECTIONS TABLE - RFIG. 47 Front Control Panel Locations ACCESS TO COMPONENTS AND CONTROLSFIG. 48 Transformer and Relay Locations VARIABLE FREQUENCY DRIVEFIG. 49 Internal Control Panel Location FIG. 50 Variable Frequency DrivePRESSURE SWITCH LOW AIR PRESSURE SWITCHEXCEL BLOWERbe used as a diagnostic indicator Default Values Pre-programmedin the Excel TEMPERATURE ADJUSTMENTCOMMAND DISPLAY TABLE - SCONFIGURING THE COMMAND DISPLAY PASSWORD FUNCTIONTABLE - T DISPLAY DEFAULT VALUES ACCESSING THE SIX CHANGEABLE POINTS FROMPOINTS FROM INFORMATION THE COMMAND DISPLAYVISIBLE FROM THE SCREEN OF FIG. 56b Command Display Data Screen FIG. 56a Command Display Data ScreenFIG. 56c Command Display Data Screen FIG. 56d Command Display Data ScreenTABLE - U STATUS POINTSStatus Point Operational Modes Status Point Alarm Modes OUTDOOR RESET FUNCTION SELECTIONSOptional on Heating Boilers Only SEQUENCING OPTIONS MULTIPLE APPLIANCE INSTALLATIONSCLOSED VIEW COMPONENTINTERFACING MULTIPLE APPLIANCES Wire to the terminal blocks as followsTABLE - W TABLE -ADDITIONAL COMPONENTS USED TO INTERFACE Wire RequirementsMULTIPLE APPLIANCES FIG. 60 Wire Termination for E-BusConnectionFIG. 62 High Water Temperature Control HIGH WATER TEMPERATURE LIMIT CONTROLHOT SURFACE IGNITION SYSTEM Service PartsIGNITION CONTROL MODULE Ignition Module Lockout FunctionsDiagnostic Status Indication Ignition Module Status LED Diagnostic CodesTABLE - Y Ignition and Control Timings TABLE - ZDiagnostic Lights and Switches OPERATION/DIAGNOSTIC LIGHTS, RESETS AND SWITCHESIndicator BURNERORIFICE COMBUSTION AIR BLOWERMOUNTING TRANSITIONApproximate Maximum Condensate Volumes ACCESS PLATECONDENSATE MANAGEMENT SYSTEM Optional TABLE - BBCondensate Trap Installation Condensate TestingReplenishing the Neutralizer FOR YOUR SAFETY READ BEFORE OPERATING LIGHTING INSTRUCTIONSIGNITION SYSTEM CHECKOUT TO TURN OFF GAS TO APPLIANCETURN TO OFF POSITION LIGHTING INSTRUCTIONSHeat Transfer Process SEQUENCE OF OPERATIONEnd of Sequence MAINTENANCED. BURNER MAINTENANCE BURNER REMOVAL AND CLEANINGE.CHANGING THE HOT SURFACE IGNITER Burner Cleaning ProcedureFIG. 77 Location of Primary Heat Exchanger F.PRIMARY HEAT EXCHANGER INSPECTION G. SECONDARY HEAT EXCHANGER INSPECTIONFIG. 78 Location of Secondary Heat Exchanger I. COMBUSTION AND VENTILATION AIR H. LUBRICATIONJ. CONTROL CIRCUIT VOLTAGE K. COMBUSTION AIR MEASUREMENTL. COMBUSTIBLE MATERIALS FREEZE PROTECTIONWATER TREATMENT HEATING BOILER INSTALLATIONSWATER CONNECTIONS HEATING BOILERS ONLY PIPING OF THE BOILER SYSTEMPIPING LENGTHS PRIMARY LOOP CIRCULATOR PUMP SPECIFICATIONSBOILER CIRCULATOR PUMP LIMITATIONS CIRCULATOR PUMP OPERATION Heating Boilers OnlyPRIMARY/SECONDARY BOILER PIPING MINIMUM BOILER WATER TEMPERATURESTO SYSTEM TO EXPANSION TANK AND MAKEUP WATER SYSTEM 12” MAX FROM SYSTEMMinimum Inlet Water Temperatures BOILER TEMPERATURE RISE CHART TABLE - DDTemperature Rise at Full Rate Fire TABLE - CCTYPICAL HEATING BOILER INSTALLATIONS TEMPERATURE/PRESSURE GAUGEPLACING THE BOILER IN OPERATION General Plumbing RulesBOILER OPERATING TEMPERATURE CONTROL INSTALLATION WITH A CHILLED WATER SYSTEMBoiler Operation DOMESTIC HOT WATER SUPPLY BOILER WATER VELOCITY CONTROLWATER HEATERS DOMESTIC HOT WATER SUPPLY BOILERSTABLE - EE Temperature Rise At Full Rate FireTABLE - FF Maximum Flow RateWATER CHEMISTRY MIXING VALVE BUILDING HOT WATER SUPPLY PIPING - MULTIPLE UNIT INSTALLATIONSRELIEF VALVE TO DRAIN LOCK-TEMP STORAGE TANK COLD WATER SUPPLY DRAIN BUILDING RETURNTemperature Rise Hot Water Supply Boiler InstallationsTABLE - GG PUMP OPERATIONMINIMUM WATER TEMPERATURES THERMOSTAT SETTINGSTABLE - APPROXIMATE TIME / TEMPERATURE RE TABLE - HHTHERMAL EXPANSION OPTIONAL RELIEF VALVECATHODIC PROTECTION HIGH WATER TEMPERATURE LIMIT CONTROL1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models Ladder DiagramWARNING:To CONTROLLER REAR WIRINGCONV HI-LIMITSWITCH Wiring Diagram continued1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models LBL90002 REV A1/09-Printedin U.S.A