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