Intelli-Fin
WARRANTY
SPECIAL INSTRUCTIONS TO OWNER
INSTALLATION AND SERVICE MANUAL
Water Heater/Domestic Hot Water Supply Boiler
TABLE OF CONTENTS
OWNER WARNING
CHECKING EQUIPMENT
DO NOT
WHAT TO DO IF YOU SMELL GAS
Combustible Construction
INSTALLATION PROCEDURE LOCATION OF UNIT
RECOMMENDED SERVICE CLEARANCES
TABLE - A Clearances from
FIG. 6 Combustion Air Through Ducts
COMBUSTION AND VENTILATION AIR REQUIREMENTS FOR
APPLIANCES DRAWING AIR FROM THE EQUIPMENT ROOM
FIG. 5 Combustion Air Direct from Outside
AIR SUPPLY TO MECHANICAL ROOM
TABLE - B Minimum Recommended Combustion
FIG. 9 Construction Air Filter
CONSTRUCTION AIR FILTER
Input
CONSTRUCTION AIR FILTER KITS TABLE - C
VENTING
TABLE - D The Category IV Flue Pipe Sizes
Venting Guidelines for a Category IV Vent
A CATEGORY IV POSITIVE PRESSURE VENTING SYSTEM
Category IV Venting
Category IV Flue Pipe Materials
FIG. 12 Drain Tee
Drain Tee Installation
General Category IV Vent Termination Clearances
2 MIN
MASONRY CHIMNEY INSTALLATIONS
VERTICAL VENTING TERMINATIONS
10 OR LESS
Cap Kit
SIDEWALL VENTING TERMINATIONS
TABLE - E Sidewall Vent Cap Kits
Sidewall Vent
4 MIN
LOCATION OF A SIDEWALL VENT TERMINATION
DIRECT VENT AND INTELLI-VENTSYSTEMS
3 MIN
Length of Air Inlet Pipe
TABLE - F Direct Vent and Intelli-VentFlue
and Air Inlet Pipe Sizes
Air Inlet
Combined Combustion Air Inlet Points
DANGER
VERTICAL DIRECT VENT SYSTEMS
VERTICAL COMBUSTION AIR INLET
Multiple Vertical Direct Vent Installations
HORIZONTAL DIRECT VENT
Sidewall Air
SIDEWALL COMBUSTION AIR INLET
TABLE - G
Flue
INTELLI-VENTSYSTEMS
Multiple Horizontal Direct Vent Installations
Maximum Length of an Intelli-VentSystem
TABLE - H
VERTICAL INTELLI-VENTWITH SIDEWALL COMBUSTION AIR
Combined Air Inlet Points
Vent
HORIZONTAL INTELLI-VENTWITH
VERTICAL COMBUSTION AIR
TABLE -
WITH SIDEWALL COMBUSTION AIR
VERTICAL COMBUSTION
HORIZONTAL INTELLI-VENT
AIR INLET
Air Inlet
TABLE - J
SIDEWALL COMBUSTION AIR INLET
Flue
TABLE - K Inlet Gas Pressure
Settings at Full Fire
GAS SUPPLY
GAS PRESSURE TEST
TABLE - O
Single Appliance Installations
TABLE - M Recommended Gas Pipe Size
TABLE - N
CHECKING GAS SUPPLY PRESSURE
GAS MANIFOLD PRESSURE ADJUSTMENT
Install Piping to Control
GAS PIPING
CHECKING MANIFOLD GAS PRESSURE
AIR INLET GAS WATER OUTLET WATER INLET
WATER CONNECTIONS
MANIFOLD GAS PRESSURE
– – – – = FIELD CONNECTED
Minimum Pipe Size Requirements
SECONDARY HEAT EXCHANGER
PRIMARY HEAT EXCHANGER
Inlet and Outlet Connections
BYPASS VALVE - Synchronization
INTEGRAL BYPASS
BYPASS - Initial Set-upof Maximum Water Flow
BYPASS PIPING ASSEMBLY
INTEGRAL CIRCULATOR
Optional Intermittent Pump Operation
Bypass Manually Fully Closed
TABLE - P Temperature Rise At Full Rate Fire
MINIMUM WATER TEMPERATURES
Temperature Rise
LOW WATER CUTOFF If Equipped
TABLE - Q Minimum Inlet Water Temperatures
WATER FLOW SWITCH
Temperature
FIG. 43 Ratio Gas Valve
RELIEF VALVE
DIAPHRAGM GAS VALVE
RATIO GAS VALVE
TABLE - R
JACKET ASSEMBLY
Venting of Gas Valves and Pressure Switches
ELECTRICAL CONNECTIONS
FIG. 47 Front Control Panel Locations
ACCESS TO COMPONENTS AND CONTROLS
FIG. 50 Variable Frequency Drive
VARIABLE FREQUENCY DRIVE
FIG. 48 Transformer and Relay Locations
FIG. 49 Internal Control Panel Location
BLOWER
LOW AIR PRESSURE SWITCH
PRESSURE SWITCH
EXCEL
be used as a diagnostic indicator
TABLE - S
TEMPERATURE ADJUSTMENT
Default Values Pre-programmedin the Excel
COMMAND DISPLAY
ACCESSING THE SIX CHANGEABLE POINTS FROM
PASSWORD FUNCTION
CONFIGURING THE COMMAND DISPLAY
TABLE - T DISPLAY DEFAULT VALUES
VISIBLE FROM THE SCREEN OF
THE COMMAND DISPLAY
POINTS FROM INFORMATION
FIG. 56d Command Display Data Screen
FIG. 56a Command Display Data Screen
FIG. 56b Command Display Data Screen
FIG. 56c Command Display Data Screen
Status Point Operational Modes
STATUS POINTS
TABLE - U
Optional on Heating Boilers Only
OUTDOOR RESET FUNCTION SELECTIONS
Status Point Alarm Modes
COMPONENT
MULTIPLE APPLIANCE INSTALLATIONS
SEQUENCING OPTIONS
CLOSED VIEW
TABLE -
Wire to the terminal blocks as follows
INTERFACING MULTIPLE APPLIANCES
TABLE - W
FIG. 60 Wire Termination for E-BusConnection
Wire Requirements
ADDITIONAL COMPONENTS USED TO INTERFACE
MULTIPLE APPLIANCES
FIG. 62 High Water Temperature Control
HIGH WATER TEMPERATURE LIMIT CONTROL
Ignition Module Lockout Functions
Service Parts
HOT SURFACE IGNITION SYSTEM
IGNITION CONTROL MODULE
TABLE - Z
Ignition Module Status LED Diagnostic Codes
Diagnostic Status Indication
TABLE - Y Ignition and Control Timings
BURNER
OPERATION/DIAGNOSTIC LIGHTS, RESETS AND SWITCHES
Diagnostic Lights and Switches
Indicator
TRANSITION
COMBUSTION AIR BLOWER
ORIFICE
MOUNTING
TABLE - BB
ACCESS PLATE
Approximate Maximum Condensate Volumes
CONDENSATE MANAGEMENT SYSTEM Optional
Replenishing the Neutralizer
Condensate Testing
Condensate Trap Installation
FOR YOUR SAFETY READ BEFORE OPERATING
LIGHTING INSTRUCTIONS
LIGHTING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
IGNITION SYSTEM CHECKOUT
TURN TO OFF POSITION
Heat Transfer Process
SEQUENCE OF OPERATION
End of Sequence
MAINTENANCE
D. BURNER MAINTENANCE
BURNER REMOVAL AND CLEANING
FIG. 77 Location of Primary Heat Exchanger
Burner Cleaning Procedure
E.CHANGING THE HOT SURFACE IGNITER
FIG. 78 Location of Secondary Heat Exchanger
G. SECONDARY HEAT EXCHANGER INSPECTION
F.PRIMARY HEAT EXCHANGER INSPECTION
K. COMBUSTION AIR MEASUREMENT
H. LUBRICATION
I. COMBUSTION AND VENTILATION AIR
J. CONTROL CIRCUIT VOLTAGE
L. COMBUSTIBLE MATERIALS
FREEZE PROTECTION
PIPING OF THE BOILER SYSTEM
HEATING BOILER INSTALLATIONS
WATER TREATMENT
WATER CONNECTIONS HEATING BOILERS ONLY
CIRCULATOR PUMP OPERATION Heating Boilers Only
PRIMARY LOOP CIRCULATOR PUMP SPECIFICATIONS
PIPING LENGTHS
BOILER CIRCULATOR PUMP LIMITATIONS
AND MAKEUP WATER SYSTEM 12” MAX FROM SYSTEM
MINIMUM BOILER WATER TEMPERATURES
PRIMARY/SECONDARY BOILER PIPING
TO SYSTEM TO EXPANSION TANK
TABLE - CC
BOILER TEMPERATURE RISE CHART TABLE - DD
Minimum Inlet Water Temperatures
Temperature Rise at Full Rate Fire
General Plumbing Rules
TEMPERATURE/PRESSURE GAUGE
TYPICAL HEATING BOILER INSTALLATIONS
PLACING THE BOILER IN OPERATION
Boiler Operation
INSTALLATION WITH A CHILLED WATER SYSTEM
BOILER OPERATING TEMPERATURE CONTROL
DOMESTIC HOT WATER SUPPLY BOILERS
WATER VELOCITY CONTROL
DOMESTIC HOT WATER SUPPLY BOILER
WATER HEATERS
Maximum Flow Rate
Temperature Rise At Full Rate Fire
TABLE - EE
TABLE - FF
WATER CHEMISTRY
COLD WATER SUPPLY DRAIN BUILDING RETURN
PIPING - MULTIPLE UNIT INSTALLATIONS
MIXING VALVE BUILDING HOT WATER SUPPLY
RELIEF VALVE TO DRAIN LOCK-TEMP STORAGE TANK
PUMP OPERATION
Hot Water Supply Boiler Installations
Temperature Rise
TABLE - GG
TABLE - HH
THERMOSTAT SETTINGS
MINIMUM WATER TEMPERATURES
TABLE - APPROXIMATE TIME / TEMPERATURE RE
HIGH WATER TEMPERATURE LIMIT CONTROL
OPTIONAL RELIEF VALVE
THERMAL EXPANSION
CATHODIC PROTECTION
WARNING:To
Ladder Diagram
1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models
HI-LIMIT
REAR WIRING
CONTROLLER
CONV
LBL90002 REV A
Wiring Diagram continued
SWITCH
1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models
1/09-Printedin U.S.A