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