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