Intelli-Fin 1, 500, 000 Btu/hr, 2, 000 Installation And Service Manual

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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

IFB-IFW-I-S-06

FIG. 1 Front View

FIG. 2 Rear View

Installation and service must be per formed by a qual i fied service in stall er, service agency or the gas supplier.

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 war ran ty. (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 man u fac tur er’s warranty (See Boiler Flow Rates and Temperature Rise for flow requirements).

This manual supplies information for the installation, operation and ser vic ing of the appliance. It is strong ly recommended that this manual be re viewed com plete ly before proceeding with an installation.

WARRANTY

SPECIAL INSTRUCTIONS

TO OWNER

NOTE:

Retain this manual for future reference.

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.

TABLE OF CONTENTS

Warranty .......................................................................... 1

Safety Warnings .............................................................. 3

Codes .......................................................................... 3

Installation Requirements ............................................ 4

Location .................................................................... 4

Clearances ................................................................ 4

Combustion/Ventilation Air Requirements .............. 5

Construction Air Filter .............................................. 7

Venting Systems ............................................................ 8

Category IV Venting ........................................................ 9

Flue Pipe Materials............................................ 9

Installation Guidelines ...................................... 9

Vent Length Requirements ................................10

Drain Tee Installation ........................................10

Vertical Terminations ........................................11

Sidewall Terminations ......................................12

Direct Vent Systems ........................................................13

Air Inlet Pipe Materials ....................................14

Air Inlet Pipe Length Requirements..................14

Vertical Direct Vent ..................................................15

Location Requirements......................................15

Multiple Direct Vent Installations......................16

Horizontal Direct Vent ..............................................16

Location Requirements......................................16

Multiple Direct Vent Installations......................18

Intelli-Vent Systems..................................................18

Materials ............................................................18

Length Requirements ........................................18

Vertical Flue - Sidewall Air ..............................19

Sidewall Flue - Rooftop Air ..............................20

Sidewall Flue - Sidewall Air..............................21

Gas Supply ....................................................................23

Gas Pressures and Piping ..................................23

Manifold Pressure..............................................23

Supply Pressure Measurement ..........................25

Manifold Pressure Measurement ......................26

Water Connections ..........................................................27

Heat Exchangers ..............................................................28

Integral Bypass ................................................................29

Valve and Pump ................................................29

Synchronization ................................................29

Set-up Maximum Flow......................................30

Bypass Operation ..............................................31

Minimum Water Temperatures ..................................31

Flow Switch ....................................................................32

Low Water Cut-Off ..........................................................32

Gas Train..........................................................................32

Relief Valve......................................................................33

Ratio Gas Valve ........................................................33

Diaphragm Gas Valve ..............................................33

Electrical Requirements ..................................................34

Jacket ..........................................................................34

Components and Controls ............................................35

Variable Frequency Drive..................................36

Low Air Pressure Switch ..................................37

Gas Pressure Switches ......................................37

Excel 10 Boiler Interface Controller ................37

Manual Override Control ..................................39

Temperature Adjustment....................................39

Command Display ............................................39

Password ....................................................40

Changeable Points ......................................40

Data Points in Display................................41

Status Points — Operation ........................43

Status Points — Alarm ..............................44

Outdoor Reset Function ............................44

Multiple Appliance Installations........................45

Sequencing Options....................................45

E-Bus Connection ......................................46

Temperature Limit Control ................................48

Hot Surface Ignition Control ............................48

Hot Surface Igniter..............................49

Diagnostic Status LED........................49

Operation/Diagnostic Lights and Switches ......50

Burner Assembly ..............................................51

Combustion Air Blower ....................................52

Condensate Management System......................53

Installation and Operation ..................53

Condensate Trap Installation ..............54

Lighting Instructions ....................................................55

Sequence of Operation ..................................................57

Maintenance ............................................................57

Maintenance and Annual Startup..............................58

Vent System ............................................................58

Flame Patterns ..........................................................58

Condensate Testing ..................................................59

Burner Cleaning........................................................59

Heat Exchanger Inspection ......................................61

Lubrication ............................................................62

Combustion Air Measurements ................................62

Freeze Protection ......................................................63

Heating Boiler ............................................................64

Piping ............................................................64

Piping Length and Diameter ....................................65

Integral Pump Limitations ................................65

Boiler Pump Operation......................................65

Primary/Secondary Piping ................................66

Minimum Water Temperatures ..........................66

Three Way Valves..............................................67

Boiler Flow Rates ..............................................67

Placing the Boiler in Operation ........................68

Boiler Temperature Control ..............................69

Water Heater/Domestic Hot Water Supply Boiler ....70

Typical Piping ....................................................70

Set-up Maximum Flow......................................70

Temperature Rise ..............................................71

Water Chemistry ................................................72

Piping Requirements ........................................73

Pump Operation ................................................74

Temperature Adjustment....................................75

Minimum Inlet Temperatures ............................75

Risk of Scald Warnings ....................................76

Relief Valve ......................................................76

Ladder Diagram ............................................................77

Wiring Diagram ............................................................78

Revision Notes ..............................................Back Cover

Upon receiving equipment, check for signs of ship ping damage. Pay par tic u lar attention to parts ac com pa ny ing the boiler, which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on packing slip with those actually re ceived. In case there is damage or a shortage, immedi ate ly notify carrier.

CHECKING EQUIPMENT

DO NOT

WARNING

Do not use this appliance if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch: do not use any phone in

your building.

• Immediately call your gas supplier from a neighbor’s

phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire

department.

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

OWNER WARNING

The information contained in this manual is intended for use by qualified professional installers, service technicians or gas suppliers. Consult your local expert for proper installation or service procedures.

IMPORTANT

Consult and follow local Building and Fire Regulations and other Safety Codes that apply to this installation. Contact the local gas utility company to authorize and inspect all gas and flue connections.

A gas appliance that draws combustion air from the equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting.

1. Boilers and water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the appliance or the vent-air intake system. Use proper care to avoid unnecessary contact (especially children) with the appliance and vent-air intake components.

2. Never cover your appliance, lean anything against it, store trash or debris near it, stand on it or in any way block the flow of fresh air to your appliance.

3. UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance, vent-air intake system or any location from which fumes could reach the appliance or vent-air intake system.

The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having ju ris dic tion shall be consulted before instal la tions are made. In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code. Where required by the author i ty having jurisdiction, the in stal la tion must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Au to mat i cal ly Fired Boilers, ASME CSD-1. All boilers conform to the latest edi tion of the ASME Boiler and Pressure Vessel Code, Section IV. Where required by the authority having ju ris dic tion, the installation must comply with the CSA International, CAN/CGA-B149 and/or local codes. This appliance meets the safe lighting performance criteria with the gas man i fold and control assembly provided, as specified in the ANSI standards for gas-fired units, ANSI Z21.13.

CODES

WARNING

Should overheating occur or the gas supply fail to shut off,

DO NOT turn off or disconnect the electrical supply to

the pump. Instead, shut off the gas supply at a location external to the appliance.

WARNING

To minimize the possibility of serious personal injury, fire or damage to your appliance, never violate the following safety rules.

1. Locate the appliance so that if water connections should leak, water damage will not occur. When such lo ca tions cannot be avoided, it is recommended that a suitable drain pan, ad e quate ly drained, be installed under the unit. The pan must not restrict combustion airflow. Under no circumstances is the manufacturer to be held responsible for water damage in connec tion with this unit, or any of its components.

2. The appliance must be installed so that the ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator re place ment, control replacement, etc.).

3. Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18" (46cm) above the floor. The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle.

4. DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present.

5. The appliance must be installed on a level floor. Combustible floor locations may be used. Maintain re quired clearances from combustible surfaces.

6. The appliance must not be in stalled on carpet.

7. The appliance must be installed indoors where it is protected from exposure to wind, rain and weather.

8. This appliance may condense the products of combustion when operating at water temperatures below 130°F (54.4°C). Ensure that the appliance is located near an acceptable drain where the condensate from the heat exchanger and venting system may be properly col lect ed, neutralized and disposed.

INSTALLATION PROCEDURE

LOCATION OF UNIT

TABLE - A

Clearances from

Combustible Construction:

Right Side - 0" Rear - 9" (23 cm) (Minimum 24" (0.61 m) suggested for service to pump and components) Left Side - 0" Front - ALCOVE* (Minimum 24" (0.61 m) suggested for service) Flue - 1" (25.4 mm) Hot Water Pipes - 1" (25.4 mm)

*An ALCOVE is a closet without a door.

RECOMMENDED SERVICE CLEARANCES

FIG. 3 Recommended Service Clearances - Front

FIG. 4 Recommended Service Clearances - Rear

NOTE

Clearances from combustible construction are noted on the appliance rating plate.

Maintain minimum specified clearances for adequate operation. All in stal la tions must allow sufficient space for servicing the vent connections, water pipe connections, integral circulating pump, bypass piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown in the clearances from combustion construction table.

Multiple appliances may be installed in a modular boiler or water heater in stal la tion. Multiple appliances may be installed side by side with no clear ance between adjacent appliances because this appliance is approved for zero clearance from combustible sur fac es and no service access is required from the sides.

Consult the venting section of the manual for specific installation in struc tions for the appropriate type of venting system that you will be using. Direct Vent and Intelli-Vent venting systems require installation with Category IV flue pipe, sealed air inlet pipe and air inlet caps, which must meet the manufacturer’s specifications.

COMBUSTION AND VENTILATION

AIR REQUIREMENTS FOR

APPLIANCES DRAWING AIR FROM

THE EQUIPMENT ROOM

Provisions for combustion and ven ti la tion air must be in accordance with Section 5.3, Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equip ment, or applicable provisions of the local building codes.

The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the unit is installed with a basic Category IV venting system.

FIG. 5 Combustion Air Direct from Outside

1. If air is taken directly from outside the building with no duct, provide two permanent openings:

a. Combustion air opening, with a min i mum free

area of one square inch per 4000 Btu input (5.5 cm

per kW). This opening must be located within 12" (30cm) of the bottom of the enclosure.

b. Ventilation air opening, with a minimum free

area of one square inch per 4000 Btu input (5.5 cm

per kW). This opening must be located

within 12" (30 cm) of the top of the enclosure.

FIG. 6 Combustion Air Through Ducts

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu (11 cm2 per kW) of input.

TABLE - B Minimum Recommended Combustion AIR SUPPLY TO MECHANICAL ROOM

Btu/hr

Input

1,500,000

375 in2(2419 cm2)

425 in2(2742 cm2)

500 in2(3226 cm2)

567 in2(3658 cm2)

667 in2(4303 cm2)

1,500 in2(9,677 cm2)

1,700 in2(10,968 cm2)

2,000 in2(12,903 cm2)

1,700,000

2,000,000

Outside Air* 2 - Openings

Outside Air*

1 - Opening

Inside Air

2 - Openings

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the out side through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the boiler only, additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances. Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada refer to the latest edition of CAN/CGA B149. Check all local code re quire ments for combustion air.

Combustion Air Source

FIG. 7 Combustion Air from Interior Space

FIG 8 Combustion Air from Outside - Single Opening

3. If air is taken from another interior space, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu (22 cm

per kW) of input,

but not less than 100 square inches (645 cm2).

4. If a single combustion air open ing is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu (7 cm

per kW). This opening must be located within 12" (30 cm) of the top of the enclosure.

CAUTION

Under no circumstances should the mechanical room ever be under a negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.

All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a com bus tion air opening a minimum of ap prox i mate ly 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12" (30 cm) of the ceiling and one must be within 12" (30 cm) of the floor of the mechanical room. Each opening must have net free area as specified in Table - B. Single openings shall commence within 12" (30 cm) of the ceiling.

The combustion air supply must be com plete ly free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the heat exchanger finned tubes, headers, flue collectors, and the vent system. The result is improper combustion and a nonwarrantable, premature appliance failure.

These chemicals, when burned form acids which quickly attack the boiler tubes, tube sheets, flue collectors, and the ap pli ance stack. The result is improper combustion and a non-warrantable, pre ma ture failure of the appliance.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue prod ucts

from the venting system into an occupied living space can cause a very hazardous condition that must be im me di ate ly corrected. If a fan is used to supply combustion air to the equipment room, the installer must make sure that it does not cause drafts that could lead to nuisance operational problems with the appliance.

A construction air filter is installed on the ap pli ance as shipped. The filter assembly is installed on the combustion air inlet located at the rear of the appliance. The filter assembly slips over the air inlet collar and is secured in place with the clamp provided with the filter. If limited space is available at the rear of the appliance, field supplied elbows may be used to mount the filter in the alternate positions shown in the illustration. This filter is For Temporary Use Only on an appliance that must be operated for temporary heat or hot water when a building is under construction. The filter will provide a temporary means to remove airborne dust, dirt and particulate matter generated by construction. The filter prevents airborne particulate contaminants from being drawn into the burner with the combustion air. The filter can be cleaned routinely during construction if necessary. Remove the filter to clean. Wash the filter with water. A flow of water from the inside to the outside should remove most particle matter. Allow the filter to dry before reinstalling. Unfiltered com bus tion air from a construction site can contain con tam i nants that will collect in the burner reducing the firing rate. A burner that becomes clogged with airborne particulate contaminants must be removed and cleaned to restore proper operation to the burner. Sustained operation of an appliance with a clogged burner may result in nuisance operational prob lems, bad combustion and non-warrantable component failures.

CONSTRUCTION AIR FILTER

FIG. 9 Construction Air Filter

ELBOW(S)

NOT

PROVIDED

REAR

MODEL

2.0 19.750

1.7

1.5

19.250

18.750

CABINET AIR INLET OPENING

12.250 4.875

10.750

9.250

4.375

3.875

FRONT

D E REAR

15.000

9.000

7.500

14.500

6.000

14.000

24.000

EDGE OF SCREEN

MEDIA OVERLAP

FOLD OVERLAP AROUND EDGE OF SCREEN AS SHOWN.

BAND CLAMP

PUSH FILTER ONTO AIR INLET AND FASTEN WITH CLAMP AS SHOWN.

The construction air filter MUST be removed from the appliance’s air inlet before the appliance is placed in normal operation. Once the construction air filter is removed, ensure that either the equipment room is supplied with combustion air from properly sized combustion and ventilation air openings or a combustion air duct from a Direct Vent or Intelli-Vent system is connected to the appliance. The optional Direct Vent and Intelli-Vent venting sys tems have specific requirements for a special com bus tion air duct from the outside that is directly connect ed to the appliance. See the requirements for this combus tion air duct in the vent ing section for each spe cial ized vent system.

CONSTRUCTION AIR FILTER KITS

TABLE - C

Input Construction

Btu/hr Air Filter Kit

1,500,000

________________________

1,700,000

________________________

2,000,000

KIT4000

________________________

KIT4001

________________________

KIT4002

VENTING

Vent System Options

This appliance has three venting system options. They are: (A) Category IV Venting system with vertical roof top termination or sidewall termination of the flue and combustion air supplied from the mechanical room. (B) Direct Vent with a Category IV flue and a separate combustion air pipe to the outdoors. The Direct Vent system ter mi nates both the flue and air inlet in the same pressure zone. The flue out let and combustion air intake may ter mi nate on either the sidewall or with a rooftop termination. (C) Intelli-Vent with a Category IV flue and a separate combustion air pipe to the outdoors.The Intelli-Vent system terminates the flue and the combustion air inlet pipe in different pressure zones. The Intelli-Vent system may terminate the flue on the roof top and combustion air intake on the sidewall, the flue on the sidewall and combustion air from the rooftop or the flue on the sidewall and combustion air from a different sidewall. All appliances are shipped from the factory equipped for Category IV venting. The optional Direct Vent and Intelli-Vent venting systems will require the installation of specific vent kits and venting materials. The following is a detailed explanation of the installation requirements for each venting system, components used and part numbers of vent kits for each model.

General

Vent installations for connection to gas vents or chimneys must be in ac cor dance with Part 7, “Venting of Equip ment,” of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Stan dard B149 Installation Codes for Gas Burning Appliances and Equipment or applicable provisions of the local building codes.

Adequate combustion and ventilation air must be supplied to the equipment room in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Codes for Gas Burning Appliances and Equip ment, or applicable provisions of the local building codes.

The distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Ap pli anc es and Equipment.

Vent connection is made directly to the flue outlet opening on the back of the unit. The connection from the ap pli ance vent to the stack must be made as direct as possible.

IMPORTANT

Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness. Also, check for corrosion or deterioration. Immediately correct any problems observed in the venting system.

TABLE - D

The Category IV Flue Pipe Sizes

Input Btu/hr Flue Size

1,500,000

________________________

1,700,000

________________________

2,000,000

________________________

_______________________

Category IV Venting

A CATEGORY IV POSITIVE

PRESSURE VENTING SYSTEM

FIG. 10 Basic Category IV Venting - Vertical

FIG. 11 Basic Category IV Venting - Horizontal

A Category IV venting system for the flue products is required on all models of this appliance. A Category IV vent ing system operates with a positive pressure in the vent. This positive pressure is generated by the internal combustion air blower which operates the combustion process and also ex hausts the flue products from the build ing. The Category IV flue from this appliance can NOT be combined with the vent from any other appliance. The Category IV flues from multiple ap pli anc es can NOT be combined into a common vent. The Category IV flue from this appliance must be a dedicated stack. The flue from this Category IV ap pli ance must have all vent joints and seams sealed gas-tight. A Category IV vent system has specific vent material and installation requirements.

The flue products in the vent system may be cooled below their dew point and form condensate in the flue. The ma te ri als used for a Category IV vent must be resistant to any corrosive damage from flue gas condensate. The flue from a Category IV vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the vent ing system.

Category IV Flue Pipe Materials

Select venting material from the fol low ing specified vent distributors:

Heat-Fab Inc. Saf-T CI Vent with AL29-4C stainless steel (Call 1-800-772-0739 for nearest distributor)

Protech Systems Inc. Fas N Seal Vent with AL29-4C stainless steel (Call 1-800-766-3473 for nearest distributor)

Z-Flex Z-Vent with AL29-4C stainless steel (Call 1-800-654-5600 for nearest distributor)

Or other listed Category IV vent sys tems suitable for a condensing, pos i tive pressure gas fired appliance.

Venting Guidelines for a Category IV Vent

The connection from the appliance vent to the stack or vent termination out side the building MUST be made with listed Category IV vent system and must be direct as possible with no reduction in diameter. The Category IV vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the vent manufacturers instructions. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes.

In a typical installation, each appliance must have a dedicated Category IV flue with no other appliance interconnected to any part of the dedicated flue. Each appliance MUST connect to the dedicated flue stack using a properly sealed vent adapter provided by the vent manufacturer. The flues from multiple Intelli-Fin appliances may only be combined when using an engineered vent system incorporating an induced draft fan to ensure that flue products will be properly exhausted from the building at all times. Failure to use a properly sized induced draft fan on a combined vent installation may result in a hazardous condition where flue gases spill into an occupied living space. Consult the induced draft fan manufacturer to size the induced draft fan and to determine the diameter of the common vent pipe required for a combined vent installation.

Any vent materials specified must be listed by a nationally recognized test agency for use as a Category IV vent material.

The venting system must be planned so as to avoid possible contact with con cealed plumbing or electrical wiring inside walls, floors or ceilings. Locate the appliance as close as pos si ble to a chimney or gas vent.

There shall be no reductions in vent diameter.

Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs should slope upwards not less than 1/4 inch per foot (21 mm/m) from the drain tee installed in the flue to the vertical portion of the flue or to the vent terminal on sidewall venting installations. This ensures proper removal of any con den sate that may form in the flue. Follow the installation instructions from the vent material manufacturer.

Do not use an existing chimney as a raceway if another appliance or fire place is vented through the chimney. The weight of the venting system must not rest on the unit. Adequate support of the venting system must be provided in compliance with local codes and other applicable codes. All con nec tions should be secured and sealed per the vent manufacturers specifications.

Vent connectors serving appliances vented by natural draft shall not be connected to any portion of the Cat e go ry IV positive pressure vent system used by this appliance. Connection of a negative draft flue into the positive pressure stack from this appliance may cause flue products to be discharged into an occupied living space causing serious health injury.

When a Category IV vent system is dis con nect ed for any reason, the flue must be reassembled and resealed according to the vent manufacturer’s in struc tions.

The installed length of the Category IV flue from the appliance to the point of termination, outside of the building, must not exceed a maximum of 100 equiv a lent feet (30.5 m) in length. Subtract 5 feet (1.5 m) of equivalent length for each 90° elbow installed in the vent. Subtract 2 1/2 feet (0.7 m) of equivalent length for each 45° elbow installed in the vent.

The flue may terminate either ver ti cal ly at the roof top or horizontally on a sidewall. See the information about the specific vent termination location for recommended location and clearances.

General Category IV Vent Termination Clearances

The vent cap should have a minimum clearance of 4 feet (1.2 m) horizontally from and in no case above or below, unless a 4 foot (1.2 m) horizontal dis tance is maintained from electric meters, gas meters, regulators and relief equipment.

The venting system shall terminate at least 3 feet (0.9 m) above any forced air inlet within 10 feet (3.05 m).

The venting system shall terminate at least 4 feet (1.2 m) below, 4 feet (1.2 m) horizontally from, or 1 foot (30 cm) above any door, window or grav i ty air inlet into any building.

Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent cannot terminate below grade. The bottom of the vent terminal shall be located at least 12 inches (30 cm) above grade and above normal snow levels.

To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

Flue gases from this appliance may contain large amounts of water vapor that will form a white plume in winter. Plume could obstruct a window view.

Flue gas condensate can freeze on ex te ri or surfaces or on the vent cap. Fro zen condensate on the vent cap can result in a blocked flue condition. Flue gas condensate can cause discoloration of exterior building surfaces. Adjacent brick or masonry surfaces should be protected with a rust re sis tant sheet metal plate.

The manufacturer shall NOT be held liable for any personal injury or prop er ty damage due to ice formation or the dislodging of ice from the vent system or the vent termination.

Drain Tee Installation

WIRE TIE

4" Ø CIRCULAR TRAP

TO SUITABLE DRAIN

FIG. 12 Drain Tee

A drain tee MUST be installed in the Category IV vent pipe to collect and dispose of any condensate that may occur in the vent system. The drain tee should be installed at the point where the flue turns vertical for a roof top termination or as one of the first fittings in a horizontal flue that will terminate on a sidewall. Ensure that horizontal portions of the vent are properly sloped to allow condensate to be evacuated at the drain tee. See the typical vent installation drawings. Plastic drain tubing, sized per the vent manufacturer’s instructions, shall be provided as a drain line from

the tee. The drain tubing must have a trap provided by a 4" (10.2 cm)-diameter circular trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent. Secure the trap loop in position with nylon wire ties. Use caution not to collapse or restrict the condensate drain line with the nylon wire ties. The con den sate drain must be routed to the con den sate neutralization system or a suitable drain for disposal of con den sate that may occur in the Category IV vent system. Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material. Ensure that the drain from the condensate tee is not exposed to freezing temperatures. See “Freeze Protection” for more information.

MASONRY CHIMNEY

INSTALLATIONS

A standard masonry chimney must NOT be used to vent the products of combustion from the flue of a Category IV, pos i tive pressure appliance. If a masonry chimney is to be used,

the chimney MUST use a sealed, metallic, corrosion re sis tant liner system to vent flue products from this high efficiency appliance. Sealed, metallic, corrosion resistant liner systems (single wall, double-wall, or flexible or rigid metallic liners) must be rated for use with a high efficiency Category IV, positive pressure vent system. Corrosion re sis tant chimney liner

systems are typ i cal ly made from a high grade of cor ro sion resistant stainless steel such as AL 29-4C. The corrosion resistant liner must be properly sized and fully sealed throughout the entire length if the flue is contained within the masonry chimney. Both the top and the bottom of the masonry chimney must be capped and sealed to provide a dead air space around the sealed corrosion resistant metallic liner. Consult with local code officials to determine code

re quire ments or the advisability of using a masonry chimney with a sealed cor ro sion resistant liner system.

CAUTION

Venting of a high efficiency Category IV appliance into a masonry chimney without a sealed stainless steel liner can result in operational and safety problems. Any breaks, leaks or damage to the masonry flue/tile will allow spillage of the positive pressure flue products from the chimney. These flue products can easily escape into an occupied living space causing a health hazard. If there is any doubt about the condition of a masonry chimney, or its acceptability for use after inser tion of a corrosion resistant liner system, consult with local code officials.

VERTICAL VENTING

TERMINATIONS

Follow all General Category IV Vent Termination Clearances.

RIDGE

CHIMNEY

3' MIN

2' MIN

10' OR LESS

FIG. 13 Vent Termination from Peaked Roof - 10 Feet or Less

from Ridge

FIG. 14 Vent Termination from Peaked Roof - 10 Feet or

More from Parapet Wall

A vertical termination less than 10 feet (3.05 m) from a parapet wall must be a minimum of 2 feet (0.61 m) higher than the parapet wall.

SIDEWALL VENTING

TERMINATIONS

This venting system uses the ap pli ance’s internal combustion air blower to force the flue products out of a horizontally-terminated flue. This blower generates a positive pres sure in the flue. Combustion air is drawn from the equipment room (see Combustion and Ventilation Air Re quire ments) unless the appliance is equipped with an optional Direct Vent or Intelli-Vent System.

FIG. 17 Sidewall Venting Installation

The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed type Category IV vent materials and accessories. The in stall er must supply suitable vent pipe material. The sidewall vent cap is available from the appliance manufacturer as a vent kit.

FIG. 18 Sidewall Vent Cap

TABLE - E

Sidewall Vent Cap Kits

Sidewall Vent

Input Btu/hr Flue Size Cap Kit

1,500,000

________________

1,700,000

________________

2,000,000

_____________

SVK3026

_________________

SVK3027

_________________

SVK3028

The sidewall vent cap kit includes the wall penetration assembly and the dis charge screen assembly. All required Category IV vent pipe and fittings must be purchased locally.

WALL OR PARAPET

2' MIN

3' MIN

CHIMNEY

2' MIN

CHIMNEY

10' OR MORE

3' MIN

NOTE: NO HEIGHT ABOVE PARAPET REQUIRED WHEN

WALL OR PARAPET

DISTANCE FOR WALLS OR PARAPETS IS MORE THAN 10'>

CHIMNEY

The installed sidewall vent cap assembly may be paint ed to match the exterior color. The opening through the wall for instal la tion of the sidewall vent cap must provide an air space clearance of 2 inches (5.1 cm) around the flue pipe. The diameter of the opening for installation of the sidewall cap will be 4 inches (10.2 cm) larger (minimum) than the nominal diameter of the in stalled vent pipe to the sidewall cap.

The sidewall cap is installed from the outside and mounted to the wall with four screws or wall anchors. Seal under the screw heads with caulking. Install the screen assembly using the stainless steel screws provided in the kit. Install the Category IV vent pipe from the appliance to the vent cap. The installed vent pipe must protrude at least 2 inches (5.1 cm) into the screen area beyond the thimble portion of the sidewall cap assembly. See detailed instructions packed with the sidewall vent kit.

Follow all requirements in the General Category IV Venting sections for vent ing flue products to the outdoors. See the Combustion and Ventilation Air Requirements section to ensure that adequate combustion and ventilation air is supplied to the equipment room. All other general installation requirements must be followed.

LOCATION OF A SIDEWALL

VENT TERMINATION

Follow all General Category IV Vent Termination Clearances.

3' MIN.

4' MIN.

10' MIN.

HORIZONTALLY

FIG. 19 Sidewall Venting Installation with Clearances from

Vent Cap

The vent cap shall terminate at least 3 feet (0.91 m) above any forced air inlet within 10 feet (3.05 m) horizontally.

The vent cap MUST NOT terminate below a forced air intake at any distance.

The vent shall terminate at least 4 feet (1.22 m) below, 4 feet (1.22 m) horizontally from or 1 foot (0.30 m) above and 2 feet (0.60 m) horizontally from any door, window or gravity air inlet to the building.

The sidewall vent termination must be at least 8 feet (2.4 m) horizontally from any combustion air intake located above the sidewall termination cap.

Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent cannot terminate below grade.

The vent shall not terminate directly above a public walkway due to the nor mal formation of water vapor in the combustion process. Horizontal ter mi na tions must not be located over areas of pedestrian or vehicular traffic.

The vent system shall terminate at least 1 foot (0.30 m) above grade, above normal snow levels and at least 7 feet (2.13 m) above grade when located ad ja cent to public walkways.

The vent terminal shall not be in stalled closer than 3 feet (0.91 m) from an inside corner of an L-shaped struc ture.

The vent cap should have a minimum clearance of 4 feet (1.22 m) hor i zon tal ly from and in no case above or below, unless a 4-foot (1.22 m) hor i zon tal distance is maintained from elec tric meters, gas meters, regulators and relief equipment.

Flue gas condensate can freeze on ex te ri or walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

The sidewall vent system must use the sidewall vent cap kit provided by the appliance manufacturer for installation on a sidewall termination.

The sidewall vent cap MUST be purchased as a kit from the appliance man u fac tur er to ensure proper operation. Lo cal ly purchased or fabricated sidewall vent caps should not be used.

DIRECT VENT AND

INTELLI-VENT SYSTEMS

Direct Vent and Intelli-Vent Systems are installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Direct Vent System terminates both the flue and combustion air

inlet in the same pressure zone. The Intelli-Vent System terminates the flue and combustion air inlet in dif fer ent pressure zones. The flue outlet and combustion air intake may terminate with either a sidewall or a rooftop termination.

Follow all requirements in the General Category IV Venting sections for proper installation and venting of flue products vertically or horizontally to the outdoors. All other general in stal la tion requirements must be fol lowed.

The Direct Vent and Intelli-Vent Sys tems require the installation of an additional pipe to supply combustion air from outdoors directly to the ap pli ance.

In cold climates, the use of type “B” double wall vent pipe or an insulated single wall pipe for combustion air is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.

Termination point for the flue products must follow the clearance requirements in the Vertical or Horizontal Vent Termination sections of the Category IV Venting.

CAUTION

Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.

TABLE - F

Direct Vent and Intelli-Vent Flue

and Air Inlet Pipe Sizes

Air Inlet

Input Btu/hr Flue Size Pipe Size

1,500,000

________________

1,700,000

________________

2,000,000

______________

_____________

________________

7"*

________________

*Piping from the appliance to the air inlet cap may be either 7" or 8". An 8" diameter sidewall air inlet cap is provided in the vent kit.

Length of Air Inlet Pipe

The maximum total length of the sidewall or vertical roof top combus tion air inlet pipe as installed from the appliance to the air inlet cap must not exceed 100 equivalent feet (30.5 m) in length. Subtract 5 feet (1.52 m) of equivalent length for each 90° elbow installed in the air inlet pipe system. Subtract 2 1/2 feet (0.7 m) of equiv a lent length for each 45° elbow in stalled in the air inlet pipe system.

Do not exceed limits for the combustion air inlet piping lengths.

Air Inlet Pipe Materials

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from those specified in this section.

Select air inlet pipe material from the following specified materials:

• PVC, CPVC or ABS (6", 7"or 8" I.D.)*.

• Dryer Vent or Sealed Flexible Duct (not recommended for roof top air inlet).

• Galvanized steel vent pipe with joints and seams sealed as specified below.

• Type “B” double wall vent with joints and seams sealed as specified below.

* Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the ap pli ance and the plastic air inlet pipe.

WARNING

Using vent or air intake ma te ri als other than those specified, fail ure to properly seal all seams and joints or failure to follow vent pipe manufacturer’s instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and cer ti fi ca tion of the appliance.

Sealing of Type “B” double wall vent material or galvanized vent pipe ma te ri al used for air inlet pipe on a sidewall or vertical roof top Com bus tion Air Supply System.

a. Seal all joints and seams of the air inlet pipe

using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the

bottom of horizontal runs.

c. Secure all joints with a minimum of three sheet

metal screws or pop rivets. Apply aluminum foil duct tape or sil i cone sealant to all screws or rivets installed in the vent pipe.

d. Ensure that the air inlet pipes are properly

supported.

The PVC, CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone

NOTE:

The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming com bus tion air.

sealant to ensure a proper seal at the appliance con nec tion and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and sup plied in proper volume.

When a sidewall or vertical roof top combustion air supply system is dis con nect ed for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of con tam i nants and supplied in proper volume.

DANGER 

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue prod ucts and carbon monoxide emissions causing severe personal injury or death.

Combined Combustion Air Inlet Points

The air inlet pipes from multiple ap pli anc es can be combined to a single common connection if the common air inlet pipe has a cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe. {Example: two 8" (20.3 cm) air inlet pipes [50.3 in

(324.5 cm2) area each] have a total area of 100.6 in2(645.2 cm2) requires a 12" (30.5 cm) [113.1 in

(729.7 cm2] common air inlet pipe.} The air inlet point for mul ti ple boiler air inlets must be pro vid ed with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air in let. This exterior opening for com bus tion air must connect directly to the outdoors. The total length of the combined air inlet pipe must not exceed a maximum of 100 (30.5 m) equivalent feet. You must deduct the restriction in area provided by any screens, grills or louvers installed in the common air inlet point. These are common on the sidewall air inlet openings and some rooftop terminations. Screens, grills or louvers installed in the common air inlet can reduce the free area of the opening from 25% to 75% based on the materials used.

VERTICAL DIRECT VENT SYSTEMS

A Vertical Direct Vent System is in stalled with a Category IV flue and a separate combustion air pipe to the outdoors. The Direct Vent system ter mi nates both the flue and air inlet in the same pressure zone. The flue out let and combustion air intake must both terminate on the rooftop.

Follow all requirements in the General Category IV Venting sections for proper installation and of venting flue prod ucts vertically to the outdoors. All other general installation requirements must be followed.

The Direct Vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the spec i fied materials.

The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 100 equivalent feet (30.48 m) in length. The maximum in stalled length of the flue pipe from the appliance to the termination cap is 100 equivalent feet (30.48 m) in length. Subtract 5 feet (1.52 m) of equivalent length

for each 90° elbow installed in either the flue pipe or the air inlet pipe.

Termination point for the flue products must follow the clearance requirements in the Vertical Vent Termination sections of the

Category IV Venting.

FIG. 20 Vertical Direct Vent Installation with Rooftop

Combustion Air Inlet

12"

VERTICAL COMBUSTION AIR INLET

FIG. 21 Air Inlet Cap for Rooftop Termination

The air inlet cap for the vertical roof top air inlet is assembled from com po nents purchased locally. The air inlet cap consist of two 90° elbows installed at the point of termination for the air inlet pipe. The first 90° elbow is in stalled on the rooftop at the highest vertical point of the air inlet pipe and turned horizontal, the second 90° elbow is installed on the horizontal outlet of the first elbow and turned down. A 90° elbow and a 90° street elbow may be used to make this assembly. If a straight piece of pipe is used be tween the two elbows, it should not ex ceed 6" (150 mm) in length. The termina tion elbow on the air inlet must be located a minimum of 12" (0.30 m) above the roof or above normal levels of snow accumulation.

The point of termination for the com bus tion air inlet cap MUST be at least 3 feet (0.91 m) below the point of flue gas termination (vent cap) if it is located within a 10 foot (3.05 m) radius of the flue outlet. Use care to ensure that the 90° elbow assembly is properly installed on the air inlet pipe.

The combustion air inlet cap must not be installed closer than 10 feet (3.05 m) from an inside corner of an L-shaped structure.

The termination point of the combustion air inlet cap must be installed at least one foot (0.30 m) above the roof top and above normal snow levels.

The combustion air cap assembly used MUST adequately protect the combustion air inlet from wind and weather.

The combustion air cap and flue gas outlet MUST be located on the same roof top surface and in the same pressure zone.

Combustion air supplied from outdoors must be free of contaminants (see Com bus tion and Ventilation Air). To pre vent recirculation of flue products in to the combustion air inlet, follow all instructions in this section.

Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products that can cause personal injury, death or prop er ty damage.

Multiple Vertical Direct Vent Installations

FIG. 22 Multiple Vertical Direct Vent Installations

The combustion air inlet caps for mul ti ple appliance installations must maintain the minimum 3 foot (0.91 m) clearance below the closest vertical flue outlet if within 10 feet (3.05 m). Multiple flue outlet caps may be in stalled side by side and multiple air inlet caps may be installed side by side but the air inlet must always be at least 3 feet (0.91 m) below the closest flue outlet if the outlet is within 10 feet (3.05 m). All clearance and installation requirements in this sec tion and the applicable portions of the general Category IV venting section must be maintained on multiple ap pli ance installations.

For venting flue products horizontally to the outdoors, follow all re quire ments in the installation instructions for sidewall venting. Termination point for the flue products must follow the clearance requirements in the Sidewall Vent Termination section of Category IV Venting.

A Horizontal Direct Vent System is installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Direct Vent system ter mi nates both the flue and air inlet in the same pressure zone. The flue out let and combustion air intake must both terminate on the same sidewall.

Follow all requirements in the General Category IV Venting sections for proper installation and of venting flue prod ucts to the outdoors with a sidewall termination. All other general in stal la tion requirements must be followed.

HORIZONTAL DIRECT VENT

The Direct Vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the spec i fied materials.

each 45° elbow installed in either the flue or the air inlet pipe.

Termination point for the flue products must follow the clearance requirements in the Sidewall Venting Termination sections of the

Category IV Venting.

FIG. 23 Horizontal Direct Vent Installations with Sidewall

Combustion Air Inlet

SIDEWALL COMBUSTION

AIR INLET

Horizontal Direct Vent systems in stalled with sidewall terminations for both combustion air and flue products must purchase the termination caps from the appliance manufacturer. The sidewall air inlet cap and sidewall vent cap for flue products are avail able as a vent kit.

FIG. 24 Sidewall Vent Cap

The part numbers for the required sidewall air inlet cap kit are listed by unit size. The manufacturer, in accordance with CSA requirements, must furnish the sidewall air inlet cap. Each kit includes the spe cial combustion air inlet cap for in stal la tion on an exterior sidewall. The sidewall air inlet cap supplied in the kit is sized to provide combustion air for a single appliance only.

TABLE - G

Flue Air Inlet Sidewall Air

Input Cap Cap Inlet & Flue

Btu/hr Size Size Cap Kit

1,500,000

___________

1,700,000

___________

2,000,000

__________

8"*

__________

HDK3018

______________

HDK3019

______________

HDK3020

*Piping from the appliance to the air inlet cap may be either 7" or 8" connecting to an 8" sidewall cap provided in the kit.

Location of a Sidewall Air Inlet Cap

The termination point of the sidewall air inlet must be installed a minimum of 12 inches (0.30 m) above ground level and above normal levels of snow ac cu mu la tion.

The point of termination for the sidewall combustion air inlet cap MUST be located a minimum of 3 feet (0.92 m) horizontally and 12 inches (0.30 m) below the point of flue gas termination (vent cap) if it is located within a 10 foot (3.05 m) radius of the flue outlet.

The sidewall combustion air inlet cap MUST NOT be installed above the sidewall flue outlet if it is located within a 10 foot (3.05 m) radius of the flue outlet.

The sidewall combustion air inlet cap must not be installed closer than 10 feet (3.05 m) from an inside corner of an L-shaped structure.

The sidewall combustion air cap as sem bly used MUST adequately protect the combustion air inlet from wind and weather.

The sidewall combustion air inlet cap and flue gas outlet MUST be located on the same sidewall surface and in the same pressure zone.

Combustion air supplied from outdoors must be free of contaminants (see Com bus tion and Ventilation Air). To pre vent recirculation of flue products into the combustion air inlet, follow all instructions in this section.

Multiple Horizontal Direct Vent Installations

FIG. 26 Multiple Horizontal Direct Vent Caps Installed on a

Sidewall

INTELLI-VENT SYSTEMS

The combustion air inlet caps for mul ti ple appliance installations must maintain the same minimum clearance from the closest vent cap installed within a 10 foot (3.05 m) radius of the point of flue gas termination as specified in single appliance installations. Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the minimum clearance of 3 feet (0.91 m) horizontal radius and 12 inches (0.30 m) below the closest flue outlet to the air inlet cap must be maintained. All clearance and installation requirements in this sec tion and the applicable portions of the general Category IV venting section must be maintained on multiple ap pli ance installations.

An Intelli-Vent system is a Category IV flue installed with a separate com bus tion air pipe to the outdoors. The Intelli-Vent system terminates the flue and the combustion air inlet pipe in different pressure zones. The Intelli-Vent system may terminate the flue and combustion air in any one of three configurations.

These are:

(1) The flue on the roof top and combustion air intake

on the sidewall;

(2) The flue on the sidewall and combustion air from

the rooftop;

(3) The flue on the sidewall and the combustion air on

a sidewall other than the sidewall where the flue is located.

All appliances are shipped from the factory equipped for Category IV venting system. The optional Intelli-Vent systems require the installation of specific venting materials that are purchased locally. Sidewall termination caps for flue products and combustion air must be purchased from the manufacturer. The sidewall caps for combustion air and flue products are available as vent kits. The following is a detailed explanation of the installation re quire ments for each venting system, components used and part numbers of vent kits for each model.

Follow all requirements in the General Category IV Venting sections for proper installation and of venting flue prod ucts to the outdoors with either a rooftop or a sidewall termination. All other general installation requirements must be followed.

The Intelli-Vent System requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the spec i fied materials.

FIG. 25 Air Inlet Cap for Sidewall Termination

FLUE OUTLETS

3' HORIZONTALLY

AIR INLET CAP

1' BELOW FLUE

Combined Air Inlet Points

The air inlet pipes from multiple ap pli anc es installed with an Intelli-Vent system can be combined to a single common connection based on the cross sectional area of the common pipe as defined in the Direct Vent basic in for ma tion section.

Maximum Length of an Intelli-Vent Sys tem

The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 100 equivalent feet (30.5 m) in length. The maximum in stalled length of the flue pipe from the appliance to the termination cap is 100 equivalent feet (30.5 m) in length. Subtract 5 feet (1.52 m) of equivalent length for each 90° elbow installed in either the flue pipe or the air inlet pipe.

Subtract 2 1/2 feet (0.7 m) of equivalent length for each 45° elbow installed in either the flue pipe or the air inlet pipe.

VERTICAL INTELLI-VENT WITH

SIDEWALL COMBUSTION AIR

FIG. 27 Vertical Intelli-Vent Installation - Sidewall Combustion Air Inlet

Intelli-Vent systems are installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Vertical Intelli-Vent system ter mi nates the flue at the rooftop and air inlet at the sidewall. The flue outlet and combustion air intake terminates in different pressure zones.

Follow all requirements in the General Category IV Venting sections for proper installation and venting of flue prod ucts vertically to the outdoors. All other general installation requirements must be followed.

The Intelli-Vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance.

Termination point for the flue products must follow the clearance requirements in the Vertical Vent Termination sec tion of the Category IV Venting.

CAUTION

Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.

SIDEWALL COMBUSTION

AIR INLET

FIG. 28 Air Inlet Cap for Sidewall Termination

The air inlet cap for the sidewall air inlet must be purchased from the ap pli ance manufacturer.

The part numbers for the required sidewall air inlet cap kit are listed by unit size. The appliance man u fac tur er, in accordance with CSA requirements, must furnish the sidewall air inlet cap. Each kit includes the special combustion air inlet cap for installation on an exterior sidewall.

TABLE - H

Air Inlet Sidewall

Input Flue Pipe Air Inlet

Btu/hr Size Size Cap Kit

1,500,000

___________

1,700,000

___________

2,000,000

___________

7"*

___________

SAK3000

___________

SAK3001

___________

SAK3002

*Piping from the appliance to the air inlet cap may be either 7" or 8" connecting to an 8" sidewall cap provided in the kit.

Location of a Sidewall Air Inlet Cap

Installation, location and clearance requirements for the sidewall air inlet cap in an Intelli-Vent application are the same as the installation, location and clearance requirements for the sidewall air inlet cap in the Hor i zon tal Direct Vent section of the venting instructions.

The sidewall combustion air inlet cap and the rooftop flue gas outlet are located in different pressure zones in an Intelli-Vent system.

HORIZONTAL INTELLI-VENT WITH

VERTICAL COMBUSTION AIR

Intelli-Vent systems are installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Horizontal Intelli-Vent system terminates the flue at the sidewall and air inlet at the rooftop. The flue outlet and combustion air intake terminate in different pressure zones.

FIG. 29 Horizontal Intelli-Vent Installation - Rooftop

Combustion Air Inlet

Follow all requirements in the General Category IV Venting sections for proper installation and of venting flue prod ucts horizontally to the outdoors. All other general installation requirements must be followed.

The Intelli-Vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance.

In cold climates, the use of type “B” double wall vent pipe or an insulated single wall pipe is recommended to prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.

Termination point for the flue products must follow the clearance requirements in the Horizontal Sidewall Vent Ter mi na tion section of the Category IV Vent ing.

CAUTION

Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.

The flue and air inlet duct sizes for a Horizontal Intelli-Vent Installation with Rooftop Combustion Air Inlet are listed by unit size. The sidewall vent cap must be purchased from the ap pli ance manufacturer as a vent kit.

TABLE - I

Air Inlet Sidewall

Input Flue Pipe Vent

Btu/hr Size Size Cap Kit

1,500,000

___________

1,700,000

___________

2,000,000

___________

7"*

___________

SVK3026

____________

SVK3027

____________

SVK3028

*Piping from the appliance to the air inlet cap may be either 7" or 8" connecting to an 8" sidewall cap provided in the kit.

12" MIN.

VERTICAL COMBUSTION

AIR INLET

FIG. 30 Air Inlet Cap for Rooftop Termination

The air inlet cap for the vertical roof top air inlet is assembled from com po nents purchased locally. The air inlet cap consist of two 90° elbows installed at the point of termination for the air inlet pipe. The first 90° elbow is in stalled on the rooftop at the highest vertical point of the air inlet pipe and turned horizontal, the second 90° elbow is installed on the horizontal outlet of the first elbow and turned down. A 90° elbow and a 90° street elbow may be used to make this assembly. If a straight piece of pipe is used be tween the two elbows, it should not ex ceed 6 inches (150 mm) in length. The ter mi na tion elbow on the air inlet must be located a minimum of 12 inches (0.30 m) above the roof or above normal levels of snow accumulation.

Location of a Rooftop Air Inlet Cap

Installation, location and clearance requirements for the rooftop air inlet cap in an Intelli-Vent application are the same as the installation, location and clearance requirements for the rooftop air inlet cap in the Vertical Direct Vent section of the venting instructions.

The rooftop combustion air inlet cap and the sidewall flue gas outlet are located in different pressure zones in an Intelli-Vent system.

In cold climates, the use of type “B” double wall vent pipe or an insulated single wall pipe is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.

Termination point for the flue products must follow the clearance requirements in the Horizontal Sidewall Vent Ter mi na tion section of the Category IV Venting.

FIG. 31 Horizontal Intelli-Fin Installation with Sidewall

Combustion Air in a Different Pressure Zone

Intelli-Vent systems are installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Horizontal Intelli-Vent system terminates the flue at the sidewall and the combustion air on a sidewall other than the sidewall where the flue is located. The sidewall flue outlet and sidewall combustion air intake must terminate in different pressure zones.

The Intelli-Vent System requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance.

HORIZONTAL INTELLI-VENT

WITH SIDEWALL COMBUSTION AIR

CAUTION

Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.

The flue and air inlet duct sizes for a Horizontal Intelli-Vent Installation with Sidewall Combustion Air Inlet are listed by unit size.

SIDEWALL COMBUSTION

AIR INLET

Intelli-Vent systems installed with sidewall terminations for both com bus tion air and flue products must pur chase the termination caps from the appliance manufacturer. The sidewall air inlet cap and sidewall vent cap for flue products are available as a vent kit.

FIG. 32 Sidewall Vent Cap

The part numbers for the required sidewall air inlet and flue cap kit are listed by unit size. The manufacturer, in accordance with CSA re quire ments, must furnish both the sidewall air inlet and flue cap. Each kit includes the both the special com bus tion air inlet cap and the sidewall flue cap for installation on an ex te ri or sidewall. The sidewall air inlet cap supplied in the kit is sized to provide combustion air for a single appliance only.

TABLE - J

Flue Air Inlet Sidewall Air

Input Cap Cap Inlet & Flue

Btu/hr Size Size Cap Kit

1,500,000

___________

1,700,000

___________

2,000,000

_______

8"*

_______

HDK3018

________________

HDK3019

________________

HDK3020

*Piping from the appliance to the air inlet cap may be either 7" or 8" connecting to an 8" sidewall cap provided in the kit.

Location of a Sidewall Air Inlet Cap

FIG. 33 Air Inlet Cap for Sidewall Termination

The sidewall combustion air inlet cap and the rooftop flue gas outlet are located in different pressure zones in an Intelli-Vent system.

GAS SUPPLY

Verify that the appliance is supplied with the type gas specified on the rating plate. Consult factory for installations at altitude.

INLET PRESSURE: Measured at the inlet pressure tap on the appliance gas man i fold. The pressure tap is located upstream of the redundant gas valve and down stream of the field installed gas cock.

TABLE - K

Inlet Gas Pressure

Natural L. P.

Gas Gas

Max. (Inches-Water Column)

______________________________

Min. (Inches-Water Column)

10.5" w.c. ________

4.0" w.c.

13.0" w.c.

_________

4.0" w.c.

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

MANIFOLD PRESSURE: Manifold pressure is a differential pressure measurement made between the high and low pressure taps at the gas orifice and the pres sure in the transition chamber where the gas is supplied to the inlet of the combustion air blower.

All manifold gas pressures are noted at full firing rate. The controls on this appliance may fire the burner from 25% up to 100% of rated input, based on system demand. Manifold gas pressure will be reduced as burner input is reduced. All ref er ence gas pressure measurements must be made at 100% of rated burner input. The gas manifold pressure is pre-set at the factory by the ratio gas valve.

Ad just ment of manifold pressure is not normally required for proper operation. The adjustment point on the ratio gas valve is set at the factory. DO NOT attempt to adjust the settings on the ratio gas valve. Improper ad just ment of the ratio gas valve may cause incomplete combustion or non-warrantable burner damage.

TABLE - L

Nominal Manifold Pressure

Settings at Full Fire

Natural L. P.

Input Btu/hr Gas Gas

1,500,000 - 2,000,000

3.5" w.c.

GAS PRESSURE TEST

1. The appliance must be dis con nect ed from the gas supply piping sys tem during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5kPa).

2. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5kPa).

3. The appliance and its gas con nec tion must be leak-tested before placing it in operation.

GAS CONNECTION

1. Safe operation of unit requires properly sized gas supply piping. See gas line sizing data.

2. Gas pipe size may be larger than appliance connection.

3. Installation of a union at the appliance gas line connection is re quired for ease of service and removal of the gas train.

4. Install a manual main gas shutoff valve, outside of the appliance gas connection and before the gas valve, when local codes require.

5. A trap (drip leg) MUST be pro vid ed in the inlet of the gas con nec tion to the appliance.

6. The diaphragm gas valve has a bleed port that requires venting to at mo sphere, outside the building.

7. Optional gas controls may require routing of bleeds and vents to the atmosphere, outside the building when required by local codes.

TABLE - M

Recommended Gas Pipe Size

Single Appliance Installations

Distance from Meter

Btu/hr

1,500,000

2 1/2"

3 1/2"

1,700,000

2,000,000

0 - 50 ft.

51 - 100 ft. 101 - 200 ft.

201 - 300 ft. 301 - 500 ft.

For each elbow or tee, add equivalent straight pipe to total length from TABLE - O.

TABLE - N

Multiple Appliance Installations Gas Pipe Size Chart

lanimoN

,eziSepiPnorI

sehcnI

teeFthgiartSniepiPfohtgneL

010203040506070809001521051571002

4/3 96365250247155114182112131160159689747

796774483823292762642652012002971461941831

4/11 004,1479987776595345205274144014963333803782

2/11 051,2005,1012,1020,13290389677076666364653152

74144

2 001,4028,2062,2059,1027,1065,1044,1033,1052,1081,1001,1479178028

2/12 064,6064,4016,3001,3027,2064,2013,2001,2000,2009,10

07,1045,1004,1003,1

3 002,11009,7004,6004,5078,4014,4000,4008,3045,3003,3000,3027,2005,2043,2

4 005,32001,61001,31001,11000,0

1000,9003,8096,7083,7078,6051,6046,5031,5027,4

Maximum Capacity of Pipe in Thousands of Btu’s per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on NAT GAS, 1025 Btu’s per Cubic Foot of Gas and 0.60 Specific Gravity).

TABLE - O

Fittings to Equivalent Straight Pipe

Diameter Pipe Fitting (inches)

3/4" 1" 1 1/4" 1 1/2" 2" 3"

Equivalent Length of Straight Pipe (feet)

2' 2'

3' 4'

5' 10' 14' 20'

GAS PIPING

FIG. 34 Gas Line Connection to Unit with Sediment Trap

and Manual Main Gas Shut-off Valve

All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and nat u ral gas. All piping must comply with local codes and ordinances. Tubing installations must comply with approved standards and practices.

Install Piping to Control

1. The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity. Verify pipe size with your gas supplier.

2. Use new, properly threaded black iron pipe free from chips. If tubing is used, make sure the ends are square, deburred and clean. All tubing bends must be smooth and without deformation. Avoid flexible gas connections. Internal diameter of flexible gas lines may not provide appliance with proper volume of gas.

3. Install a manual main gas shutoff valve at the units gas inlet, outside of the appliance and before the gas valve. Install a union at the ap pli ance gas line connection for ease of service and removal of the gas train.

4. Run pipe or tubing to the units gas inlet. If tubing is used, obtain a tube to pipe coupling to connect the tubing to the units gas inlet.

5. Install a sediment trap in the supply line to the units gas inlet. (see Figure 34).

6. Remove seal over gas inlet to the appliance.

7. Apply a moderate amount of good quality pipe compound (DO NOT use Teflon tape) to pipe only, leaving two end threads bare.

8. Connect gas pipe to inlet of ap pli ance. Use wrench to support gas man i fold on the appliance.

9. For LP gas, consult your LP gas supplier for expert installation.

GAS MANIFOLD

PRESSURE ADJUSTMENT

The manifold gas pressure on the Intelli-Fin appliance is not field adjustable. The ratio gas valve has been factory set with an internal bias adjustment to ensure a 1:1 air/gas ratio on operation. Tampering with this adjustment will void the warranty on the gas valve assembly and the burn er. An Intelli-Fin supplied with a properly sized gas line, properly sized meter and a minimum of 4 inch water column of gas supply pressure while firing at full rate will ensure full burner in put. The manifold pressure supplied to the burner is a differential pressure. This pressure is the result of the difference in two gas pressure mea sure ments. A differential manifold gas pressure measurement should not be made until you have measured the gas supply pressure. Gas supply pressure must be a minimum of 4 inch water column with all appliances on the gas line firing at full rate before a manifold pressure measurement is made. Use the following pro ce dure to check gas supply pressure with a manometer connected to the inlet pressure tap on the gas line connection at the rear of the appliance.

CHECKING GAS SUPPLY PRESSURE

FIG. 35 Gas Supply Pressure Measurement

GAS INLET

TRAP

1. Turn the main power switch to “OFF” position.

2. Shut off gas supply at the manual gas cock in the as piping to the ap pli ance. If fuel supply is LP gas, shut off gas supply at the tank.

3. Remove the 1/8" hex plug from the gas pressure test port located on the inlet gas supply connection at the rear of the appliance. Install a fitting in the inlet pressure tapping suitable to connect to a manometer or magnahelic gauge. Range of scale should be 14 inch w.c. or greater to check inlet pressure.

4. Turn on gas supply at the field installed manual gas cock, turn on LP gas at tank if required.

5. Turn the power switch to “ON” po si tion and ensure that the Run/Stop switch is in the “Run” position.

6. Adjust the temperature setpoint on the Command Display to call for heat.

7. Observe the gas supply pressure as the burner fires at 100% of rated in put. Percent of burner input will be displayed on the Command Display.

8. Ensure inlet pressure is within specified range. Minimum and Maximum gas supply pressures are specified in Gas Supply section of this manual.

9. If gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control.

10. If gas supply pressure is within normal range, proceed to remove gas manometer and replace pressure tap fittings in the gas piping to the appliance.

11. Turn the power switch to “OFF” po si tion.

12. Shut off gas supply at the manual gas cock in the gas piping to the ap pli ance. If fuel supply is LP gas, shut off gas supply at the tank.

13. Remove the manometer and related fittings from gas pressure test port at the inlet gas supply connection to the appliance. Replace 1/8" hex plug in gas pressure test port and tighten.

14. Turn on gas supply at the manual valve, turn on LP gas at tank if required.

15. Turn the power switch to “ON” position.

16. Adjust the temperature setpoint on the Command Display to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable, see “Maintenance-Normal Flame Pattern.” Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

IMPORTANT

Upon completion of any testing on the gas system, leak test all gas connections with a soap solution while the main burner is firing. Immediately repair any leak found in the gas train or related components. DO NOT operate an appliance with a leak in the gas train, valves or related gas piping.

CHECKING MANIFOLD

GAS PRESSURE

There is a pressure test tree located in the top chamber of the appliance. This pressure test point can be ac cess ed by swinging out the front control panel. The pressure test tree is mounted on the front edge of the com bus tion air blower. It consists of an angle support and four test cocks. There is one cock for positive air and one for negative air, one cock for positive gas and one for negative gas. Manifold pressure measurement will utilize both the positive and negative test points for gas.

1. Open the front controls panel and swing the controls out. Locate the pressure test tree on the front edge of the combustion air blower. The positive and negative gas pressure terminals will be used to check differential gas pressure from the gas manifold and the air box. Each gas pressure connection point will have a small manual cock to attach a hose.

2. Connect a hose from the positive gas and the negative gas to each of the two sides of a manometer. This will allow the two pressure points to be measured at the same time. Open the two gas pressure test point cocks.

3. Set the Command Display to a set point which will fire the burner at 100% of rated input.

4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of the manometer. The sum of these two readings as they are effected by the two gas pressures is the differential man i fold pressure.

5. The differential manifold gas pres sure should be

3.5 inches of water column (+ 0.1" w.c.) when the burner is firing at 100% of rated input.

6. If the differential manifold pres sure is not 3.5 inches water column (+ 0.1" w.c.), recheck the gas

supply pressure and adjust to ensure a supply pressure between 4.0 and 10.5 inches water col umn natural gas (13.0" w.c. for propane) while the appliance is firing at 100% of rated input.

7. This is a reference pressure only and is not field adjustable. An ap pli ance supplied with a minimum of 4 inch es water column of gas supply pres sure will operate at the correct man i fold pressure as the burner input var ies with temperature demand.

8. Close the two gas pressure test cocks on the pressure test tree and remove the hoses to the manometer.

9. Close the front control panel.

IMPORTANT

WATER CONNECTIONS

FIG. 37 Water Connections

FIG. 36 Manifold Gas Pressure Measurement

AIR INLET

GAS

WATER OUTL

WATER INLET

FLUE OUTLET

– – – – = FIELD CONNECTED

3.5" W.C.= gas

MANIFOLD GAS PRESSURE

Inlet and Outlet Connections

For ease of service, install unions on inlet and outlet of the appliance. The connection to the appliance marked “Inlet” on the header should be used for return from the system. The con nec tion on the header marked “Outlet” is to be connected to the supply side of the system.

Minimum Pipe Size Requirements

Minimum water pipe connections to this appliance is 3 inch (76.2 mm) pipe for single unit installations installed not more than 70 equivalent feet (21.3 m) of pipe from the main system loop or storage tank. The equivalent number of straight feet of pipe for each valve and fitting in the connecting piping must be considered to properly arrive at the total equivalent feet of straight pipe in the field installed piping to the appliance. See the pip ing requirements in the heating boiler or water heater section of this manual. Consult factory if longer piping dis tances are required for a specific application.

PRIMARY HEAT EXCHANGER

FIG. 38 Primary Heat Exchanger

This appliance uses two finned copper tube heat exchangers to maximize the heat transfer process. The primary heat exchanger is mounted in the inner jacket on the front side of the ap pli ance.

The primary heat exchanger is composed of two circular glass lined cast iron headers with 24 vertical finned copper tubes. A series of “V” shaped baffles are installed between the individual tubes to control

the movement of the flue products over the finned copper surface and increase heat transfer. Water enters the primary heat exchanger and makes four passes over the area exposed to direct heat from the burner. An internal cir cu lat ing pump ensures proper water flow over the heat transfer surfaces during burn er operation. Water temperatures in the primary heat exchanger are con trolled by the operation of the au to mat ic bypass assembly. Operation of the bypass maintains water temperatures above 130°F (54.4°C) in the primary heat exchanger to prevent flue gas condensation on the primary heat ex chang er surfaces.

SECONDARY HEAT EXCHANGER

FIG. 39 Secondary Heat Exchanger

A secondary heat exchanger is mounted in an inner jacket chamber at the rear of the appliance. The secondary heat exchanger is constructed from two glass lined cast iron headers and multiple hor i zon tal finned copper tubes. The secondary heat exchanger is mounted in the dis charge of the flue products from the primary heat exchanger. This allows additional heat to be absorbed from the flue products exhausted from the com bus tion process. The return water from the system passes through the secondary heat exchanger before it enters the primary heat exchanger. This allows the coolest return water temperatures to enter the secondary heat exchanger before proceeding to the primary heat exchanger. When return water tem per a tures are below approximately 130° F (54.4°C), the flue products passing over the secondary heat exchanger may be cooled below their dewpoint re sult ing in the formation of condensate. The secondary heat exchanger has a special high

INTEGRAL BYPASS

HOT

WATER

OUTLET

SECONDARY

HEAT

EXCHANGER

COLD

WATER

INLET

PRIMARY

HEAT

EXCHANGER

PUMP

BYPASS VALVE

FIG. 40 Bypass Piping with Valve Actuator and Pump

temperature conformal coating to prevent any corrosive damage to the copper tubes or cast iron head ers from the low pH condensate.

The protective coating is brown in color and covers both the headers and finned tube surfaces. The secondary heat exchanger is designed to maximize heat transfer efficiency by fully condensing flue products. The inner jacket that houses the secondary heat exchanger is designed to collect the flue gas con den sate and discharge it from the jacket.

This appliance contains an integral bypass and circulating pump that con nects the primary and secondary heat exchangers. A floating-point automatic bypass valve regulates the flow of water through the bypass between the two heat exchangers. The valve is a butterfly type valve with an EPDM seat and a 24 VAC gear driven motorized actuator. The appliance’s internal Excel-10 con trol ler senses inlet water temperature to the primary heat exchanger and pro vides a 24 VAC signal to open or close the valve as required. Operation of the bypass is based on an assumed flue gas dewpoint temperature of 130°F (54.4°C) as referenced in the ANSI standards.

The dewpoint of flue gasses becomes the minimum acceptable inlet water temperature for the primary heat exchanger. Sustaining water tem per a tures in the primary heat exchanger above the dewpoint prevents formation of flue gas condensate on the primary heat exchanger. The Excel 10 es tab lish es a dead band around the 130°F (54.4°C) setting of +1.8°F (2°C). This means the actual temperature can vary positive or negative approximately 2° around the 130°F (54.4°C) minimum desired setting. The variable input rate of the burner from 25% to 100% will also affect the po si tion of the bypass valve as it adjusts to maintain primary heat exchanger (Bypass) temperatures above the 130°F (54.4°C) setting. The inlet temperature to the primary heat exchanger is displayed by the command display and provides the Excel 10 the adjustment point for the bypass valve. The inlet water tem per a ture to the primary heat exchanger generally should not remain below the minimum dewpoint temperature for more than approximately five minutes. In this case, the inlet temperature to the primary heat exchanger is

rarely below 125°F (51.7°C). The actuator on the bypass valve will take between a minimum time of 180 seconds up to a maximum time of 300 seconds to move from a “full closed” position to a “full open” position or vice versa. Operation of the bypass valve actuator assures that water temperature in the primary heat exchanger is maintained high enough to prevent condensate formation on the primary heat exchanger.

BYPASS VALVE - Synchronization

As the main power is switched on and/or when the run/stop switch is placed in the “RUN” position, the bypass valve will go through a synchronization process to establish a reference point for op er a tion. After the initial synchronization on start-up, the bypass will resynchronize in approximately 2 week intervals of normal operation. This resynchronization will only occur in an off cycle operation of an installed appliance. During the synchronization process the Excel 10 controller will overdrive the valve actuator to a full closed position. This establishes a reference point to assure quicker re sponse to variation in inlet water temperature. The bypass valve op er ates best when it can start operation from a full closed position. A status point mode of Byp Synch will be in di cat ed in the Command Display as the actuator on the bypass valve is overdriven to the closed position for synchronization.

BYPASS PIPING ASSEMBLY

The primary and secondary heat ex chang ers are interconnected with a bypass and pump mounted in 2 1/2 inch (63.5 mm) diameter copper pipe. All access to the piping is from the rear of the appliance. On initial start up, all air must be removed from the bypass piping to ensure proper water flow through the appliance. The bypass piping has an air bleed cock located on the discharge side of the internal pump. This bleed cock should allow any trapped air in the internal piping to be purged from the piping before operation. The bypass piping also contains a flow switch to sense operation of the circulating pump, bulb wells for tem per a ture sensors and a relief valve(s).

INTEGRAL CIRCULATOR

The appliance has an integral cir cu lat ing pump mounted in the bypass piping. The pump has a 3/4 H.P. motor wired for 120 volt, single-phase operation as shipped. The on-off operation of the circulating pump is controlled by the Excel 10 controller. The pump will start and run continuously when the power switch is in the “ON” position and the run/stop switch is in the “RUN” posi tion. A flow switch installed in the bypass piping assembly proves water flow.

Optional Intermittent Pump Operation

On-Off operation of the circulating pump is available as an option. Cycling of the integral pump is controlled by the Excel 10 controller. The pump will start on a call for heat and a flow switch installed in the bypass piping assembly proves operation. After the burner cycles off and the call for heat is satisfied, the pump will continue to operate for a timed period to remove any residual heat from the combustion cham ber before the pump is turned off. If the ambient temperature at the tem per a ture sensor for the Excel 10 drops below 45° F (7.2° C) the circulator pump will turn on to help prevent freezing of the heat exchanger.

BYPASS - Initial Set-up of Maximum Water Flow

On initial start-up of the Intelli-Fin the maximum water flow to the two in ter nal heat exchangers must be manually set before the automatic operation of the bypass begins.

FIG. 41 Bypass Valve and Actuator Assembly

Setting temperature rise on an Intelli-Fin with an automatic bypass is ac com plished by disconnecting the power leads to the bypass actuator at the multi-pin connector on the rear of the appliance, declutching the actuator drive and manually closing the bypass valve. Manual adjustment of the bypass must not be attempted

if the 24 VAC power leads are connected to the terminals on the appliance, the ap pli ance is operating or if there is any torque on the bypass valve by the ac tu a tor. Disconnect the 24 VAC power

leads to the valve actuator. The declutch button on the actuator must be pushed down and held in the depressed position to disengage the gear driven motor that operates the valve. The declutch button must push in easily without forcing its movement. If the button does not easily move when pushed, the valve is under torque. Forcing the declutch button in will cause non-warrantable damage to the actuator. Torque can be removed by disconnecting the power leads to the valve actuator. With the declutch button fully depressed, move the ac tu a tor handle till it is perpendicular to the piping. This fully closes the by pass valve. The position of the handle is the same as the position of the butterfly in the valve seat. With the bypass fully closed, all inlet water flows through the secondary heat ex chang er and then through the primary heat exchanger. No water will flow through the bypass at this time. Turn the appliance on and allow the burner to come on and fire at full rate (100% of input as shown on the Command Dis play). Adjust the field-installed ball valve in the outlet piping from the appliance to achieve the proper tem per a ture rise for your specific model. Adjustment to achieve this temperature rise ensures a maximum of 90 GPM to the bypass and pump when in operation.

TABLE - P

Temperature Rise At Full Rate Fire

Bypass Manually Fully Closed

Btu/hr Input Temperature Rise

1,500,000

_______________________

1,700,000

_______________________

2,000,000

31.5°F (17.5°C)

_______________________

35.7°F (19.8°C)

_______________________

42.0°F (23.3°C)

NOTE:

The Excel 10 controller makes all internal calculations in °C and converts the displayed temperature to °F. This may limit exact temperature adjustment. Setting of temperature rise to the nearest °F is acceptable when setting maximum flow.

Turn off power to the appliance. Reconnect the power leads to the bypass actuator. Turn power on and place the run/stop switch in the run position and allow the bypass valve to go through the synchronization process before it begins normal operation.

WARNING

Moving the bypass handle while appliance is firing can result in abnormally high water temperature that may cause sudden relief valve discharge.

BYPASS OPERATION

1. Main burner ignition is achieved.

2. Integral bypass begins the ad just ment process to control inlet water temperature to the primary heat exchanger.

3. The Excel 10-controller senses inlet water temperature to the primary heat exchanger.

4. Inlet water temperature into the primary heat exchanger is displayed as “Bypass Temperature” in one of the 21 points on the Command Display.

5. The floating-point bypass valve begins to adjust position to maintain an inlet temperature to the primary heat exchanger above the dew point of flue products.

6. Minimum inlet water temperature to prevent condensation of flue products is fixed at 130°F (54.4°C). This con trol point is programmed into the soft ware in the Excel 10 controller.

7. The Excel 10 provides 24 VAC to operate a high torque motor in the actuator, which adjusts the position of the floating-point bypass valve.

8. The actuator for the bypass valve adjusts in as many as 500 micro-steps to achieve the desired water tem per a ture at the inlet to the primary heat exchanger.

9. With each micro-step of movement in the position of the valve, the Excel 10 checks for a change in water tem per a ture at the inlet to the primary heat exchanger. As long as the inlet water temperature is below 130°F (54.4°C) the bypass is moving toward full open to increase the inlet water temperature. When the inlet water temperature is above 130°F (54.4°C) the bypass is mov ing toward full closed to sustain the water temperature above the dewpoint of the flue products.

10. Operation of the bypass valve main tains water temperatures above the dew point of flue products at the primary heat exchanger to ensure that condensate formation occurs only on the secondary heat exchanger.

The use of a Floating-Point Bypass Valve means that there is no fixed open or closed position on the valve. If errant hands manually move the bypass adjustment handle, it will take longer to adjust to the proper setting but it will still function properly to main tain water temperatures.

CAUTION

Failure to disconnect power to the actuator before declutching or manually moving the valve handle can cause non-warrantable damage to the actuator.

MINIMUM WATER TEMPERATURES

A minimum return water temperature of 50°F (10°C) has been established for each model based on the Btu/hr output at 100% of rated burner input. The temperature set point for the Excel 10 controller sensing system temperature or stored water temperature must not be set lower than the specified minimum for each model. Maintaining inlet water temperatures to the appliance equal to or higher than the specified minimum temperature setting ensures proper op er a tion of the bypass and allows all con den sate formation to occur on the sec ond ary heat exchanger. An appliance allowed to sustain operation at water temperatures lower than the specified minimum temperature may not provide enough heat from the burner to maintain water temperatures in primary heat exchanger above the 130°F (54.4°C) dew point of flue prod ucts. Operation of the appliance at a temperature below the specified minimum set point temperature will result in non-warrantable operational problems from the con den sate formation on the primary heat exchanger.

TABLE - Q

Minimum Inlet Water Temperatures

Input Minimum Return Minimum

Btu/hr Temperature Setpoint

1,500,000

___________

1,700,000

___________

2,000,000

105°F (40.6°C)

_______________

90°F (32.2°C)

_______________

70°F (23.9°C)

50°F (10°C)

____________________

50°F (10°C)

____________________

50°F (10°C)

CAUTION

An appliance allowed to operate at return temperatures below the specified minimum settings may experience problems with the operating controls, safety switches, obstruction of the flue gas passages on the primary heat exchanger, incomplete combustion and possible flue gas spillage. Sustained operation at lower than specified water temperatures may cause hazardous conditions that may result in personal injury or non-warrantable damage to the appliance.

A boiler installed above radiation level must be provided with a low water cutoff device either as part of the unit or at the time of installation.

WATER FLOW SWITCH

A water flow switch is factory in stalled in the internal bypass piping on all heating boilers, hot water sup ply boilers and water heaters. The flow switch is wired in series with the 24 VAC safety control circuit. This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition.

A factory supplied flow switch installed in the discharge piping from the top header requires a minimum flow of 26 GPM to make the flow switch and start burner operation. A water flow switch meets most code re quire ments for a low-water cut off device on boilers requiring forced circulation for operation. A status point alarm of LowH2OFlow will be indicated in the Command Display on a low water con di tion as sensed by the flow switch.

LOW WATER CUTOFF

(If Equipped)

If this boiler is installed above ra di a tion level, a low water cut-off device must be installed at the time of boiler installation. Electronic or float type low water cut-offs are avail able as a factory supplied option on all models. Low water cut-offs should be inspected every six months, including flushing of float types. A status point alarm of LowH2OFlow will be indicated in the Command Display on a low water condition as sensed by a low water cutoff.

GAS TRAIN AND CONTROLS

FIG. 42 Gas Train Assembly

DIAPHRAGM VALVE

ORIFICE

RATIO VALVE

RELIEF VALVE

This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Sec tion IV (“Heating Boilers”). The re lief valve(s) is installed in the ver ti cal position and mounted in the hot water outlet. No valve is to be placed between the relief valve, and the unit. To prevent water damage, the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs. No reducing cou plings or other restrictions shall be installed in the discharge line. The discharge line shall allow complete drainage of the valve and line. Relief valves should be manually operated at least once a year.

CAUTION

Avoid contact with hot discharge water.

NOTE:

The gas train and controls assembly provided on this unit have been tested under the applicable American National Standard to meet minimum safety and performance criteria such as safe lighting, combustion and safety shutdown operation.

RATIO GAS VALVE

FIG. 43 Ratio Gas Valve

The main gas valve supplying gas to the burner on this appliance utilizes a pressure regulating electro hydraulic actuator providing a slow opening, fast closing safety shut off and air/gas ratio control for the gas combustion process. This gas valve controls the pressure difference across the re stric tion in the gas supply line as a func tion of the pressure difference across the combustion air supply to the burn er. The actuator maintains a con stant air to gas ratio as the volume of air changes based on the operation of the combustion

air blower. The valve is a 1:1 differential pressure air/gas ratio controller. The valve adjusts the same pressure difference on the gas side as it senses on the air side. The valve performs the functions of safety shutoff, constant pressure regulation and air/gas ratio control. Slow open ing and safety shutoff is accomplished by operation of an electro hydraulic cylinder. Full closing of the valve seat occurs in less than 0.8 seconds when the valve is de-energized.

A visual stroke position indicator is provided on the valve assembly to in di cate the position of the valve seat. Operation of the gas valve in com bi na tion with the combustion air blower allows the burner input rate to vary from 25% to 100% based on temperature demand.

There is no need for an ad di tion al upstream constant gas pressure regulator internally to the appliance as long as the gas supply is maintained within the specified minimum and max i mum pressures.

The manifold pressure is preset at the factory and adjustment is not usually required if gas supply pressure is maintained within the specified range. If the manifold pressure is to be mea sured, follow the “Gas Manifold Pres sure Measurement Procedure” for proper measurement.

There are no serviceable parts on the ratio gas valve actuator.

DIAPHRAGM GAS VALVE

FIG. 44 Diaphragm Gas Valve

A diaphragm type gas valve is also provided in the gas train. As the second valve seat in the gas train, it supplies a redundant safety shutoff valve seat in the gas supply to the burner to ensure safe operation in the remote event of a gas valve failure. The diaphragm gas valve is energized with 24 VAC power at the same time the ratio gas valve is powered in the op er a tion al sequence to ignite the burn er.

Venting of Gas Valves and Pressure Switches

The diaphragm type gas valve and op tion al gas pressure switches are pro vid ed with threaded termination points to be vented to the atmosphere, outside the building. The gas pressure reg u la tion function is provided by the ratio gas valve which does not require in stal la tion of a vent line. The di a phragm gas valve and optional gas pres sure switches are installed in the upper chamber of the appliance. Threaded vent line connections from components requiring an external vent line are provided on the component. These vent line connection points may be accessed by removing the top jacket panels. Local codes may require the routing of these bleeds and vents to the atmosphere, outside the building. Proper routing of vent lines to the atmosphere from the factory supplied termination points is the re spon si bil i ty of the installing contractor.

ELECTRICAL CONNECTIONS

FIG. 45 Electric Power Connections - Controls and Pumps

A 120 VAC, 15 Amp, 1 ph, 60 Hz circuit is required for operation of the integral circulating pump and a 120 VAC, 15 Amp, 1 ph, 60 Hz circuit for the ap pli ance controls are recommended. If a single electrical service is provided to operate both the controls and pump, a 120 VAC, 30 Amp, 1 ph, 60 Hz circuit is recommended. The combustion air blower motor operates on 230 VAC, 3 ph, 60 Hz. This three phase voltage is generated by the variable frequency drive (VFD) and supplied directly to the blower motor. NOTE: No 230 VAC electrical service is

required for operation of the combustion air blower.

The appliance, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition of the National Electrical Code ANSI/NFPA No. 70. When the unit is installed in Canada, it must conform to the CAE C22.1, Canadian Electrical Code, Part 1 and/or local Electrical Codes.

1. All wiring between the appliance and field installed

devices shall be made with type T wire [63°F (35°C) rise].

2. Line voltage wire exterior to the appliance must be

enclosed in approved conduit or approved metal clad cable.

3. The pump must run continuously when appliance

is being fired. The Excel 10 temperature controller will energize the integral circulating pump for continuous operation when the main power switch is in the “ON” position and the run stop switch is in the “RUN” position. If the internal water temperature drops below 45°F (7.2°C) the pump will automatically cycle on to help prevent freezing

(see Freeze Protection).

4. To avoid serious damage, DO NOT energize the

appliance until the system is full of water. Ensure that all air is removed from the bypass piping before beginning initial operation. Se ri ous damage may result if the ap pli ance is operated without proper flow.

5. Provide the appliance with proper overload

protection.

TABLE - R

AMP DRAW DATA

1,000,000 through 2,000,000 Btu/hr Models

APPROXIMATE TOTAL

Blower & Pump Amps

Btu/hr Controls FLA @ 120 AC

1,500,000

__________

1,700,000

__________

2,000,000

15.5

____________

8.8

__________

8.8

__________

8.8

6.7

____________

7.2

____________

7.2

JACKET ASSEMBLY

Inner Jacket - The inner jacket as sem bly is constructed from a special cor ro sion resistant stainless steel. This includes both the front primary heat exchanger chamber and the rear sec ond ary heat exchanger chamber. All screws and fasteners used for assembly of

ELECTRICAL JUNCTION BOX

CONTROL

PUMP

the inner jacket and secondary heat exchanger chamber are also stainless steel. The stainless steel screws are identified by a sealing washer mounted on each screw. DO NOT mix stainless steel and

standard plated fasteners when disassembling and reassembling the inner jacket sheet metal components. Standard plated fasteners may be dam aged by the flue product condensate when used on the inner jacket as sem blies.

Outer Jacket - The outer jacket as sem bly is constructed from steel,

gal va nized on both sides. The galvanized surface is specially prepared and phos phate coated to allow application of a multiple coat enamel paint process. This coating process ensures a long life from the jacket assembly.

ACCESS TO COMPONENTS AND CONTROLS

FIG. 47 Front Control Panel Locations

FIG. 46 Component and Auxiliary Controls Connections with Junction Box

FIG. 48 Transformer and Relay Locations

VARIABLE FREQUENCY DRIVE

FIG. 49 Internal Control Panel Location

FIG. 50 Variable Frequency Drive

A transformer and relay mounting panel is located above the front control panel, underneath the curved exterior front jacket panel. This panel contains a 100 VA transformer to drop 120 VAC to 24 VAC for internal control operation, an optional electronic low water cut-off, a high limit alarm re lay, an alarm relay, an ignition relay, gas valve relay, pump relay, louver relay and VFD power relay.

This appliance uses a variable frequency drive (VFD) to control operation of the combustion air blower motor. The variable frequency drive is supplied with 120 VAC power. The blower motor operates on 230 VAC 3 phase power. This three phase voltage is generated by the variable frequency drive and supplied directly to the blower motor. The variable frequency drive receives a signal from the Excel 10 controller based on water temperature to vary the frequency of the voltage supplied to the blower motor from 15 Hz up to 60 Hz. This varies the output of the combustion air

blower from 25% up to 100% of capacity corresponding to the same variation in burner input. The output from the Excel 10 to the variable frequency drive ensures that combustion air and gas are always supplied in the proper ratio for clean combustion. The vari able frequency drive is driven to 100% during the pre-purge portion of the start-up sequence. The variable fre quen cy drive is then provided a signal to operate at 50% for initial burner ignition. After main burner ignition is established, the Excel 10 will use the variable frequency drive to vary the blower speed based on desired water temperature set point, the variation in actual water temperature from the de sired set point and the various op er at ing characteristics programmed into the control’s software.

When removing the variable frequency drive from the appliance, disconnect the power wires to the combustion air blower at the terminals on the variable frequency drive. DO NOT disconnect the power wires at the blower motor. Note the marking of the wires for proper reinstallation of the three phase power wires to the VFD. Both the wires and the VFD terminals are marked for proper location of wire terminals. Incorrect installation of the wires may reverse rotation of the blower motor resulting in major operational problems.

CAUTION

The voltage output from the variable frequency drive to the combustion air blower is 230 volt 3 phase. Avoid contact with high voltage wiring.

LOW AIR PRESSURE SWITCH

FIG. 51 Low Air Pressure Switch

FIG. 52 Excel 10 Control Module

EXCEL 10

A differential air pressure switch is used to prove operation of the com bus tion air blower. The pressure switch sensing points are installed across the point of pressure drop as the air moves into the inlet of the burner. This switch measures the same pressure drop points similar to those used by the ratio gas valve to adjust manifold gas pressure. Cor rect differential pressure across the sensing points of the pressure switch proves operation of the combustion air blower to the Excel 10 control. The Command Display will exhibit a Status Alarm of LowAirPress and the appliance will shut down operation when the differential pressure switch detects a sustained low air condition.

HIGH GAS PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

(Optional)

High and/or low gas pressure switches are available as an option on this appliance. The high gas pressure switch is used to monitor the maximum gas supply pressure supplied to the gas train. If gas pressure exceeds the maximum setting of the pressure switch, the appliance will shut down and a gas pressure fault will be indicated in the Command Display. The low gas pressure switch is to monitor the minimum gas supply pressure supplied to the gas train. If gas pressure falls below the minimum setting of the pres sure switch, the appliance will shut down and a gas pressure fault will be indicated on the Command Display. GasPressFail will be shown on the Display for either a high or low gas pressure problem.

PRESSURE SWITCH

BLOWER

TRANSITION

BURNER

Excel 10 Boiler Interface Controller - The boiler interface control ler for this appliance is based on the Excel 10 controller platform with unique software customized for op er a tion of the Lochinvar Intelli-Fin. The Excel 10 is also compatible with LonWorks

building management systems. All of the appliances’ internal safety, operating and ignition controls in ter face with the Excel 10 controller. Local communication, programming and a digital display of the appliance func tions and operating conditions are accessible through a Command Display. The Command Display is mounted on the front control panel of the appliance as shipped from the manufacturer. If mul ti ple Intelli-Fin appliances are to be installed in a single application, see “Multiple Appliance Installations” for information on interfacing, sequencing and display of multiple Intelli-Fin appliances.

NOTE:

A single Command Display is shipped for each job site installation with up to 16 Intelli-Fin appliances. A single Command Display is used to display and access the operating conditions of up to 16 Intelli-Fin appliances.

The Excel 10 Boiler Interface Control serves as the operating temperature control to regulate the amount of heat added to the water system for both heating boilers and potable water heat ers. Custom software programmed into the Excel 10 will determine the proper operating profile for your specific application. Ensure that an Intelli-Fin is properly applied. A unit or dered as a heating boiler must be ap plied as a heating boiler and a unit ordered as a potable water heater must be applied as a water heater. The Excel 10 Boiler Interface Control provides on/off control of the gas supply to the burner, operation of a VFD to control a variable speed combustion air blower, interface with the ignition control system, on/off control of the integral circulating pump, operation

of a float ing point bypass valve, control of water temperature set points, and mon i tor ing of all safety functions. The operation and status of these and all related functions are displayed on the Command Display.

The Excel 10 has a single LED located in the middle of the control module. In normal operation of a boiler equipped with an optional outdoor reset function, this LED will blink at the rate of one blink per second. Active alarms will blink this service LED at a faster than normal rate of two blinks per second to indicate an alarm. The alarms which are displayed in this manner are: Network communications failure, sensor failure, hard lockout, water flow failure, low air, blocked drain, low/high gas pressure, flame failure, soft lockout, heat mode fail ure, high temperature alarm, and boiler not operational. A boiler that is not equipped with the outdoor reset func tion or a water heater will always blink the LED at the faster rate of approximately two blinks per second. This LED is not to

be used as a di ag nos tic indicator.

The Excel 10 controller is mounted on the backside of the front control panel that mounts the Command Display and the Ignition Control Module. This panel is hinged on the right side so it can be exposed for viewing and service. All connections from the appliance safety and operating controls to the Excel 10 are accomplished with multiple wiring harnesses. Each wiring harness is connected to unique multiple pin terminations to ensure proper con nec tion of all components. The multiple termination points are located on two printed circuit boards mounted on ei ther side of the Excel 10 controller. Use caution when connecting or dis con necting wires at the plug in terminals to prevent damage to the printed circuit boards.

There is a bar code label on the back of the Intelli-Fin near the terminal connections. This is the Neuron I.D. label which identifies the exact nu mer i cal sequence applied to the Excel 10 control installed in the boiler/water heater. This information is required for the local/remote communication network. The numerical sequence

FIG. 53 Excel 10 Control Module with Circuit Boards and Wire Terminal Connections

is unique to each Excel 10 and must be placed into the network of an energy management system so that the Excel 10 can be recognized by the system. NOTE: If the Excel 10 is ever

replaced, a tear-off label on the new Excel 10 must be placed over this label on the back of the unit for easy ref er ence.

The Excel 10 may have values for the control points specified at the time the control is configured at the fac to ry. If exact control settings are not specified at the time an appliance is ordered, the Excel 10 controller will be pre-programmed with the fol low ing default values as shipped from the factory. Special arrangements should be made with the factory during the ordering process to have job site spe cif ic values programmed into the con trol. These values are different for boiler and water heater applications.

TABLE - S

Default Values

Pre-programmed in the Excel 10

Point

_______________

Setpoint Temp

_______________

O.A. Lockout

_______________

O.A. Max

_______________

O.A. Min

_______________

Max Setpoint

_______________

Min. Setpoint

_______________

Operating Sensor _______________

Heater I.D.

Water Heater

_______________

120.0°F

_______________

N/A

_______________

N/A

_______________

N/A

_______________

190.0°F

_______________

50.0°F

_______________

Return/Inlet

_______________

Water Heater

Boiler

_______________

130.0°F

_______________

70.0°F

_______________

60.0°F

_______________

10.0°F

_______________

220.0°F

_______________

100.0°F

_______________

Return/Inlet

_______________

Boiler

MANUAL OVERRIDE CONTROL

This unit is trimmed with an auxiliary thermostat to provide a manual override in the event of a failure of the Sequencer Control or the Excel 10. When the manual override is activated, it will provide temporary control until a replacement Sequencer or Excel 10 can be installed.

The manual override fires the appliance at 100% Btu/hr input rate during the entire cycle. Modulating burner control is not available with the manual override. In addition, the pump will run continuously. Intermittent pump operation is not available with the manual override.

Modulation of the bypass valve may not be available with the manual override. If the primary control failure is in a remote Sequencer, the bypass valve should modulate. If the Excel 10 inside the appliance has failed, the bypass valve may not modulate.

The manual override is located on the back of the appliance below the bypass piping loop. To the left of the thermostat is a toggle switch to alternate the control of the appliance from the primary control to the manual override thermostat.

Some models may have a reduced firing rate when manual override is activated.

To Activate the Manual Override:

1. In the event of a failure of the primary control, move the “Stop/Run” switch on the front of the control panel to “Stop”.

Move the toggle switch, located on the back of the unit to “Manual Override”.

3. If the bypass valve does not modulate under the control of the manual override thermostat, it will be necessary to manually to set the bypass valve to deliver a minimum 140°F water temperature to the primary heat exchanger following the procedure below:

a. Disconnect the bypass valve’s 3-pin wire harness from its

connection in the junction box on the upper left of the rear of the appliance.

b. If the Excel 10 readout function is still active, check the

“Return/In Temp” for a return water temperature the unit might see in regular operation.

c. Press the “Down” or “Up” arrow key to find the “Bypass

Temp” readout.

d. Fire the unit with the manual override control. As the unit

reaches a steady state operation, depress the clutch mechanism and turn the handle slowly counterclockwise to open the bypass valve to a point at which the “Bypass Temp” is 140°F.

e. Release the clutch and leave the valve in this position until

the primary control can be replaced. Do not

reconnect the

3-pin bypass wire harness.

To Return to the Primary Control:

1. After the replacement primary control is installed, reconnect the 3-pin bypass wire harness.

2. Move the toggle switch to “Primary Control”.

3. Turn the manual override thermostat to the lowest setting.

4. Move the “Stop/Run” switch to “Run”.

If you have any questions or comments, please call the Lochinvar Technical Product Service Line at 1-800-722-2101.

TEMPERATURE ADJUSTMENT

COMMAND DISPLAY

FIG. 54 Command Display Panel

The Command Display provides a com mu ni ca tion interface with the Excel 10 via a series of display screens. The front view of the display screen shows the digital display with a cluster of arrow keys on the lower left side. These directional arrow keys move the cursor in the direction of the arrow.

On the lower right side is a back key which moves the display to the previous screen and a select key which high lights a field in the display.

There are also four softkeys along the right side of the display. A notation on the specific screen defines the function of each of these keys. The softkeys may be defined as configure, change, save, cancel, + to increase a value or - to decrease a value on the screen.

PASSWORD FUNCTION

On initial operation of the Intelli-Fin the owner may enter three levels of password with the Command Display to limit access to the changeable op er at ing parameters in the Excel 10. Each password is composed of a four digit number. As shipped from the factory all passwords are zeros. The first level of password allows access to the six changeable points accessible from the Command Display. The second level of password allows access to the configura tion settings of the Command Display. The third level of password allows the password to be changed.

FIG. 55 Command Display Password Screen

The configure button also allows the user to access the password function to enter a password in the Excel 10 from the Command Display. Use of a password will limit the access to the changeable points. When located at the password screen, move the cursor to the first blank space (by using the left or right buttons on the left side of the Command Display). Use the “+” or “-” buttons on the right side of the Command Dis play to either increase (+) or decrease (-) the number to the desired number. Then use the left or right buttons to move the cursor to the next space and repeat this procedure. Once the pass word has been entered, push the “SAVE” button. Once a password number sequence has been entered into the Command Display, they must be correctly reentered to change any of the six adjustable points. If an incorrect password sequence is entered, the pass word screen will stay in place.

NOTE:

Once a password is correctly entered, it will not have to be reentered unless five minutes of inactivity on the Command Display has elapsed.

CONFIGURING THE

COMMAND DISPLAY

When the “CONFIGURE” button on the right side of the Command Display is pressed, a password screen will appear. The user must enter the appropriate password and press “SAVE” to access the changeable screen. Pressing this but ton provides access to a “setup” screen that allows the user to adjust such items as:

TABLE - T

DISPLAY DEFAULT VALUES

____________________

Contrast

____________________

Backlight Mode

____________________

Beep on New Alarm

____________________

Beep Rate

____________________

Time Format

____________________

Date Format

____________________

Engineering Units

Option

_____________

0 - 100%

_____________

OFF/ON

_____________

0 - 60s

_____________

DD/MM/YY

_____________

S.I.

Default

_____________

50%

_____________

AUTO

_____________

OFF

_____________

4.0s

_____________

MM/DD/YY

_____________

English

ACCESSING THE SIX

CHANGEABLE POINTS FROM

THE COMMAND DISPLAY

When the “CHANGE” button on the right side of the control is pressed, a pass word screen will appear. The user must enter the appropriate password and press “SAVE” to access the changeable screen. The desired point to change must be highlighted by moving the cur sor and then use the “+” or “-” buttons on the right side to change the value to the desired value. Once the desired value is reached, press the “SAVE” button and the new value will be saved and the Command Display will return to the first screen of the 21 points for that boiler/water heater. The password must be entered each time a user wants to change the settings of any of the six changeable points. However, if you go to the screen again within 5 minutes of the last time, it will not require the password again. If the screen is left in the changeable point screen for more than 5 minutes with no activity, it will automatically return to the first screen of the 21 points for the boiler/water heater. Re-entry into this changeable point screen will then require password access again.

NOTE:

Allow 10 seconds for data shown in the display screens to update when viewing or making adjustments to any of the six adjustable points.

POINTS FROM INFORMATION

VISIBLE FROM THE SCREEN OF

THE COMMAND DISPLAY

1. Calculated Set Point — The water temperature as adjusted by an optional outdoor reset function used on a heat ing boiler only. If no outdoor reset function is used, this displays the same temperature as the set point. Outdoor Air Reset function not available on a water heater application.

2. Set Point Temp — The desired water temperature as adjusted by the owner/operator. This becomes the lowest boiler operating temperature when an optional outdoor reset function is used (Changeable Point from the Com mand Display).

3. Return/Inlet Temp — The tem per a ture of the water entering the boiler or water heater, a basic thermometer function to display inlet water temperature.

4. Supply/Outlet Temp — The tem per a ture of the water leaving the boiler or water heater, a basic thermometer func tion to display outlet water temperature.

5. Temp. Rise — The difference be tween inlet and outlet water tem per a ture at the boiler or water heater to show the water temperature rise.

6. Status — Displays current status of the control as the appliance is going through its firing sequence and possible faults that could occur and the condition of each. See Status Point Modes and Alarms.

7. O.A. Lockout — The maximum out door air temperature where the boiler will continue to operate. When the outdoor temperature rises above this setting, no heat should be needed for the building and the boiler will lock out and not fire.

8. O.A. Max — The warmest outdoor air temperature where the boiler reset function will begin to function and operate the boiler at the initial set point temperature. The boiler set point will increase based on a cor re spond ing drop in outdoor temperature below this temperature.

9. O.A. Min — The coldest outdoor air temperature where the boiler reset function will reach a maximum boiler water temperature. No additional reset (increase) in boiler temperature will occur past this point as outdoor tem per a ture continues

to drop lower (Change able Point from the Command Display).

10. O.A. Temp. — A display of the outdoor air temperature as sensed by the optional outdoor air reset sensor.

11. Max. SetPoint — The maximum water temperature the boiler or water heater may be set to operate at (Changeable from the Command Display).

12. Min. SetPoint — The minimum water temperature the boiler or water heater may be set to operate at. This temperature is established in the configuration process at the factory.

13. Total Run Time — The accumulated number of hours that the boiler or water heater burner has been in operation. Time is accumulated in one hour increments and can total up to 99,999 hours before rolling over to restart the accumulation process.

14. Sequencing Type — The type of sequencing selected for operation of multiple units, FOFO, FOLO, etc., when ordered as an option. See “Sequencing Options” (Changeable Point from the Command Display).

15. Percent Modulation — The percent of maximum input that the burner is actually firing at. This may vary from 25% up to 100% of rate based on demand.

16. Auxiliary Relay — The “ON” or “OFF” status of an additional relay to in di cate a specified function of the unit.

17. Percent Bypass — The percent that the bypass valve is open to allow heat ed discharge water to be recirculated into the inlet of the primary heat exchanger in order to control condensate formation on the primary heat exchanger. 0% indicates that the valve is fully closed and 100% in di cates that the valve is fully open. The percentage will vary with valve operation.

18. Bypass Temp. — A display of the water temperature in the inlet to the primary heat exchanger after being mixed with hot discharge water from the bypass piping when the bypass valve is open.

19. Operating Sensor — A display which indicates the location of the operating sensor in the unit. The operating sensor may be in the Return/Inlet or Supply/Outlet of the boiler or water heater (Changeable Point from the Command Display).

20. Heater Pump — The “ON” or “OFF” sta tus of the integral circulating pump for the boiler or water heater.

21. Heater I.D. — An indication of whether the unit is a boiler or water heater (Changeable Point from the Command Display).

FIG. 56a Command Display Data Screen

FIG. 56b Command Display Data Screen

FIG. 56c Command Display Data Screen

FIG. 56d Command Display Data Screen

FIG. 56e Command Display Data Screen

FIG. 56f Command Display Data Screen

FIG. 56g Command Display Data Screen

STATUS POINTS

In the screen display for a specific boiler or water heater, there will be a Status indication. The status point details the operational mode of the appliance or in the event of a control sensed failure, a status point alarm. The status point alarm mode indicates the reason for the control sensed shut down of the appliance.

POWER-UP AND NAVIGATION

BETWEEN THE SCREENS OF

THE COMMAND DISPLAY

The first screen is viewable on the Command Display as it is powered up. This Command Display screen gives the current software version running on the Excel 10. This screen goes away after 60 seconds. The amount of time until this screen changes is displayed on the bottom left of the screen in a numeric count. After the 60 seconds expires or when the user presses any key during this interval, the next screen is dis played. This feature is used for perform ing factory tests.

After power-up, the Command Display starts acquiring data from the Excel 10. The following screens display the status of the bytes of data received from the Excel 10. After receiving all the data bytes, the Command Display shows the Heat Source(s) and the pres ence of an Optional Sequencer, if equipped. Note that the Heat Source names can vary but typically they may be Boiler #01 up to Boiler #16 or WtrHtr #01 up to WtrHtr #16, based on the application. At the time an order is placed, the owner may specify a unique name for each appliance if desired. Pressing the Configure softkey will take you to the System Configure screen with two active softkeys. The Setup softkey will take you to a screen which allows you to setup the display in the screen. The Password softkey will take you to the password screen to set the three levels of password required to access the various functions of the Excel 10.

TABLE - U

Status Point Operational Modes:

Self Test: Excel 10 self test period, approximately 5 seconds during power up of Excel 10.

_________________________________________________________________________________________________________

Standby: There is no call for heat and the boiler is waiting for a call for heat. _________________________________________________________________________________________________________

H2OFlow OK: Checking operation of flow switch to verify water flow from the pump. _________________________________________________________________________________________________________

Air Press OK: Low air switch verifies operation of combustion air blower.

_________________________________________________________________________________________________________

Drain OK: Verifies that the condensate drain flow to the optional Condensate Management System is not

blocked.

_________________________________________________________________________________________________________

GasPress OK: Verifies gas pressure at optional switch(es) - high and/or low.

________________________________________________________________________________________________________

PrePurge: Pre purge operation of combustion air blower. _________________________________________________________________________________________________________

HSI OK: Hot Surface Igniter On. _________________________________________________________________________________________________________

Burner ON: Burner On. _________________________________________________________________________________________________________

Heating: Temperature is beginning to rise. _________________________________________________________________________________________________________

PostPurge: Post purge combustion blower operation after a call for heat sequence.

Pressing the Back key will return you to the Heat Source display.

The up and down arrow keys can be used to scroll the cursor up and down to the various heat sources (boilers or water heaters) at this location. To the right of each heat source displays the operational status of the in di vid u al appliance. Pressing the Select key when the cursor is on a specific heat source displays the parameters for this boiler or water heater. Pressing the Change softkey takes you to a screen displaying the six adjustable points for the boiler or water heater. Use the up and down arrow keys to move the cursor to each point. Use the + and - softkeys to adjust the setting pressing Select softkey to enter the revised setting into memory. Pressing the Back button will return you to the screen dis play ing the parameters for this Boiler or Water Heater. Pressing the Back button will return you to screen displaying the Heat Source(s) and the presence of an Optional Sequencer, if equipped.

FIG. 57 Command Display Data Screen

OUTDOOR RESET FUNCTION

SELECTIONS

(Optional on Heating Boilers Only)

As an option, the Excel 10 control may be equipped with an outdoor reset func tion. This function uses a sensor to measure the outdoor temperature and automatically adjust the boiler set point temperature to compensate for colder outdoor temperatures. O.A. Min, Max, SetPoint and Setpoint Temp are changeable points from the Command Display. The additional values required by the Excel 10 to properly operate the reset function should be specified at the time a boiler is ordered. If spe cif ic settings are not available the default values will be programmed into the Excel 10 at the factory. The op er at ing parameters for the reset function are:

O.A. Lockout — The maximum outdoor air temperature where the boiler will con tin ue to operate. When the outdoor temperature rises above this setting, no heat should be needed for the build ing and the boiler will lockout and not fire. The default setting if not specified is

70.0°F (21.1°C). This setting should be spec i fied at the time the boiler is ordered.

O.A. Max — The warmest outdoor air temperature where the boiler reset function will begin to function and operate the boiler at the initial set point temperature. The boiler set point will increase based on a cor re spond ing drop in outdoor temperature below this temperature. The default setting if not specified is 60.0°F (15.6°C).

O.A. Min — The coldest outdoor air temperature where the boiler reset function will reach a maximum boiler water temperature (Max. SetPoint). No additional reset (increase) in boiler temperature will occur past this point as outdoor temperature continues to drop lower. The default setting if not specified is 10.0°F (-12.2°C). This setting is a Changeable Point from the Command Display.

O.A. Temp. — A display of the outdoor air temperature as sensed by the out door air sensor.

Max. SetPoint — The maximum water tem per a ture that the boiler or water heat er may be set to operate at. The de fault setting if not specified is 220.0°F (104.4°C). This setting is a Changeable Point from the Command Display.

TABLE - V

Status Point Alarm Modes:

Low H2O Flow: Low water or flow condition exists.

_________________________________________________________________________________________________________

Low Air Press: Low air condition exists.

_________________________________________________________________________________________________________

Block Drain: Blocked condensate drain exists.

_________________________________________________________________________________________________________

Block Flue: Blocked flue or louver proving switch failed to prove.

_________________________________________________________________________________________________________

Gas Press Fail: Low or high gas pressure condition exists.

_________________________________________________________________________________________________________

Flame Fail: Hard lockout on a flame failure signaled from the ignition control.

_________________________________________________________________________________________________________

Soft Lockout: Wait period for the ignition control to recover from soft lockout conditions.

_________________________________________________________________________________________________________

Over Temp: Indicates that a higher than programmed temperature has been reached.

Setpoint Temp — This is the lowest boiler operating temperature that the boiler will maintain when the outside air temperature is at the O.A. Max. This setting is a Changeable Point from the Command Display.

Calculated Set Point — The water tem per a ture as adjusted by the optional outdoor air reset function used on a heat ing boiler only. If no outdoor reset function is used, this displays the same temperature as the set point. The Outdoor Air Reset function is not available on a water heater application.

These functions are shown in the screens of the Command Display. Where noted, these settings are changeable from the Command Display to configure boiler operation to the building heat load and weather conditions in a spe cif ic geographic area.

MULTIPLE APPLIANCE

INSTALLATIONS

SEQUENCING BOX

(MULTI-BOILER)

REMOTE DISPLAY MOUNTING

CLOSED VIEW

COMPONENT

LOCATIONS

FIG. 58 Sequencer Control Panel

SEQUENCING OPTIONS

The sequencer is supplied as a separate control enclosure that is connected to the multiple appliances via an E-bus connector on the rear of the appliance. The sequencer comes mounted in an enclosure that requires a field installed 24 VAC power source. An optional enclosure with a sub base and 24 VAC power supply is available to allow remote mounting of a Command Display adjacent to the sequencer. Multiple sequencing options are available. The specific software programming required to sequence multiple boilers must be specified at the time the appliances are ordered. The sequencing options are used to control how multiple boilers or water heaters are cycled to meet system demand. The sequencing options are programmed into an Excel 10 controller at the factory based on the number of selectable sequencing algorithms or dered. The desired method of se quenc ing multiple boilers or water heaters may be selected from the screen of the Command Display. There are up to five sequencing options that are selectable from the Command Display, based on the sequencing package purchased.

NOTE:

Separate sequencers are required to control multiple boilers and water heaters.

1. First On - First Off — This is a lead/lag control functionality. The se quenc ing of the boilers or water heat ers is based on the total loop load with added units being brought on when the units that are running are at 100% and the loop load is not being met. Boilers or water heaters are turned off when the loop load falls and the first boiler or water heater on is at minimum load.

2. First On - Last Off — This is a simple first on/last off without rotation of the lead boiler or water heater.

3. Efficiency Optimized — The lead/lag will be based on first on/first off lead/lag. The overall efficiency will be optimized to run the boilers or water heaters at their highest ef fi cien cy. Highest efficiency occurs at the minimum loading for each boiler or water heater. Therefore, this option will add boilers or water heaters when the load reaches a point where the next boiler or water heater can run at minimum load.

4. Efficiency Optimized with Time Equal iza tion — This is the same as “Ef fi cien cy Optimized” but the lead/lag is based on boiler or water heater run times. The boilers or water heaters will be sequenced to equalize run times to within approximately a 24 hour time period. If no opportunity is given to cycle, the control will not interrupt action to equalize runtime.

5. None — This is the default for any boiler or water heater control which has not purchased one of the Sequencing Option Packages.

INTERFACING MULTIPLE

APPLIANCES

PARALLEL CONNECTION

FIG. 59 E-Bus Connection to Controls

Connection between multiple Intelli-Fin appliances is accomplished via an E-Bus connection. An E-Bus terminal is provid ed on the rear of each appliance. The minimum specification for the communication wire is for a Level IV, 22 AWG (0.034 mm

) plenum or non-plenum rated (as applicable), unshielded, twisted pair, stranded wire. Use plenum rated wire where required. See “Wire Requirements” for a listing of manufacturers who supply communication wire meeting this specification. The twisted pair wire is used to make daisy chain connections between the E-Bus terminals on multiple appliances. The E-Bus connection uses a Free Topology Transceiver (FTT) to support a polarity-insensitive free topology wiring scheme for

NOTE:

When attaching two or more wires to the same terminal, twist wires together (see Fig. 60). Deviation from this rule can result in improper electrical contact.

star, loop and/or bus wiring. The maximum number of nodes per segment is 60. The maximum number of nodes in a two-segment FTT network is 120, when using a repeater between the two segments. Consult factory for additional information on interface wiring of multiple Intelli-Fin appliances connected to an EMS.

FTT networks are flexible and con ve nient to install and maintain. However, it is imperative to plan the network layout and to create and maintain ac cu rate documentation. Careful planning and up to date documentation fa cil i tates compliance verification and fu ture FTT network expansion. It also minimizes unknown or inaccurate wire run lengths, node to node (device to device) distances, node counts, total wire length, inaccurate repeater lo ca tions, and misplaced or missing terminations.

Wire to the terminal blocks as follows:

TABLE - W

Daisy-Chain Doubly Terminated FTT Network Bus Topology Specifications

Wire/Cable Type

__________________________________

Level IV 22 AWG unshielded, twisted

pair, stranded communications wire (use

plenum rated wire where required)

Maximum FTT network Bus length

for segment(s) in feet (meters)

_________________________________

4593 (1400)

Maximum node-to-node length

for segment(s) in feet (meters)

___________________________________

3773 (1150)

TABLE - X

Singly Terminated FTT Network Bus Topology Specifications

Wire/Cable Type

__________________________________

Level IV 22 AWG unshielded, twisted

pair, stranded communications wire (use

plenum rated wire where required)

Maximum FTT network Bus length

for segment(s) in feet (meters)

_________________________________

1640 (500)

Maximum node-to-node length

for segment(s) in feet (meters)

___________________________________

1312 (400)

STRIP 1/2"

FROM WIRE

TO BE ATTACHED.

1/2" (13MM)

TWIST WIRES

TOGETHER WITH

PLIERS (MINIMUM

OF THREE TURNS)

INSERT TWISTED WIRES UNDER TERMINAL AND TIGHTEN. CHECK FOR A GOOD MECHANICAL CONNECTION.

FIG. 60 Wire Termination for E-Bus Connection

1. Strip 1/2 in. (13 mm) in su la tion from the conductor.

2. Insert the wire in the required terminal location and tighten the screw to complete the termination.

3. If two or more wires are being inserted into one terminal location, twist the wires together a minimum of three turns before inserting them.

4. Cut the twisted end of the wires to 3/16 in. (5 mm) before inserting them into the terminal and tightening the screw.

5. Pull on each wire in all terminals to check for good mechanical connection.

Wire Requirements

The minimum type and grade of wire required to “net work” the Intelli-Fin to other units or LonMark

devices is a Level IV, 22 AWG (0.034 mm2) plenum or non-plenum rated (as applicable), unshielded, twisted pair, stranded com mu ni ca tion wire. The following man u fac tur ers supply com mu ni ca tion wire that meets or exceeds this specification for E-Bus connections.

Anixter (847) 677-2600

www.anixter.com

__________________________________________________

Belden Wire and Cable Co. (800) 235-3361

www.belden.com

__________________________________________________

BICC General (800) 424-5666

www.biccgeneral.com

(BICC Cable, Brand-Rex, General Cable, Carol Cable) __________________________________________________

ConnectAir International (800) 247-1978

www.connect-air.com

__________________________________________________

Eastman Wire & Cable (800) 257-7940

www.eastmanwire.com

__________________________________________________

Honeywell Inc. (800) 345-6770

www.honeywell.com

__________________________________________________

Lucent Technologies (305) 569-3600

www.lucent.com/netsys/

systimax

__________________________________________________

Windy City Wire (800) 379-1191

www.smartwire.com

__________________________________________________

NOTE:

The minimum specification for Level IV, 22 AWG (0.034 mm2) unshielded, twisted pair, stranded communication cable must be plenum-rated when the wire is routed through air ducts or plenum areas. Non-plenum rated communication cable is for general use when the wire is not being routed through air ducts or plenum areas.

ADDITIONAL COMPONENTS

USED TO INTERFACE

MULTIPLE APPLIANCES

Serial LonTalk® Adapter (SLTA) — A serial LonTalk®adapter is required to provide communication between the E-Bus and either a PC serial port or an approved modem using the SLTA-10 EIA-232 port. The SLTA interfaces with LonSpec

software. There are specific null modem cable requirements for proper connection to a modem. The SLTA has a DB-9 female connection. Direct connection to a PC can be made with a DB-9 to DB-9 cable or a DB-9 to DB-25 cable, based on the available PC connection.

FTT Repeater — A repeater is available to increase the network wiring length in an E-Bus network. The repeater is designed to be installed in a standard field supplied 4 by 4 junction box.

Excel 15 — The Excel 15 Building Manager is a LonMark

compliant device that provides network management functions for the E-Bus in a Light Commercial Building Solutions System. The Excel 15 is compatible with the E-Bus and uses the free topology transceiver (FTT). Individual Excel 15 Controllers and Communicating Subbases distributed on the E-Bus perform specific HVAC equipment control. The Excel 15 monitors and controls both local and remote controller points. If E-Bus communications are interrupted, the Excel 15 is capable of stand-alone operation.

FIG. 61 Typical Building Management System Diagram

HIGH WATER TEMPERATURE

LIMIT CONTROL

FIG. 62 High Water Temperature Control

A Manual Reset High Limit control is located on the left front side of the control panel, beside the Command Dis play. Additional switches, alarm in di cat ing lights and optional low water cut-off control switches are also located on this panel. The setting of this con trol knob limits maximum discharge water temperature. A red reset but ton, located beside the knob, must be pushed whenever water temperature has exceeded the set point of manual reset limit.

The temperature of the water in the heat exchanger must drop a minimum of 15°F (8.3°C) below the setting of the manual reset high limit control before the reset function can be activated.

A red indicating light is illuminated when the water temperature exceeds the set ting of the high limit control. A sta tus point alarm of Over Temp will be displayed in the Command Display when water temperature exceeds the Set Point Temperature programmed into the Excel 10 control on operation of the high water temperature limit control.

NOTE:

The high limit control will not reset until the water temperature has dropped below the set point of the high limit.

HOT SURFACE IGNITION SYSTEM

IGNITION CONTROL MODULE

DIAGNOSTIC STATUS CODES

FIG. 63 Hot Surface Ignition Control Module

FIG. 64 Hot Surface Igniter

This appliance uses a proven hot sur face ignition control system. The operation of the electronic control module for the hot surface igniter proves the presence of an ignition source much like a proven standing pilot before the gas valves are energized. The ignition control module starts and proves the operation of the combustion air blower, proves the presence of the proper ignition temperatures from the hot surface igniter, energizes the main gas valves, proves the presence of main burner flame, provides for soft lock outs on control sensed faults, provides a hard lockout on flame failure and controls the pre and post purge timings of the combustion air blower. A status point alarm of FlameFail will be dis played in the Command Display on a hard lockout for flame failure.

Service Parts

This appliance uses a proven electronic ignition control module and a hot sur face igniter. The electronic ignition module is not repairable. Any mod i fi ca tion or repairs will invalidate the warranty and may create hazardous con di tions that result in property damage, personal injury, fire, explosion and/or toxic gases. A faulty hot surface igniter or ignition module MUST be replaced with a new

OEM unit only. An OEM specification igniter and ignition control module for this specific unit is available from your local dis tributor. DO NOT use general purpose field replacement ignition modules or ig nit ers. Each appliance has one ignition module and one hot surface igniter.

Ignition Module Lockout Functions

The ignition module may lockout in either a hard lockout condition re quir ing pushing of the reset button to recycle the control or a soft lockout condition which may recycle in a fixed time period to check for correction of the fault condition. A typical hard lockout fault is a flame failure con di tion. Pushing the reset button for the ignition control is the only way to reset an ignition module that is in a hard lockout condition. The reset button is located on the inside front control panel. The reset button is active after the post purge cycle when there is a hard lockout condition as indicated by the Status LED. Turning the main power “OFF” and then “ON” or cy cling the thermostat will not reset a hard lockout condition. Wait five seconds after turning on the main power before pushing the reset button when the ignition module is in a hard lock out. The ignition module will go into a soft lockout in conditions of low air, low voltage or low hot surface igniter current. A soft lockout con di tion will operate the combustion air blower for the post purge cycle and then the ignition module will pause for a fixed time period. The timed length of the pause is based on the type of fault sensed by the control module. At the end of this timed pause, the ig ni tion module will attempt a new trial for ignition sequence. If the soft lockout fault condition has subsided or has been corrected at the end of the timed pause, main burner ignition should be achieved with the resumption of the normal trial for ignition se quence. If the control sensed fault is not corrected, the ignition module will continue in the soft lockout condition. If the electronic thermostat opens during the soft lockout period, the ignition module will exit soft lockout and wait for a new call for heat from the thermostat. A soft lockout con di tion may also be reset by manually cycling the electronic thermostat or turning the main power switch “OFF” and then “ON” after the control sensed fault has been corrected. SoftLockout will be shown in the screen of the Command Display when the ignition con trol module has gone into a soft lock out condition.

Diagnostic Status Indication

The ignition module has an LED that indicates the status of the ignition safety circuits. The flashing op er a tion of this LED indicates the di ag nos tic status of the ignition control module. The following listing gives the flashing diagnostic status codes as signaled by the ignition module.

FIG. 65 Flame Current Measurement on the HSI Module

Proven Pilot Hot Surface Ignition System

Pre-purge Time

15 Seconds

Hot Surface Igniter Heat-up Time

25 - 35 Seconds

Main Burner Flame Establishing Period

4 Seconds

Failure Response Time

0.8 Seconds at < 0.5 µA flame current

Post-purge Time

30 Seconds

TABLE - Y

Ignition and Control Timings

TABLE - Z

Ignition Module Status LED Diagnostic Codes

Code Sequence Condition

Constant ON System OK, no faults present.

_________________________________________________________________________________________________________

Constant OFF Possible control fault, check power; LED may be defective, do not replace control if all operational

sequences function properly - see Trouble Shooting Guide.

_________________________________________________________________________________________________________

One Flash Low air, check air pressure switch and hoses to pressure sensing points, blower start-up/proving

blower, venting and sealing of pressurized chamber. Note: Brief flashing normal on blower startup.

_________________________________________________________________________________________________________

Two Flashes Flame without call for heat, check for a gas valve stuck in the open position, air, venting, burners and

the combustion process. Blower will remain on.

_________________________________________________________________________________________________________

Three Flashes Lockout due to flame failure, push reset button on inner control panel after correcting ignition problem.

Initial heater start up without properly bleeding air from the gas line may require multiple reset functions to achieve proper ignition.

_________________________________________________________________________________________________________

Four Flashes Igniter failure, igniter will not maintain minimum 2.7 amp current draw, caused by low voltage, bad

wiring/continuity, high resistance or igniter failure.

_________________________________________________________________________________________________________

Five Flashes Power supply problem, check for low supply voltage or transformer output less than 18 VAC.

_________________________________________________________________________________________________________

Six Flashes Replace ignition module, internal fault.

D. C. MICROAMP METER

IGNITION MODULE

OPERATION/DIAGNOSTIC

LIGHTS, RESETS AND SWITCHES

ADJ

HI-LIMIT

CIRCUIT

BREAKER

ALARM

RESET

SOUND

ALARM

POWER

SILENCE

AUTO

RESET TEST

MANUAL

LOW WATER CUT-OFF

ALARM

BURNER

FIG. 67 Burner Assembly

FIG. 66 Exterior Control Panel

The control panel has a lighted ON/OFF power switch and 11 indicating lights and switches to show operation, control sensed malfunctions and diagnostics.

TABLE - AA

Diagnostic Lights and Switches

Indicator Function

Power Lighted ON/OFF Main Power Switch. _________________________________________________________________________________________________________

Alarm Silence Rocker Switch to Silence an Optional Audible Alarm.

_________________________________________________________________________________________________________ Alarm Light Amber Indicating Light for an Alarm Condition.

_________________________________________________________________________________________________________ High Limit Light Red Indicating Light for Water Temperature Exceeding Maximum Setting of High Limit Control.

_________________________________________________________________________________________________________ High Limit Knob Adjustable Rotary Knob to Set Maximum Water Temperature.

_________________________________________________________________________________________________________ High Limit Reset Red Push Button to Reset High Limit when High Limit Setting is Exceeded.

_________________________________________________________________________________________________________ Circuit Breaker Reset Button for a 5 Amp breaker on the 24 VAC Control Circuit.

_________________________________________________________________________________________________________ Low Water Cut-Off

_________________________________________________________________________________________________________ Test Switch Black Momentary Rocker Switch interrupts the sensing circuit of the Low Water Cut-Off to prove

operation.

_________________________________________________________________________________________________________ Reset Switch Red Momentary Rocker Switch to Reset the Low Water Cut-Off after a test or Low Water Condition

when operating in the Manual Reset Mode.

_________________________________________________________________________________________________________ Command Display

_________________________________________________________________________________________________________ Run/Stop Switch “RUN” allows normal operation - “STOP” shuts down operation, but allows communication with a

network.

_________________________________________________________________________________________________________ Ignition Control

_________________________________________________________________________________________________________ Flame Failure Reset Red Push Button to reset the Hot Surface Ignition Control when a hard lockout condition from a Flame

Failure has occurred.

This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the primary heat exchanger. There is a unique burner for each one of the three models.

Burners may NOT be changed between different Btu/hr input models. The burner consists of a round mounting flange welded to a mixing tube. The top side of the mixing tube provides the transition which mounts the discharge from the combustion air blower into the burner. The bottom side of the mixing tube is attached to a stainless steel perforated sleeve. This stainless steel sleeve is covered with a loose fitting, woven alloy ma te ri al that forms the burner port sur face. The woven burner port material is called Alcromesh which is a unique alloy of iron, chrome, aluminum and several rare earth metals. This alloy is designed to operate stress free as a burner port surface. The Alcromesh burner port surface can sustain op er a tion from a blue flame down to infrared conditions as the burner input varies. Internally, the burner has a cone and distribution baffles to balance the air/gas mixture over the surface of the burner. The burner mounting flange provides a flame view port and the mounting point for the hot surface igniter. The hot surface igniter is removable from the burner mounting flange without removing the burner assembly from the heat exchanger.

NOTE:

An index mark is provided on the burner flange to ensure proper ori en ta tion when removing and reinstalling the burner. A properly indexed burner will ensure correct location of the com bus tion air blower and adequate clearances from other components in the top jacket chamber.

FIG. 68 Combustion Air Blower

The burner is designed to operate from 100% of rated input down to 25% of rated input in normal operation. Burn er operation at input rates of less than 50% may include operation in the infrared state. At input rates firing above 50%, there may be some slight infrared visible on the tips of the woven burner port material. This is normal burner operation.

COMBUSTION AIR BLOWER

FIG. 69 Combustion Air Blower and Transition Chamber

A sealed transition chamber is mounted on the inlet to the combustion air blower. This chamber contains the gas orifice and a sensing point for op er a tion of the ratio gas valve. Inside the transition chamber, at the inlet to the combustion air blower there is a filter to prevent particulate matter and small foreign objects from entering the blower and burner. This filter should be checked and cleaned on a six month interval or more often in a con tam inated environment. An inspection port is provided on the side of the transition chamber to allow access to the internal filter for inspection and cleaning. If cleaning is required, remove the filter through the inspection port and clean with soapy water or compressed air.

This appliance uses a sealed air blower to provide combustion air for the burn er and operate the Category IV venting system. The blower assembly consists of a sealed housing and blower wheel constructed from cast aluminum. The blower is operated by a fully en closed 230 VAC, 3 Phase electric motor. This motor has a 3/4 HP rating on the 1,500,000 Btu/hr model and a 1 HP rat ing on the 1,700,000 and 2,000,000 Btu/hr models. The blower housing and motor assembly is fully sealed and CANNOT be field serviced.

ORIFICE MOUNTING

TRANSITION CHAMBER

FILTER ACCESS PLATE

FIG. 70 Cleaning the Internal Combustion Air Blower Inlet

Filter

CONDENSATE MANAGEMENT

SYSTEM (Optional)

FIG. 71 Location and Connection of Neutralization Reservoir

This high efficiency appliance may operate as a condensing appliance for extended periods of time based on return water temperatures. Condensate occurs when the products of combustion are cooled below their dew point in the heat transfer process. The liquid con den sate formed from this high efficiency heat transfer pro cess is mildly acidic. The con den sate will typically have a pH ranging from 4.0 to 5.0 as it is discharged from the con den sate drain on the rear of the appliance. The internal jacket area where the condensate is col lect ed (secondary heat exchanger) is con struct ed from a spe cial corrosion resistant stainless steel. All ma te ri als external to the appliance in contact with the con den sate must be corrosion resistant. This is typically accomplished by gravity requiring a minimum downward slope of 1/4" per foot to ensure proper flow to the condensate management system and /or a suitable drain. The neutralizer reservoir MUST always be mount ed on the same lev el or lower than the bottom of the appliance cabinet. All con den sate pip ing and con nec tions must be eas i ly ac ces si ble for rou tine main te nance and inspection. Sufficient lengths of tubing and barbed connectors are supplied in the kit to allow the neu tral iz er res er voir to be po si tioned to the right, left or rear of the appliance.

FIG. 72 Condensate Drain Location On Rear of the

Appliance

Operation of the appliance in a full condensing mode for extended periods of time may produce flue gas condensate in amounts up to the following volume:

TABLE - BB

Approximate Maximum

Condensate Volumes

Model/Input Btu/hr Gallons Per Hour

1,500,000

_______________________

1,700,000

_______________________

2,000,000

7.3

_______________________

8.3

_______________________

9.7

Many codes will require the acidic condensate to be neu tral ized before it can be placed in a drain system. The optional condensate management system consists of a neutralizer kit to control the pH of the liquid discharged to a drain system. The neutralizer in the condensate man age ment system con sists of an industrial grade, non-corrosive plastic reservoir for collection of the condensate. The reservoir is charged with a reagent grade calcium carbonate. The initial calcium carbonate fill is shipped installed in the reservoir. The top to the reservoir is sealed and held in place with two straps. It is not necessary to open the reservoir before placing the neu tral iz er in service. The reagent grade calcium carbonate should fill approximately 3/4 of the reservoir in an even layer over the bottom. The condensate outlet from the appliance must be piped to the reservoir inlet. A barbed fitting is provided for connection to the appliance condensate drain hose (lower hose). The drain from the condensate drain tee in the vent ing system may also be routed to the reservoir inlet for disposal of any condensate formed in the flue. This would be accomplished by adding a field installed tee to the hose assem bly. Ensure that a trap is provided in the drain line from the flue to prevent flue gases from escaping with the con den sate. The condensate collects in the reservoir where it is in direct contact with the calcium carbonate. As the reservoir fills, it provides an extended residence time to neutralize the condensate. The neutralized condensate exits from the reservoir outlet to the condensate trap.

When the condensate level in the reservoir raises to the drain, the pH is controlled to a range of 6.5 to 7 before exiting the system. (A pH of 7 is neutral. As the pH number increases in numerical value, the relative acidity of the discharge decreases.) The neutralized condensate may then be discharged into a suitable drain system without fear of damage to the drain system. Ensure that the top remains on the reservoir keeping it sealed to prevent any contamination to the treatment process.

Condensate Testing

The initial fill of reagent grade calcium carbonate should sus tain neutralization for 3 months of operation. An appliance operating at higher temperatures will produce condensate at lower levels allowing the calcium carbonate to remain ef fec tive as a neutralizer for a maximum of 6 months. The pH of the neutralized condensate discharged from the reservoir should be checked at 30 day intervals. A pH meter or indicating test strips may be used to monitor the relative acidity of the con den sate. When the pH of the condensate discharged from the reservoir can not be maintained above a pH of 6.0, the calcium carbonate must be recharged. Recharge packages of reagent grade calcium carbonate are available from your distributor.

Replenishing the Neutralizer

All of the depleted calcium carbonate must be removed from the reservoir and properly disposed of. Rinse and clean the reservoir thoroughly before adding the new charge to the system. Ensure that the piping to and from the reservoir is clear with no obstructions. Add the new reagent grade calcium carbonate in an even layer over the bottom of the reservoir. Replace the top on the reservoir, replace the two straps to secure the top and return the appliance to service. Check the related piping for leaks on the initial firing after the system is recharged.

Condensate Trap Installation

1. Locate the condensate trap kit shipped loose with the appliance. The kit includes a sheet metal mounting base, two (2) nuts and the condensate trap.

2. Install the condensate trap mounting base on the rear of the appliance in the lower left-hand corner as depicted in Figure 73. Use the pre-drilled holes on the appliance to secure the mounting base to the appliance.

3. Secure the condensate trap to the base using the two (2) nuts supplied with the kit. The trap should be oriented so that the barb connections are pointing toward the appliance (Figure 73).

4. Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap.

5. Locate the two hoses exiting the back of the appliance. Attach the larger hose on the appliance to the lower barb connection on the condensate trap. Secure the hose to the barb with a field supplied hose clamp (Figure 73).

6. Attach the upper hose on the unit to the upper barb connection on the condensate trap. Secure the hose to the barb with a field supplied hose clamp (Figure 73).

7. Route the wire connector harness from the condensate trap to the matching connector on the lower back of the appliance as shown in Figure 73. This is the blocked drain safety switch. This switch will shut the appliance off if the condensate trap becomes too full of liquid.

8. Place the appliance in operation. While the appliance is firing, check the 1/2" connection on the condensate trap for flue gas spillage. If spillage is detected, check the routing of the hoses from the appliance to the condensate trap and verify that the trap is level.

9. If spillage is still occurring, shut the appliance off. Remove the four (4) screws securing the top cover to the condensate trap and remove the cover (Figure 73).

10. Locate the plastic ball inside the float tube. The ball prevents flue gas spillage from the condensate trap when there is not enough liquid in the trap to raise it and drain. Verify there is nothing under the ball causing it to not seat properly.

11. Replace the top cover on the condensate trap. Re-install the four (4) screws removed in Step 9 to secure the top cover.

12. A 1/2" pipe connection is supplied on the condensate trap. Connect a suitable pipe or tube to this connection (see Figure 73).



WARNING

Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap.

Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

NOTE:

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

13. Slope the condensate line down and away from the appliance into a drain or condensate neutralizing filter. Do not expose the condensate line to freezing temperatures.

NOTE:

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, the blocked drain safety switch will prevent the appliance from firing.

FIG. 73 Install Condensate Trap

LIGHTING INSTRUCTIONS

FOR YOUR SAFETY,

READ BEFORE

OPERATING

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING, smell around the appliance

area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas sup pli er from a neighbors phone.

• Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to turn the gas control

handle. Never use tools. If the handle will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been

under water. Im me di ate ly call a qualified service tech ni cian to inspect the boiler. The possible damage to a flooded appliance can be extensive and present numerous safe ty hazards. Any appliance that has been under water must be replaced.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information.

2. Set the Temperature Set Point func tion of the Command Display to the lowest setting.

3. Turn Off all electrical power to the appliance.

4. This appliance is equipped with an ignition device, which automatically lights the burner. DO NOT try to light the burner by hand.

5. Turn the main manual gas cock handle clockwise to the “OFF” position.

FIG. 74 Gas Cock with Handle in “OFF” position

6. Wait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow “B” in the safe ty information. If you don’t smell gas go on to the next step.

7. Turn the main manual gas cock handle counterclockwise to the “ON” position.

FIG. 75 Gas Cock with Handle in “ON” position

TO TURN OFF GAS TO APPLIANCE

1. Set the Temperature Set Point function of the Command Display to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Turn the main manual gas cock handle clockwise to the “OFF” position.

WARNING

Should overheating occur or the gas fails to shut off, turn off the manual gas control valve to the appliance.

IGNITION SYSTEM CHECKOUT

1. Set run/stop switch to “STOP” position.

2. Set the Temperature Set Point function on the Command Display and high limit controls to the highest setting.

3. Turn electric power on.

4. Set run/stop switch to “RUN” position.

5. Allow bypass to synchronize and safety switches to prove.

6. The igniter will cycle on trial for ignition.

7. The ignition module will lock out and indicate a flame failure through the appropriate flash code.

8. Readjust Temperature Set Point of the Command Display and high limit to normal settings.

9. Turn on gas supply.

10. Push the reset button to the right of the ignition module on the front control panel to reset ignition module.

11. If ignition system fails to op er ate properly, repair work must be per formed by a qualified serviceman or installer.

1. The power switch is placed in the “ON” position and the run/stop switch is in the “RUN” position.

2. 120 VAC Power is supplied to the con trol junction box and to the integral pump.

3. 120 VAC Power is supplied to the con trol Transformer, Ignition Module and Excel 10.

4. The bypass valve will synchronize on initial startup only.

5. 24 VAC is supplied to all low volt age controls.

6. Integral pump starts and is proven by a Flow Switch.

7. Command Display Set Point (Operating Temperature) is set to call for heat.

8. Excel 10 Controller initiates a start-up sequence by checking the Tem per a ture Sensors and input signals from the safety controls.

8. Turn on all electric power to the appliance.

9. Set the Temperature Set Point function of the Command Display to the desired setting.

10. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

SEQUENCE OF OPERATION

TURN TO OFF POSITION

TURN TO ON POSITION

9. Excel 10 enables the Ignition Mod ule.

10. Ignition Module enables the Vari able Frequency Drive.

11. Excel 10 Controller drives the Variable Frequency Drive.

12. The Variable Frequency Drive sup plies the Combustion Air Blower with 230 VAC 3 phase power.

13. Combustion Air Blower starts op er a tion and drives to 100% speed for prepurge.

14. Blower makes the low air switch contacts to enable the Ignition Module.

15. Blower cycles down to 50% speed and the Ignition Module initiates the heat-up sequence of the Hot Surface Igniter.

16. Hot Surface Igniter proves 1800°F (982°C) Ignition Temperature by current draw through the Ignition Module.

17. The Ignition Module supplies voltage to the Variable Ratio Gas Valve and the Redundant Gas Valve.

18. Relay contacts prove operation of the Igniter, Gas Valves and Safety Switches to the Excel 10.

19. Variable Ratio Gas Valve senses the pressure from the Combustion Air Blower and supplies gas to the orifice and into the Blower inlet to pre-mix.

20. The Gas/Air mixture is forced into the Burner and out of the Burner Ports under pressure.

21. Hot Surface Igniter lights the Gas/Air mixture and then serves as a flame sensor to prove Main Burner Flame by rectification.

22. Burner is now in a soft start fir ing at 50% of rated input.

23. Excel 10 Controller signals the Variable Frequency Drive to adjust blower speed based on desired water temperature Set Point.

24. Burner input rate is variable down to 25% of rate or up to 100% of rate as required to satisfy the Set Point pro grammed into the Command Display.

25. Excel 10 Controller senses Inlet Water Temperature to the Primary Heat Exchanger and provides a signal to adjust the floating point Bypass Valve (based on return/inlet control choice).

26. Bypass Valve adjusts position to maintain an inlet temperature to the Primary Heat Exchanger above the dew point of flue products.

27. Operation of the Bypass Valve main tains water temperatures above the dew point of flue products to ensure that condensate formation occurs only in the Secondary Heat Exchanger.

Heat Transfer Process

28. Burner Input continues to increase until water temperature reaches the Set Point temperature.

29. Burner Input may stabilize at a fixed rate where demand equals input.

30. Burner Input will decrease rate when water temperature exceeds tem per a ture Set Point and demand.

31. Heated products of combustion pass over the Primary Heat Exchanger trans fer ring heat to the water.

32. Rate of flue product movement is controlled by “V” Baffles on the heat exchanger to maximize heat transfer.

33. Heated products of combustion then pass over the Secondary Heat Exchanger to absorb additional heat.

34. Flue products pass into the flue collector and are exhausted from the unit.

End of Sequence

35. Set Point temperature is satisfied.

36. Power to the gas valves is turned off.

37. Combustion Air Blower ramps up to 100% speed and runs for a 30 second post purge timing and turns off.

38. Excel 10 is now in a standby mode waiting for the next “Call for Heat”.

MAINTENANCE

The following items must be checked to ensure safe reliable oper a tion. Verify proper operation after servicing.

WARNING

Follow the Service and Maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in several personal injury, death, or substantial property damage.

WARNING

The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table CC and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

WARNING

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

A. EXAMINE THE VENTING SYSTEM at least once a year.

Check more often in the first year to determine inspection interval. Check all joints and pipe connections for tightness, corrosion or deterioration. Flush the condensate drain hose with water to clean. Clean screens in the venting air intake system as re quired. Have the entire system, in clud ing the venting system, pe ri od i cal ly inspected by a qualified service agency.

B. VISUALLY CHECK MAIN BURNER FLAMES at each

start up after long shutdown pe ri ods or at least every six months. A burner viewport is located on the burn er mounting flange.

FIG. 76 Flame Pattern

Service technician

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Inspect and clean condensate trap

• Check for leaks (water, gas, flue, condensate)

• Verify flue and air lines in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check control settings

• Check ignition and flame sense

• Check wiring and connections

• Perform start-up checkout and performance verification per Intelli-Fin Installation and Operation Manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 7 microamps at high fire)

If combustion or performance indicate need:

• Clean heat exchangers

• Remove and clean burner using compressed air only

• Clean the blower wheel

Owner maintenance

Daily

• Check boiler area

• Check pressure/temperature gauge

Monthly

• Check vent piping

• Check air piping

• Check air and vent termination screens

• Check relief valve

• Check condensate drain system

• Check automatic air vents

• Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

• Check boiler piping (gas and water) for leaks

• Operate relief valve

End

of season

months

• Shut boiler down (unless boiler used for domestic hot water)

MAINTENANCE & ANNUAL STARTUP

TABLE CC SERVICE & MAINTENANCE SCHEDULES

ANNUAL START-UP

WARNING

The area around the burner viewport is hot and direct contact could result in burns.

1. Normal Flame

: A normal flame at 100% of burner input is blue,

with slight yellow tips a well defined flame and no flame lifting.

2. Yellow Tip

: Yellow tipping can be caused by blockage or

partial obstruction of air flow to the burner.

3. Yellow Flames: Yellow flames can be caused by blockage of primary air flow to the burner or excessive gas input. This condition MUST be corrected immediately.

4. Lifting Flames

: Lifting flames can be caused by over firing the

burner, excessive primary air or high draft.

If improper flame is observed, examine the venting system, ensure proper gas supply and adequate supply of combustion and ventilation air.

NORMAL BURNER FLAME

ABNORMAL BURNER FLAME

C. FLUE GAS PASSAGEWAYS CLEANING

PROCEDURES: Any sign of soot around the inner jacket,

outer jacket, flue pipe connections, burner or in the areas between the fins on the copper heat exchanger indicates a need for clean ing. The following cleaning procedure must only be performed by a qualified serviceman or installer. Proper ser vice is required to maintain safe operation. Properly installed and ad just ed units seldom need flue cleaning.

NOTE:

All gaskets/sealant on disassembled components or jacket panels must be replaced with new gaskets/sealant on reassembly. Gasket and sealant kits are available from your distributor.

CAUTION

When a Category IV vent system is disconnected for any reason, the flue must be reassembled and resealed according to the vent manufacturer’s instructions.

D. BURNER MAINTENANCE: The burner should be removed

for in spec tion and cleaning on an annual basis. An appliance installed in a dust or dirt contaminated atmosphere will require inspection and cleaning on a more frequent schedule. An appliance installed in a contaminated environment may require cleaning of the burner on a 3 to 6 month schedule or more often, based on severity of the con tam i na tion. The fan assisted combustion process may force airborne dust and dirt contaminants, contained in the combustion air, into the burner. With sustained operation, non-combustible contaminants may reduce burner port area, reduce burner input or cause non-warrantable damage to the burner.

Use extreme care when operating an appliance for temporary heat during new construction. Airborne contaminants such as dust, dirt, concrete dust or dry wall dust can be drawn into the burner with the combustion air and block the burner port area. An external combustion air filter is provided with the appliance. The combustion air filter is for Temporary Use Only and MUST be removed when the appliance is placed in normal service. An additional filter is located inside the transition chamber, at the inlet to the combustion air blower, to also prevent particulate matter and small foreign objects from entering the blower and burner. This internal filter should be checked and cleaned on a six month interval or more often in a contaminated environment. See the Combustion Air Blower section of this manual for cleaning instructions. The burner of an appliance used for temporary heat with out a combustion air filter in stalled will probably require a thor ough cleaning before the unit is placed into normal service.

BURNER REMOVAL AND CLEANING

Access to the burner will require the following steps:

a. Turn off main electrical power to the appliance.

b. Turn off main manual gas shutoff to the appliance.

c. Remove the outer control panel cover. Open the control panel

and remove the screws from the lower front edge of the radiused front outer jacket panel. Lift the edge of the radiused panel and locate the internal screws attaching the back edge of the radiused panel. Reach through the control panel opening with a 5/16” nut driver and loosen the 2 internal screws holding the rear edge of the radiused panel. Pull the panel slightly forward and remove it. Remove the screws along the front and rear edge of the top outer jacket panel to remove the jacket top. This allows access to the components in the top of the appliance.

d. Disconnect the gas supply connection to the internal gas train at

the field installed union.

e. Remove the air inlet pipe con nec tion to the boiler/water heater.

f. Remove the insulation blanket* on top of the heat exchanger.

Note: Take care not to tear insulation blanket on removal.

g. Disconnect the blower motor power wires at the connection to

the VFD.

h. Disconnect the power wires to the gas valves, flow switch and

pressure switches (if equipped). Multiple pin connectors are used at all of these components for ease of service.

i. Remove the sensing tubes from the air ratio gas valve to the

combustion air blower.

j. Remove the 6 nuts holding the blower assembly to the blower

and remove the blower assembly.

k. Disconnect the power wire to the hot surface igniter.

CONDENSATE TESTING

A pH meter or indicating test strips may be used to monitor the relative acidity of the condensate. When the pH of the condensate discharged from the reservoir cannot be maintained above a pH of

6.0, the calcium carbonate must be recharged. Recharge packages

of reagent grade calcium carbonate are available from your distributor.

WARNING

Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

NOTE:

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 OR D2845. Cement and prime must comply with ASME D2564 or F493. For Canada, use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

NOTE:

When the combustion air blower is removed for any reason, the inlet to the burner must be covered to prevent foreign objects from falling into the burner. A foreign object such as a nut, bolt, wire or other metallic items will cause a rapid non-warrantable failure of the burner on operation.

NOTE:

Use care when removing and handling the burner. Sharp objects or impact may damage or tear the woven burner flame surface.

Burner Cleaning Procedure

Remove any visible dust or dirt block age from the surface of the burner with a vacuum. Compressed air may also be blown across the burner surface to clean the “pores” of the woven burner port material.

The burner may best be cleaned by im mers ing the burner port area in a so lu tion of dishwashing detergent and hot water. Do not use chlorine based sol vents or cleaning agents on the burner. Allow the burner to remain in the so lu tion for a short period of time to remove dust, dirt and oil or grease laden contaminants. Rinse the burner thoroughly with clean water to remove any residue from the detergent cleaner. The burner should be air dried quickly after removal from the cleaning so lu tion and rinsing to prevent any oxida tion or rusting of the ferrous components in the burner port material.

8. Check the replacement igniter for cracks or damage before installing.

9. Ensure that the fiber gasket used to seal the base of the igniter to the burner flange is reinstalled to seal the base of the replacement igniter.

10. Carefully insert the igniter into the mounting point on the burner flange and position on the mounting studs.

11. Reinstall the two wing nuts and tighten by hand only. Over tightening the wing nuts may break the ceramic mounting flange.

12. Ensure that the igniter gasket is properly installed and seals the point of contact between the igniter and burner mounting flange.

13. Reconnect the power leads to the igniter.

14. Replace the insulation blanket flaps.

15. Turn on main gas supply.

16. Turn on main power.

17. Test fire the appliance to ensure proper operation.

FIG. 77 Location of Primary Heat Exchanger

l. Remove the hot surface igniter. The hot surface igniter is

fragile. Use care to prevent impact damage to the silicon carbide igniter surface when removing the igniter.

m. Remove the 8 nuts holding the burn er to the heat exchanger.

n. The burner can now be lifted vertically out of the heat

exchanger cavity.

o. Use care to prevent damage to the woven burner port surface

on removal.

* Insulation jacket is tucked under the control panel assembly and cannot be “removed” without removing the control panel.

E. CHANGING THE HOT SURFACE IGNITER

1. Turn off main electrical power to the appliance.

2. Turn off main manual gas shutoff to the appliance.

3. Carefully pull back the insulation flaps to expose the burner mounting flange.

4. Locate the Hot Surface Igniter.

5. Disconnect the two power leads to the hot surface igniter.

6. Loosen and remove the two wing nuts that mount the igniter.

7. Lift the igniter vertically out of the burner mounting flange. Use care, do not hit or break the silicon carbide igniter.

NOTE:

All gaskets/sealant on disassembled components or jacket panels must be replaced with new gaskets/ sealant on reassembly. Gasket and sealant kits are available from your distributor.

F. PRIMARY HEAT EXCHANGER INSPECTION

1. Turn off all power to the appliance.

2. Turn off main gas to appliance.

3. Remove the front outer jacket door.

4. Remove the front inner jacket door.

5. Check the heat exchanger surface for soot. If soot is present, heat ex chang er must be cleaned and problem corrected.

6. Remove burner as described in Burner Maintenance procedure.

7. Check “V” baffles on the exchanger. Remove and clean if necessary.

8. Remove soot from heat exchanger with a stiff bristle brush. Use a vacuum to remove loose soot from surfaces and inner chamber.

9. The heat exchanger can be removed by disconnecting all water piping to the bypass and secondary heat exchanger, removing the screws holding the heat exchanger to the top of the inner jacket. and sliding the heat exchanger towards the front of the appliance. Once the heat exchanger is removed, a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces. NOTE: Do not wet the insulation blankets on the inside of the outer jacket panels.

10. Ensure that any soot present on the burner is removed. See Burner Cleaning Procedure.

11. Carefully reinstall the heat ex chang er and “V” baffles if removed from the appliance.

12. Reinstall inner jacket panels, burner, manifolds, wires and hoses. Use new gasket material to ensure a proper air seal.

13. Reassemble all gas and water pip ing. Test for gas leaks.

14. Reassemble outer jacket panels.

15. Cycle unit and check for proper operation.

G. SECONDARY HEAT EXCHANGER INSPECTION

FIG. 78 Location of Secondary Heat Exchanger

1. Turn off all power to the appliance.

2. Turn off main gas to appliance.

3. Break the union, pump flange and bypass valve flange to remove the pump and external portion of the bypass assembly.

4. Remove the inner jacket door.

5. Check the heat exchanger surface for soot or fouling. If soot is present, heat exchanger must be cleaned and problem corrected.

6. Check “V” baffles on the exchanger. Remove and clean if necessary.

7. Remove soot from heat exchanger with a soft bristle brush. Use care not to damage coating on the exterior of the secondary heat exchanger. Use a vacuum to remove loose soot from surfaces and inner chamber.

8. The heat exchanger can be removed by disconnecting all water piping to the bypass and secondary heat exchanger and sliding the heat exchanger towards the rear of the appliance. Once the heat exchanger is removed, a garden hose can be used to wash the tubes to ensure that all surface deposits are removed from the exterior of the heat exchanger surfaces.

9. Carefully reinstall the heat ex chang er if removed from the appliance.

10. Reinstall inner rear jacket panels, bypass piping and condensate hoses. Use new gasket material to ensure a proper air seal.

11. Reassemble all water piping. Test for leaks.

12. Reassemble rear outer jacket pan els.

13. Cycle unit and check for proper operation.

H. LUBRICATION

Combustion Air Blower: Each combustion air blower should

be checked every 6 months. Clean internal filter to blower as required when installed in a dust or dirt contaminated location. See Combustion Air Blower in the com po nent section for cleaning procedure. The motor and bearings on the com bus tion air blower are sealed and per ma nent ly lubricated requiring no addition of oil or lubricants.

Water Circulating Pump: Inspect pump every 6 months and oil as necessary. Use SAE 30 non-detergent oil or lu bri cant specified by pump manufacturer.

I. COMBUSTION AND VENTILATION AIR

Check frequently to be sure the flow of combustion and ventilation air to the boiler is not obstructed. Combustion and ventilation air must be provided to the mechanical room with openings sized per the requirements of the National Fuel Gas Code when the appliance is installed with a standard Category IV vent system. The optional Direct-Vent and Intelli-Vent systems use a separate combustion air pipe to bring in combustion air from the outdoors directly to the appliance. Ensure that the construction air filter is NOT used for continuous service after the con struc tion phase.

J. CONTROL CIRCUIT VOLTAGE

This appliance uses a transformer to supply a low voltage control circuit. The voltage on the secondary side should be 24 to 28 VAC when measured with a voltmeter. A secondary voltage of 18 VAC or less supplied to 24 VAC components may cause operational prob lems. A 5 AMP circuit breaker is provided on the secondary side of the trans form er. The circuit breaker is located on the left front control panel. A tripped circuit breaker indicates a short in the 24 VAC controls that must be corrected.

FIG. 79 Measuring Combustion Air Pressure Differential to

Ratio Gas Valve

K. COMBUSTION AIR MEASUREMENT

This appliance uses a variable speed combustion air blower to operate the combustion process and venting system. A single combustion air blower is used to supply combustion air to the burner. The discharge air from the blower is factory pre-set and is not field ad just able. The blower and transition are mounted on the top of the burner. The blower is enclosed inside of the top chamber.

There is a pressure test tree located in the top chamber of the appliance. This pressure test point tree can be accessed by swinging out the front control panel. The pressure test tree is mounted on the front edge of the combustion air blower. It consists of an angle support and four labeled test cocks. There is one cock for + air and one for - air, one cock for + gas and one for - gas. Differential air pres sure measurement at the combustion air blower will utilize both the + air and - air test points.

1. Open the front control panel and swing the controls out. Locate the pressure test tree on the front edge of the combustion air blower. The + and - air pressure terminals will be used to check differential air pressure from the blower discharge to the burner inlet. Each air pressure connection point will have a small manual cock to attach a hose.

2. Connect a hose from the + air and the - air to each of the two sides of a manometer. This will allow the two pressure points to be measured at the same time. Open the two air pressure test point cocks.

3. Set the Command Display to a set point which will fire the burner at 100% of rated input.

ORIFICE

GAS

AIR BOX

(FRONT VIEW)

GAS

BLOWER

AIR

GAS

GAS VALVE (TOP VIEW)

GAS

AIR

BURNER

MANIFOLD AIR PRESSURE

– – – – = FIELD CONNECTED

3.5" W.C. = ai

FREEZE PROTECTION

CAUTION

Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of the manometer. The sum of these two readings as they are effected by the two air pressures is the differential air pressure.

5. The differential air pressure should be 3.5 inches of water column (+ 0.1” w.c.) when the burner is firing at 100% of rated input.

6. If the differential air pressure is not 3.5 inches water column (+ 0.1” w.c.), review the installation. Check for proper installation of the venting system. Review the venting requirements in this manual for the specific venting system installed with this appliance. Correct as required. Ensure that an adequate supply of combustion air is supplied to the appliance. If a separate pipe is used to supply combustion air, ensure that it is installed per the combustion air pipe requirements contained in the venting section of this manual. Correct as required. Check the air inlet screen to the combustion air blower. Clean as required. Check the burner for dirt or contamination and clean as required. Recheck for correct differential air pressure after correcting an installation related problem or after cleaning an obstructed component. Ensure that a combustion air differential of 3.5 inches water column (+ 0.1” w.c.) is present while the appliance is firing at 100% of rated input.

7. This is a reference pressure only and is not field adjustable. An appliance supplied with an unrestricted supply of combustion air from a correctly sized combustion air opening or separate direct vent combustion air pipe will operate at the correct air pressure differential as the burner input varies with temperature demand.

8. Close the two air pressure test cocks on the pressure test tree and remove the hoses to the manometer.

9. Close the front control panel.

L. COMBUSTIBLE MATERIALS

Installations are not recommended in areas where the danger of freezing exists. Proper freeze protection must be provided for appliances installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower. If freeze protection is not provided for the system, a low ambient temperature alarm is rec om mend ed for the mechanical room. Damage to the appliance by freezing is non-warrantable.

1. Pump Operation - MOST IMPORTANT - This appliance is designed for con tin u ous pump operation when the burners are firing. The integral circulating pump will run continuously when the power switch is in the “ON” position and the run/stop switch is in the “RUN” position. As an optional feature an intermittent pump control system can be provided. The intermittent pump option allows the integral circulating system pump to be cycled on at each call for heat and cycled off when the set point is satisfied. The intermittent pump will operate for a timed period after the burner cycles off to remove residual heat from the combustion chamber area. If the operating temperature sensor for an intermittent pump system sees a drop in water temperature to 45°F (7.2°C), the integral circulating pump will cycle on. This flow of warm boiler water can help prevent freezing.

2. Location - Heating boilers, hot water supply boilers or water heaters must be located in a room having a temperature safely above freezing [32°F(0°C)].

3. Caution - A mechanical room op er at ing under a negative pressure may experience a downdraft in the flue of an appliance that is not firing. The cold outside air may be pulled down the flue and freeze a heat exchanger. This condition must be corrected to provide adequate freeze protection.

4. A motor driven damper may be installed in the air inlet to prevent cold air movement in cold climates. The damper MUST be interlocked with boiler/water heater controls to open and prove on a call for heat.

5. Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze. Fol low the manufacturers instructions. DO NOT use undiluted or automotive type antifreeze.

6. Shut-down and Draining - If for any reason, the unit is to be shut off, the following precautionary measures must be taken:

(a) Shut off gas supply.

(b) Shut off water supply.

(d) Drain the unit completely. Remove the caps from the two drains located on the rear of the appliance. Open the relief valve and manually open the bypass valve to allow air into the system so the water will drain out. Open the union fitting on the inlet so water can be drained from the secondary heat exchanger.

(e) Ensure that the pump, bypass piping and connecting piping are fully drained.

FREEZE PROTECTION FOR A

HEATING BOILER SYSTEM

(If Required)

1. Use only properly diluted in hib it ed glycol antifreeze designed for hydronic systems. Inhibited propylene glycol is recommended for systems where incidental contact with drinking water or any potable water is possible.

CAUTION

DO NOT use undiluted or automotive type antifreeze.

2. A solution of 50% antifreeze will provide maximum protection of ap prox i mate ly -30°F.

3. Follow the instructions from the antifreeze manufacturer. Quantity of antifreeze required is based on total system volume including expansion tank volume.

4. Glycol is denser than water and changes the viscosity of the system. The addition of glycol will decrease heat transfer and increase frictional loss in the boiler and related piping. An increased flow rate through the boiler heat exchanger may be required to achieve proper heat transfer rates in a glycol system. Reduced flow in a boiler due to a high percentage of glycol in the system may result in boiler noise or flashing to steam.

5. Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system.

WATER TREATMENT

In hard water areas, water treatment should be used to reduce the in tro duc tion of minerals to the system. Min er als in the water can collect in the heat exchanger tubes and cause noise on operation. Excessive build up of min er als in the heat exchanger can cause a non-warrantable failure.

WARNING

DO NOT attempt to fire this appliance without completely filling the heat exchangers, bypass and all related system piping. Ensure that all air is properly bled from the system before firing. Failure to properly fill the boiler and related piping before firing may result in personal injury or nonwarrantable property damage.

HEATING BOILER INSTALLATIONS

PIPING OF THE BOILER SYSTEM

The drawings in this section show typ i cal boiler piping installations. This boiler MUST always be installed in a primary/secondary piping system for proper operation. Before beginning the installation, consult local codes for specific plumbing requirements. The installation should provide unions and valves at the inlet and outlet of the boiler so it can be isolated for ser vice. An air separation device must be supplied in the installation piping to eliminate trapped air in the system. Locate a system air vent at the highest point in the system. The system must also have a properly sized expansion tank installed. Typically, an air charged diaphragm-type expansion tank is used. The expansion tank must be installed close to the boiler and on the suction side of the system pump (Boiler Inlet) to ensure proper operation. Caution: This boiler system should not be operated at less than 12 PSIG. Hot water piping must be supported by suitable hangers or floor stands, NOT by the boiler. Copper pipe systems will be subject to considerable expansion and contraction. Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system. Padding is recommended on rigid hangers installed with a copper system. The boiler pressure relief valve must be piped to a suitable floor drain. See the relief valve section in the In stal la tion and Service Manual.

CAUTION

A leak in a boiler “system” will cause the “system” to intake fresh water constantly, which will cause the tubes to accumulate a line/scale build up. This will cause a NON-

WARRANTABLE FAILURE.

WATER CONNECTIONS

HEATING BOILERS ONLY

All boilers have 3 inch (76.2mm) copper pipe inlet and outlet connections. In stalled piping to and from the boiler must be a minimum of 3 inches (76.2mm) diameter and must not exceed the maximum spec i fied piping length. Caution: Field installed reducing bushings must not be used. Any reduction in pipesize may decrease flow resulting in high water temperatures, boiler noise, flashing to steam and non-warrantable heat ex chang er damage.

PIPING LENGTHS

The boiler’s integral circulator pro vides the water flow from the primary boiler piping, through the boiler and back to the primary system. Pipe di am e ter and length are critical to ensure proper flow through the boiler. A 3 inch (76.2 mm) diameter pipe installed from the primary system to the boiler inlet must not exceed 70 equivalent feet (21.2 m) in length. The return piping from the boiler back to the primary boiler pip ing system must also not exceed 70 equivalent feet (21.2 m) in length. Subtract 8 feet (2.9 m) of equivalent length for each 90° elbow installed in the piping to and from the boiler.

The secondary loop piping to and from the boiler must have a fully ported ball valve installed in both the supply and return side piping.

The ball valves must be the same diameter as the installed piping.

The ball valve in the piping supplying water to the boil er will only be used as a service valve. The ball valve installed in the discharge from the boiler back to the primary system will be used to adjust boiler flow and temperature rise to ensure proper performance.

BOILER CIRCULATOR PUMP

LIMITATIONS

The integral circulator provided on this boiler WILL NOT function as a main system circulator. This boiler was designed for installation in a primary/secondary piping system. The boiler’s integral pump is only sized to provide flow in the secondary loop, from the primary sys tem, through the boiler and back to a primary boiler system piping. Pipe di am e ter and length are critical to ensure proper flow through the boiler and secondary piping. The boiler primary piping system must have a primary cir cu la tor installed in the main system loop to carry the heated boiler water to the point of use in the main system.

This is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, efficient operation. The internal circulating pump will provide this flow for a properly in stalled secondary loop to the boiler. Pipe diameter and length are critical to ensure proper flow through the boil er and secondary piping. Tem per a ture rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing. Example: The boiler inlet temperature is 160°F (71.1°C) and the boiler outlet tem per a ture is 180°F (82.2°C).

This means that there is a 20°F (11.1°C) temperature rise across the boiler. The boiler temperature rise is visible on the Command Display on the boiler’s front control panel. When the automatic bypass valve is open, a portion of the heated water is re cir cu lat ed back into the primary heat ex chang er. Operation of the bypass will yield higher discharge temperatures from the boiler.

PRIMARY LOOP CIRCULATOR

PUMP SPECIFICATIONS

1. Maximum operating pressure for the pump must exceed system operating pressure.

2. Maximum water temperature should not exceed nameplate rating.

3. Cast iron circulators may be used for closed loop systems.

4. A properly sized expansion tank must be installed near the boiler and on the suction side of the pump.

CIRCULATOR PUMP OPERATION

(Heating Boilers Only)

The boiler pump should run continuously when the boiler is firing. External wire leads are furnished in the elec tri cal junction box to allow separate power supplies to the pump and boiler controls or the two circuits (pump and controls) can be combined for con nec tion to one 120 VAC, 20 AMP circuit for both. As shipped from the factory, the control system will turn on the boiler pump when the main power switch is placed in the “ON” position and the Run/Stop switch is in the “RUN” position.

INTERMITTENT PUMP OPERATION

(Optional)

An intermittent pump operation feature is available as an option. When equipped with this option, the boiler’s integral circulating pump will cycle on at each call for heat, before the burn er fires. The pump will continue to operate while the burner is firing. The pump will run for a 30 second period after the temperature set point is sat is fied. This will remove any residual heat from the combustion chamber before turning the pump off. See wiring di a gram shipped with the unit.

PUMP MAINTENANCE: Inspect the pump every 6 months and oil as nec es sary. Use SAE30 non-detergent oil or lubricant specified by the pump manufacturer.

This high efficiency boiler MUST be installed with a primary/secondary piping system. This type of system uses the integral boiler circulating pump to supply flow to and from the boiler only. This pump is sized based on a specified minimum pipe diameter and maximum length. These limitations are critical to ensure proper flow through the boiler and secondary piping. The length of the secondary piping to and from the boiler to the main system loop must not exceed 70 equivalent feet (21.2 m) in length each di rec tion when installed in 3" (76.2 mm) di am e ter pipe. Each elbow and fitting installed in the piping to and from the boiler will reduce the available equivalent length of pipe that can be installed. See Water Connection-Piping Lengths for calculation of equivalent length of pipe and reductions in length for in stalled fittings.

PRIMARY/SECONDARY BOILER PIPING

TO EXPANSION TANK

AND MAKEUP WATER SYSTEM

TO SYSTEM

12” MAX.

FROM SYSTEM

FIG. 80 Primary/Secondary Piping of a Single Boiler

CAUTION

At no time should the system pressure be less than 12 PSIG.

MAKE-UP WATER

FROM SYSTEM

CAP EACH MANIFOLD

TO SYSTEM

MINIMUM BOILER WATER

TEMPERATURES

Inlet water temperatures below the specified minimum recommendations can excessively cool the products of combustion resulting in condensation on the primary heat exchanger. The boiler is designed to condense only on the secondary heat exchanger. Conden sa tion on the primary heat exchanger can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the related components.

FIG. 81 Primary/Secondary Piping of Multiple Boilers

A properly sized primary system pump provides adequate flow to carry the heated boiler water to radiation, air over coils, etc. The fittings that connect the boiler to the primary sys tem should be a maximum of 12" (0.30 m) (or 4 pipe diameters) apart to ensure connec tion at a point of zero pressure drop in the primary system. There should be 10 pipe diameters of straight pipe before and after the boiler secondary loop connections to prevent turbulent flow at the secondary loop connections. Multiple boilers may also be installed with a primary/secondary manifold system. Multiple boilers should be connected to the common manifold in reverse return to assist in balancing flow to multiple boilers.

The installer must ensure that the boiler has adequate flow without ex ces sive temperature rise. Low system flow can result in overheating of the boiler water which can cause short burner cycles, system noise relief valve discharge and in extreme cases, a knocking flash to steam. These conditions indicate the need to increase boiler flow to and from the boiler. This is generally accomplished by increasing the diameter of the piping that connects the boiler to the primary system. A larger di am e ter pipe reduces head loss and in creas es flow.

The automatic bypass system allows part of the boiler discharge water to be mixed with the inlet water to the pri ma ry heat exchanger to increase the boiler inlet temperature above 130°F (55°C). This will prevent the products of combustion from condensing on the primary heat exchanger. A valve must also be provided on the boiler dis charge, after the bypass. Closing this discharge valve sets the maximum flow through the appliance. (See Bypass—Initial Set-up of Maximum Water Flow for more details.)

A minimum water temperature of 50°F (10°C) has been established for each boiler based on the Btu/hr input at 100% of rated burner input. The temperature set point for the Excel 10 controller sensing system must not be set lower than the specified minimum for each model. Maintaining inlet water temperatures to the boiler equal to or higher than the specified minimum set point ensures proper operation of the bypass and allows all condensate formation to occur on the secondary heat exchanger. A boiler allowed to sustain operation at water temperatures lower than the specified minimum set point may not provide enough heat from the burner to maintain water temper a tures in the primary heat exchanger above the 130°F (55°C) dew point of flue products. Operation of a boiler at a temperature below the specified minimum set point will result in non-warrantable operational problems from the condensate formation on the primary heat exchanger.

TABLE - DD

Minimum Inlet Water Temperatures

Input Minimum Return Minimum

Btu/hr Temperature Setpoint

1,500,000

_________

1,700,000

_________

2,000,000

105°F (40.6°C)

______________

90°F (32.2°C)

______________

70°F (23.9°C)

50°F (10°C)

__________________

50°F (10°C)

__________________

50°F (10°C)

CAUTION

A boiler allowed to operate at set point temperatures below the spec i fied minimum settings may experience operational problems with the operating controls and safety switches, ob struc tion of the flue gas passages on the primary heat exchanger, incomplete combustion and possible flue gas spill age. Operation at lower than specified water temperatures may cause hazardous conditions that result in non-war rant able damage to the appliance.

THREE WAY VALVES

The installation of a three way valve on this boiler is not recommended be cause most piping methods allow the three way valve to vary flow to the boiler. This boiler is a low mass, high efficiency unit which requires a constant water flow rate for proper operation. Low flow rates can result in overheating of the boiler water which can cause short burner cycles, system noise, relief valve discharge and in extreme cases, a knocking flash to steam. These con di tions can cause operational problems and nonwarrantable failures of the boiler.

MAXIMUM FLOW FOR

HEATING BOILER

CAUTION

The maximum flow rate through the boiler with a copper heat exchanger must not exceed the following:

Btu/hr Input Maximum Flow

1,500,000 - 2,000,000 90 GPM

If higher flow rates are required through the boiler, an optional Cupro-Nickel heat exchanger is available. Consult the factory for specific ap pli ca tion requirements.

The heat exchanger is capable of op er at ing within the design flow rates for the boiler secondary loop requirements. Erosion of the finned copper tubes may occur if the flow rate exceeds the maximum allowable flow rate through the boiler. The maximum flow through the boiler must be adjusted with the bypass valve in the full closed position. Maximum flow is 90 GPM. Flow rate can be determined by measuring the tem per a ture rise through the boiler when it is firing at full rate input. See Bypass-Initial Setup for adjustment procedure.

BOILER TEMPERATURE

RISE CHART

TABLE - EE

Temperature Rise at Full Rate Fire

Bypass Fully Closed and 90 GPM Flow

Btu/hr Input Temperature Rise

1,500,000

_______________________

1,700,000

_______________________

2,000,000

31.5°F (17.5°C)

________________________

35.7°F (19.8°C)

________________________

42.0°F (23.3°C)

TEMPERATURE/PRESSURE GAUGE

This boiler is equipped with a dial type temperature/pressure gauge. This gauge is factory installed in the out let side of the boiler bypass piping. The gauge has one scale to read system pressure and a separate scale to read water temperature in °F. The tem per a ture/pressure gauge is provided to meet code requirements. Water temperatures can be more accurately monitored from the data provided in the Command Display.

TYPICAL HEATING BOILER

INSTALLATIONS

General Plumbing Rules

1. Check all local codes.

2. For serviceability of boiler, always install unions.

3. Always pipe pressure relief valve to an open drain.

4. Locate system air vents at high est point of system.

5. Expansion tank must be installed near the boiler and on the suction side of the system pump.

6. Support all water piping.

PLACING THE BOILER

IN OPERATION

Pre-Start Check List

1. Review the location of the boiler, clearances from combustible surfaces and available service clearances.

2. Review the installed Vent System. Ensure that all vent components are Category IV material with adequate clearance from combustibles.

3. Ensure that the boiler condensate drain and all vent system condensate drains are properly routed to an ac cept able floor drain or neutralization system.

4. Ensure that an optional condensate neutralization system is properly in stalled if required by codes.

5. Review the vent termination point for proper location and clearances.

6. Ensure that proper volumes of com bus tion and ventilation air are pro vided to the mechanical room. If a separate combustion air pipe is used, ensure that it is properly sized, sealed and terminated.

7. Review the water piping from the boiler to the system. The boiler must be installed in a primary/ secondary piping system. Review the diameter and equivalent length of the installed piping to and from the boiler to ensure proper flow.

8. Ensure that a properly sized primary system pump is installed with an expansion tank.

9. Check system pressure. Ensure a minimum of 12 PSI and not more than the rated pressure of the relief valve.

10. Review the installed gas piping from the meter to the boiler. Ensure that the gas pipe, meter and any regulators are adequately sized.

11. Review the field wiring and elec tri cal service for both the boiler controls and pump. Ensure that the electrical service(s) is adequately sized.

12. Review wiring to an energy man age ment system and wiring to any remote temperature sensors.

Boiler Set-Up

13. Ensure that the boiler and piping system are full of water. Bleed all air from the secondary loop and bypass piping on the boiler.

14. Check system for any water leaks.

15. Check system for installation of glycol or water treatment.

16. Turn on power to the primary system pump and the integral boiler secondary pump and verify operation.

Boiler Operational Checks

17. Turn the boiler main power switch to the “ON” position and the run/stop switch to the “STOP” position.

18. Verify operation of the Excel 10 and Command Display.

19. Program the adjustable points from the Command Display.

20. Turn the run/stop switch to the “RUN” position to start boiler operation. Note: The bypass must go through the synchronization process before start-up begins.

21. Push the resets for low water lev el, high water temperature and flame failure.

22. Carefully follow the bypass ad just ment procedure to set maximum flow to the boiler at 90 GPM. Verify by check ing temperature rise while burner is firing at 100% of rated input.

23. Install a manometer on the gas supply to the boiler and verify minimum gas supply pressure as the burner fires at 100% of rated input.

24. Verify operation of safeties as necessary (low water cut-off, high limit, gas pressure, etc.).

25. Turn the run/stop switch to the “STOP” position.

26. Verify that all adjustable points in the Command Display are set as required.

27. Reconnect any wiring disconnected during the boiler set-up.

Boiler Operation

28. Turn the run/stop switch to the “RUN” position to start boiler operation.

29. Push the resets for low water lev el, high water temperature and flame failure.

30. Observe the boiler synchronization process before start-up of the boiler begins.

31. Boiler should begin the start-up process for the sequence of operation.

32. The boiler will fire at 50% of rated input on initial start-up and adjust input as required to meet system demand.

33. The integral bypass valve will automatically adjust to maintain min i mum inlet temperatures to the primary heat exchanger.

34. Ensure that inlet water temperature does not fall below the specified min i mum for the boiler.

35. Based on system demand, the boiler may run for an extended period of time at a reduced rate of input to maximize efficiency.

36. As system demand is satisfied, the burner will cycle off and the com bus tion air blower will run for a post purge operation before the boiler shuts down.

INSTALLATION WITH A

CHILLED WATER SYSTEM

EXPANSION

TAN K

HEATING AND

COOLING COIL

GAS SUPPLY

PUMP

WATER

SUPPLY

CHILLER

FIG. 82 Installation with a Chilled Water System

Pipe refrigeration systems in parallel. Install duct coil downstream at the cooling coil. Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation, the boiler piping system must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. The coil must be vented at the high point and hot water from the boiler must enter the coil at this point. Due to the fast heating capacity of the boiler, it is not necessary to provide a ductstat to delay circulator op er a tion. Also, omit thermostat flow checks as the boiler is cold when heat ing thermostat is satisfied. This provides greater economy over main tain ing standby heat.

BOILER OPERATING

TEMPERATURE CONTROL

The operating temperature control for the boiler is the Excel 10 controller. It is located on the back side of the front control panel, behind the front access door. Access to adjust the temperature set point and other owner/operator adjustable points is made through the Command Display located on the front control panel. The sensing element for the operator is placed in a bulb well installed in the inlet connection to the boiler. The outlet sensor is located in a bulb well on the outlet side of the primary heat exchanger top header. Carefully observe the discharge water temperature on the initial boiler on cycles. The location of the tem per a ture sensor may generally require a lower temperature set point on the operating control to achieve the de sired discharge water temperature from the boiler. The return/inlet sensing element lo ca tion allows a boiler to sustain longer burner on cycles.

The location of the operating sensor, inlet or outlet, is selectable from the screen on the Command Display.

The exact temperature set point is based on your system’s requirements. Set the control set point(s) to the desired operating water temperature. Observe the boiler discharge tem per a ture after each set point adjustment to ensure proper operation.

The maximum set point for operation of a heating boiler is 220°F (104.4°C) on a standard Excel 10 control. The minimum tem per a ture setting programmed into this stan dard Excel 10 control is 100°F (37.7°C).

DOMESTIC HOT WATER SUPPLY BOILER

This section applies only to those appliance used to supply domestic hot water, installed with a storage tank(s). The integral circulating pump installed in the bypass piping assembly is used to control water ve loc i ty through the appliance. Proper water velocity is important for correct operation of your water heater or hot water supply boiler.

WATER HEATERS

1,500,000 - 2,000,000 Btu/hr Models

DOMESTIC HOT WATER SUPPLY BOILERS

1,500,000 - 2,000,000 Btu/hr Models

FIG. 83 Typical Water Heater Piping with Storage Tank

This section contains specific in struc tions for those appliances used to supply domestic hot water. All warn ings, cautions, notes and instructions in the general installation and service sections apply to these instructions. Hot water supply boilers and water heaters are designed for installation with a storage tank. The operation of the integral circulating pump, properly sizing of the piping between the tank and heater and the control of water velocity, as explained below, are im por tant for correct operation of your water heater or hot water supply boiler.

WATER VELOCITY CONTROL

To ensure proper velocity through the heat exchangers, it is nec es sary to regulate the temperature rise across the heat exchanger from inlet to outlet. This must be done on initial installation and periodically re checked. With the correct temperature rise across the heat exchangers when the water heater is firing at 100% of rated input, you may be assured of the proper velocity in the tubes. This will yield long life and economical operation from your water heater or hot water supply boiler.

IMPORTANT

Excessive lime/scale build-up in the heat exchanger tubes is a result of restricted flow and too little velocity in the tubes. Excessive pitting or erosion in the tube is caused by high water flow and too much velocity through the tubes. Care should be taken to measure temperature rise and maintain a velocity as follows:

BYPASS - Initial Set-up of Maximum Water Flow

On initial start-up of the Intelli-Fin the maximum water flow through the two in ter nal heat exchangers must be manually set before the automatic operation of the bypass begins.

CAUTION

The maximum flow rate through an Intelli-Fin water heater with a copper heat exchanger must be set to provide and not exceed 90 GPM.

BUILDING

HOT WATER SUPPLY

RELIEF VALVE

TO DRAIN

LOCK-TEMP

STORAGE TANK

DRAIN

MIXING

VALV E

COLD WATER SUPPLY

BUILDING RETURN

TABLE - FF

Maximum Flow Rate

Btu/hr Input Maximum Flow

1,500,000 - 2,000,000 90 GPM

If higher flow rates are required through the water heater, an optional Cupro-Nickel heat exchanger is avail able. Consult the factory for specific application requirements.

The heat exchanger is capable of op er at ing within the design flow rates required for the water heater, storage tank(s) and connecting piping. Erosion of the finned copper tubes may occur if the flow rate exceeds the maximum al low able flow rate through the water heater. The maximum flow through the water heater must be adjusted with the bypass valve in the full closed po si tion. Maximum flow is 90 GPM. Flow rate can be determined by measuring the temperature rise through the water heater when it is firing at full rate input. Also see Bypass Initial Setup of Maximum Water Flow for adjustment procedure.

Setting temperature rise on an Intelli-Fin with an automatic bypass is ac com plished by disconnecting the power leads to the actuator, (multi-pin connector on rear of appliance), declutching the actuator drive and manually closing the bypass valve. Manual adjustment

of the bypass must not be attempted if the 24 VAC power leads are connected to the terminals on the appliance, the ap pli ance is operating or if there is any torque on the bypass valve by the ac tu a tor. Disconnect the 24 VAC power leads to the bypass valve actuator. The declutch button on the actuator must be

pushed down and held in the depressed position to disengage the gear driven motor that operates the valve. The declutch button must push in easily without forcing its movement. If the button does not easily move when pushed, the valve is under torque. Forcing the declutch button in will cause non-warrantable damage to the actuator. Torque can be removed by disconnecting the power leads to the valve actuator. With the declutch button fully depressed, move the ac tu a tor handle till it is perpendicular to the piping. This fully closes the by pass valve. The position of the handle is the same as the position of the butterfly in the valve seat. With the bypass fully closed, all inlet water flows through the secondary heat ex chang er and then through the primary heat exchanger. No water will flow through the bypass at this time. Turn the appliance on and allow the burner to come on and fire at full rate (100% of input as shown on the Command Dis play). Adjust the field-installed ball valve in the outlet piping from the water heater to the storage tank to achieve the proper temperature rise for your specific model. Adjustment to achieve this temperature rise ensures a maximum of 90 GPM to the bypass and pump when in operation.

TABLE - GG

Temperature Rise At Full Rate Fire

Bypass Manually Fully Closed

Btu/hr Input Temperature Rise

1,500,000

_______________________

1,700,000

_______________________

2,000,000

31.5°F (17.5°C)

_______________________

35.7°F (19.8°C)

_______________________

42.0°F (23.3°C)

NOTE:

1. The pump must run continuously when the burner is firing.

2. With the pump running and the burner in the water heater or hot water supply boiler in the off cycle, the Return/Inlet Temp and Supply/Outlet Temp readings on the Command Display should read approximately the same tem per a tures. Temp Rise in the Command Dis play should read zero.

3. Turn the water heater or hot water supply boiler on and allow time for the temperature to stabilize. Check the temperature rise in the Com mand Display when the burner is firing at 100% of rated input.

4. Compare the temperature rise on the Command Display with the required tem per a ture rise. Should adjustment be needed, proceed as follows:

If the temperature rise is too high, the water velocity is too low. Adjust as follows:

1. Check for restrictions in the outlet of the water heater or hot water supply boiler.

2. Check diameter and equivalent length of the piping between the storage tank and water heater.

3. Be sure all valves are open between the water heater or hot water supply boiler and the storage tank. Ensure that all ball valves are fully ported.

4. Check the pump to be sure it is running properly and that the pump motor is running in the proper direction.

5. Be sure the pipes between the water heater or hot water supply boiler and storage tank are not less than 3 inch (76.2 mm) diameter for up to 70 equivalent feet (21.2 m) of pipe to and from the heater. If maximum equivalent length for the specified pipe diameter is exceeded, larger diameter pipe may have to be installed to achieve correct flow and temperature rise.

6. Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tank circulating tappings to ensure proper flow.

If the temperature rise is too low, the water velocity is too high.

Adjust as follows:

1. Temperature rise can be increased by slowly closing the field-installed ball valve in the outlet piping from the water heater to the storage tank to achieve the proper temperature rise.

2. Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchangers. This is a non-warrantable failure. Temperature rise must be properly adjusted to achieve the specified flow rate.

3. Once temperature rise has been prop er ly set, reconnect the power leads to the bypass actuator.

4. Turn power on and place the run/stop switch in the “RUN” position and allow the bypass valve to go through the synchronization process before it begins normal operation.

WARNING

Moving the bypass handle while appliance is firing can result in abnormally high water temperature that may cause sudden relief valve discharge.

CAUTION

Temperature rise cannot be adjusted when the burner is firing at less than 100% of rate input.

WATER CHEMISTRY

NOTE:

Water temperature rise and maximum flow data are based on heating potable water with a hardness of 5 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm.

The required temperature rise and the standard integral pump are sized based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not ex ceed ing 350 ppm. Consult the man u fac tur er when heating potable water ex ceed ing these specifications. Heating of high hardness and/or high total dissolved solids water may require a larger circulating pump, an optional cupro-nickel heat exchanger and a re vised temperature rise specification based on the water chemistry of the water to be heated. Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non-warrantable damage to the heater, pump and associated piping. Corrosion due to water chemistry generally shows up first in the hot water system be cause heated water increases the rate of corrosive chemical reactions.

PIPING - MULTIPLE UNIT INSTALLATIONS

FIG. 84 Single Water Heater Piping with Two Storage Tanks

FIG. 85 Multiple Water Heater Piping with Single Storage Tank

FIG. 86 Multiple Water Heater Piping with Multiple Storage Tanks

MIXING VALVE

BUILDING

HOT WATER SUPPLY

RELIEF VALVE

TO DRAIN

LOCK-TEMP

STORAGE TANK

DRAIN

BUILDING RETURN

COLD WATER SUPPL

MIXING VALVE

BUILDING

HOT WATER SUPPLY

RELIEF VALVE

TO DRAIN

DRAIN

BUILDING RETURN

LOCK-TEMP

STORAGE TANK

BUILDING HOT WATER SUPPLY

MIXING VALVE

COLD WATER SUPPLY

MIN. 3” (75mm) COMMON

COLD WATER SUPPLY

MANIFOLD SIZE

RELIEF VALVE TO DRAIN

LOCK-TEMP STORAGE TANK

DRAIN

MIN. 3” (75MM) COMMON MANIFOLD SIZE

BUILDING RETURN

TABLE - HH

Common Water Manifold Size

For Multiple Water Heater

Hot Water Supply Boiler Installations

Btu/hr Input Temperature Rise

Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.

Common Manifold

Number of Units Size (Min)

_______________________

PUMP OPERATION

1. The water heater or hot water supply boiler has a properly sized integral circulating pump. This pump is sized to circulate water between the heater and storage tank only.

2. The internal pump is sized to the heater input and water chemistry spec i fi ca tions noted in “Water Chemistry.”

3. The diameter and length of the piping installed between the storage tank(s) and water heater must be properly sized based on the equivalent length specifications.

4. The pump must run continuously when the water heater or hot water supply boiler is firing. This is the stan dard operating system for a water heat er or hot water supply boiler.

An intermittent pump control function with an all bronze pump is installed as standard equipment on all water heater systems. The pump will operate only while there is a “Call for Heat” and for a timed period after the water temperature set point is satisfied to remove any residual heat from the com bus tion chamber.

5. Lubricate pump to manufacturers recommendations. Pump damage due to inadequate lubrication is non-warrantable.

This is a highly sophisticated heat exchanger system, designed to carry water in such a way that it generates a scouring action which keeps all interior sur fac es free from build-up of impurities. The straight-line, four pass design of the tubes sends water into the headers at a properly rated velocity. The configuration of the headers, in turn, creates a high degree of turbulence which is sufficient to keep all con tam i nants in suspension. This “scour ing action” provides greater cost sav ings for owners. Tubes are always able to transfer heat at peak efficiency. Every surface within this water con tain ing section is of a non-ferrous material, providing clear, clean, rust-free hot water. Straight copper tubes finned on the outside for maximum heat transfer and glass lined, cast iron, one piece, cored headers make up an entirely rust-proof unit. On all mod els, header inspection plugs in the primary heat exchanger can be removed for field inspection and clean ing of copper tubes. Each of the heat exchangers may be removed from the unit.

HEAT EXCHANGER

6. The operating temperature sensor for a water heater or hot water supply boiler is installed in inlet piping to the water heater or hot water supply boiler.

The operating sensor must be installed in the tapping provided in the lower 25% of the stor age tank to achieve proper operation. As shipped from the factory, the op er at ing sensor is installed in a bulb well mounted in the inlet piping to the water heater. When the pump cycles off in normal operation, this sensor location may not adequately sense a quick drop in tem per a ture from a draw of hot water from the storage tank. Placing the sensor in the tapping provided on the storage tank will improve temperature response and prevent short cycles of operation when a water heater is equipped with the optional intermittent pump feature.

The standard integral pump on this water heater is sized based on in stal la tion of a single storage tank and heater in close proximity. If the number of fittings and straight pipe exceeds the specified maximum equiv a lent number of straight feet for a specified diameter of pipe, non-war rant able operational problems may be experienced.

When installing multiple water heaters and/or multiple storage tanks, the diameter of the inner connecting pipe and all fittings must be increased. An increase in pipe diameter will decrease head loss in the system piping and ensure proper flow. Proper pipe size between the heater and storage tank MUST be maintained to ensure that the standard pump supplied on the water heater will maintain desired flow.

NOTE:

Minimum pipe diameters and maximum length specifications must be per the requirements in this section.

THERMOSTAT SETTINGS

1. The Excel 10 temperature con trol ler is adjusted to a low test setting when shipped from the factory.

2. Using the Command Display, adjust the temperature set point to the lowest settings which will satisfy hot water demands and prevent a risk of scald injury.

TEMPERATURE ADJUSTMENT

MINIMUM WATER TEMPERATURES

(Domestic Hot Water Use)

Inlet water temperatures below the specified minimum recommendations can excessively cool the products of combustion resulting in condensation on the primary heat exchanger. The water heater is designed to condense only on the secondary heat exchanger. Condensation on the primary heat ex chang er can cause operational problems, bad combustion, sooting, flue gas spill age and reduced service life of the related components.

A minimum water temperature has been established for each model based on the Btu/hr input at 100% of rated burner input. The temperature set point for the Excel 10 controller sensing stored water temperature must not be set lower than the specified minimum for each model. Maintaining inlet water temperatures to the water heater equal to or higher than the specified minimum ensures proper op er a tion of the bypass and allows all con den sate formation to occur on the sec ond ary heat exchanger. A water heater allowed to sustain operation at water temperatures lower than the specified minimum may not provide enough heat from the burner to maintain water temperatures in the primary heat exchanger above the 130°F (55°C) dew point of flue products. Operation of a water heater at a temperature below the spec i fied minimum will result in non-warrantable operational problems from the condensate formation on the primary heat exchanger.

FIG. 87 Warning Label

TABLE - II

Minimum Inlet Water Temperatures

Input Minimum Return Minimum Btu/hr Temperature Setpoint

1,500,000

___________

1,700,000

___________

2,000,000

50°F (10°C)

____________________

50°F (10°C)

____________________

50°F (10°C)

105°F (40.6°C)

_______________

90°F (32.2°C)

_______________

70°F (23.9°C)

CAUTION

An appliance allowed to op er ate with return temperatures set point below the specified minimum settings may ex peri ence operational problems with the operating controls and safety switches, obstruction of the flue gas passages on the primary heat exchanger, incomplete combustion and possible flue gas spill age. Operation at lower than specified water temperatures may cause hazardous conditions that result in non-war rant able damage to the appliance.

The maximum temperature set point that can be programmed into the Excel 10 controller from the Command Display for water heater operation is 190°F (87.8°C). The Excel 10 control is factory pre-set at approximately 120°F (48.9°C). Facilities with small children or invalids may require 120°F (48.9°C) or lower temperature setting to reduce risk of scald injury. Some states may require a lower temperature setting. Check with your gas supplier for local requirements governing the temperature setting. Remember, no water heating system will provide exact temperature at all times. Allow a few days of operation at this setting to determine the correct temperature setting consistent with your needs.

The following chart (Table JJ) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

TABLE - JJ

APPROXIMATE TIME / TEMPERATURE RE-

LATIONSHIPS IN SCALDS

120°F More than 5 minutes

125°F 1 1/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1 1/2 seconds

155°F About 1 second

• Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.

• Children, disabled and elderly are at highest risk of being scalded.

• See instruction manual before setting temperature at heating appliance.

• Feel water before bathing or showering.

• If this appliance is used to produce water that could scald if too hot, such as domestic hot water use, adjust the outlet control (limit) or use temperature limiting valves to obtain a maximum water temperature of 125°F (52°C).

NOTE:

(1) This water heater, when set at the lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes.

(2) Higher stored water tem per a ture increases the ability of the water heater to supply desired quan ti ties of hot water, however remember-

Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the primary heat exchanger and operational problems.

The cold water supply piping must be installed in the discharge piping from the heater to the storage tank. This allows the cold water to be tempered in the storage tank before entering the heater. See typical in stal la tion drawings provided with the unit for correct piping. Higher water temperatures reduce the volume of condensate formed.

CAUTION

Hotter water increases the risk of scald injury. Setting the temperature selector to higher settings provides hotter water, which increases the risk of scald injury.

The manufacturer recommends the use of a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 110°F (43.3°C). Storing the water at a higher temperature and thermostatically mixing the water will decrease the size of the storage tank and increase the available quantity of mixed hot water. Storing water at higher temperatures can help to control the level of condensate formed and help prevent the growth of water born bac te ria. Caution! Adequate care MUST be taken to prevent potential scald injury when storing water at 140°F (60°C) and hotter.

WARNING

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

HIGH WATER TEMPERATURE

LIMIT CONTROL

A Manual Reset High Limit control is located on the left front of the left front side of the control panel, beside the Command Display. Additional switches, alarm in di cat ing lights and optional low water cut-off control switches are also located on this panel. The setting of this con trol knob limits maximum discharge water temperature. The water heater or hot water supply boiler temperature limit control is adjustable up to a fixed maximum set ting of 200°F (93°C). A red reset but ton, located beside the knob, must be pushed whenever water temperature has exceeded the set point of the manual reset limit. The temperature of the water in the heat exchanger must drop a minimum of 15°F (8.3°C) below the setting of the manual reset high limit control before the reset function can be activated. A red indicating light is illuminated when the water temperature exceeds the set ting of the high limit control. A sta tus point alarm of Over Temp will be displayed in the Command Display when water temperature exceeds the Setpoint Temperature programmed into the Excel 10 control.

OPTIONAL RELIEF VALVE

This water heater or hot water supply boiler is normally supplied with a temperature and pressure relief valve sized in accordance with applica ble codes. Units may be supplied with an optional pressure only relief valve. When a water heater or hot water supply boiler equipped with this optional relief valve is piped to a separate storage vessel, the storage vessel must have a properly installed temperature and pressure relief valve which complies with local codes.

THERMAL EXPANSION

A relief valve that discharges pe ri od i cal ly may be due to thermal expansion in a closed system. A water heater or hot water supply boiler installed in a closed system, such as one with a backflow preventer or check valve in stalled in the cold water supply, shall be provided with means to control ex pan sion. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug or cap the relief valve discharge!

CATHODIC PROTECTION

Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is ex treme ly flammable. To prevent the possibility of injury under these con di tions, we recommend the hot water faucet be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipe as the hot water begins to flow. There should be no smoking or open flames near the faucet at the time it is open.

Ladder Diagram

1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models

RES

PROB

A SENSOR

INLET SENSO

REAR

UNICATION

CABLE CONN

ION

PANEL

COMMUNICATIO

CABLE

NNECTION

LVE

OUVE

REL

ACT

STD.

VFD POWER

RELAY

COM

POWER

SWITCH

VFD

BLOWER

ASSEMBLY

120VAC G A

S VALVE

COM

EXT. GAS VALVE

VENT VALVE

OPTIONAL

24 VA

LOW VOLTA

SFOR

MER

120

VAC

MMAN

D D

ISP

LAY

EBUS

EBU

EARTH

HI-LIM

T ALARM

RELAY

OVER

EMP

INDI

CAT

24VAC SOL ENOID V

ALVE

ITIO

DULE

N/A T

F M/S F

RESET

ITIO

OPTI

Louver

Gas

Hig

Gas

Blocke d

Drain

PTIONAL

IGNITION MODULE

HOT

SURFACE

IGNITER

ENABLE

A1-

GND

OUT

A1-

OHM

A1-

OHM

A1-

VAC

COM

Inl

ter

wAi

r/Bloc

rain

-L

ouve

ter S

e F

w W

BYP

SENS

ASS

GROUND

N/ST

P S

WITCH

VAC

HSI

30 29

25 24

23 22

20 19

BYPASS SENSOR

MMUNICAT

CABLE #

tion

Relay

CONTROLL

NPUTS

UTLET

SENSO

OUT

COM

REL

PUMP MOTOR

PUMP POWER

120VAC 15AM P

RELAY

ARM

CONTAC

ARM

24VAC OUT

ARM

INDICAT

SILE

SWITCH

STD

E TI

MANUA

OVER-

RI DE

SIG IN -

SIG IN +

24V Pwr

Com

mA Out

Volts Ou t

PWM

CONV

P SWITCH #5 ON

TIC

ORY

CALI

BRA

O NOT

NITI

N REL

HI-L

UNIT POW ER 120VAC 15AMP

MMUN

CABLE #

S VALVE RELAY

SWITCH

TCH

CONTROL LER HSI

GROUN

ER 2

VAC

CONTROLLE

INP

NPU

CONT

OUT

OUVER RE

CONTROLLER

HOT

NEUTRAL

GROUND

GND

LV2

GAS

AME

URE

PTIONA

DRAI

VER

LBL20021

REV B

WD REV

1L2

S N K

S R C

WARNING:

To avoid possible shock hazard, disconnect power before servicing.

TES

VAC

esi

VERRIDE TOGGLE

SWITCH

TO PUM

RELAY

VERRIDE

TOGGLE

SWI

TCH

Wiring Diagram

1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models

888

RUN

VFD

ENABLE

GND

A1-

ND G

2VD

BUS

DDI

GND

nlet Wa

r Sen

Bypass

r Se

nsor

S/S

OA Se

LowAi r

/Block Dra

Hi-LoG

Louver

Outl

t W

nsor

Fail

ure

tr Flow

Gas Va

4VAC

31 30

29 2

826

24 2

21 20 19

18 17 1

Back Select

I-LIMIT

COM

BL/

COM

HI-LIMIT ALARM

ELAY

ALARM

ELAY

COM

PUM

P R

ELAY

120

VAC

CIRCUIT

BREAKER

OVER TEMP

INDICATOR

ALARM

NTACTS

ALARM

VAC

ICATO

BKB

L/BK

PUMP MOTOR

T I

BAS

MANUA

OVER-

RIDE

SIG IN -

SIG IN +

24V Pwr

Com

mA Out

Volts Out

o l

24V

PWM

NV.

COMMAND DISPLAY

24 VAC

VFD POWER RELAY

COM

POWER SWITCH

EBUS

EARTH

24VAC

BK/W

L/W

BL/W

PWM/4

-20m

loa

Clos

Ignition

Ena

Pump R

CONTROLLER

CHA

SSIS

ROUN

SILENCE

LOW VOLTAGE

TRANSFORMER

BL/BK

120VAC

15AMP

120VAC

15AMP

TWO 15 AMP CIRCUITS

OR ONE 30 AMP CIRCUIT

UNIT POWER

OWER

CHASSIS GROUND

CHA

SSIS

ROUN

IGNI

TION RELAY

FLOAT

BYPASS COMMO

L/W

REAR WIR

CONN

CTION

24VAC ALARM

OUT

BYPASS

VALVE

NAL

LARM

NTACTS

MMO

OSE

BL/W

SENSOR

INPUTS

IP SWITCH #5 ON

UMP

NOTICE:

FACTO

CALIBR

ED .

DO NO

ADJ

ST.

SWITC

IVE

UTPUTS

FLOAT CLOSE

W/BK

1L2T

S N K

S R C

RAL

CH I

SITI

T 1

FAN

O.C.

ESE

ESET

CHA

TEST

SWITCH

ANUA

’

Wiring Diagram (continued)

1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models

Hz L

mit

Res

1.2

NAL

NUMB

TIO

NAL

LIM

ESI

NAL

WARNING:

To avoid possible

shock hazard, disconnect power before servicing.

PTI

5 1

4 1

3 1

214321

BYPASS SE

OUT

LET

NSOR

NAB

SWI

CHA

SSIS

GRO

UND

RUN/STOP SWITCH

789

A SEN

SOR

INLET SENSO

BYPASS

NSOR

IGNITION

MODULE

24VAC GAS

VALVE

ouver

ving

AIR

WITCH

High

FLO

Blocked

ain

FC-FC+

S2/FS

N/A TH PI

LV1

PS F

HOT

SURFACE

IGNITER

LBL90002 REV A

120VAC GA

GAS VA

LVE RELAY

COM

EXT.

AS VALVE

LV2

RESET

COMM

UNICATIO

CABLE #1

EAR

MMUNICATION

CABL

NNECTIO

CONTR

OL PANEL

MMUNICATION

CABLE

NNEC

TION

ICATION

ABLE #3

BYP

VALVE

COM

LOUVER

RELAY

LOUVER

RELAY

CONTACTS

BLO

WER

ASSEM

BLY

STATUS

LED

BL/BK

IGNITION

SET

AT OPEN

OPT

ONA

VENT VALVE

OPTIO

TIONAL

STD.

EXT. GAS

VALVE

VERS

LOUVE

TACTS

MMON

CLO

D INPUT

OPEN INPUT

120

VAC

INLET

SENSOR

)

Where poss

ble, swit

hes and circuitry ar e sh

n in power

off s

tate

NOTES:

(3) When replacing wi

ring,

use

wire

of equal or h

ighe

r tem

pera

ture

and

) Schematic shows

lec

trica

l connect

ons only.

Please

refer

to wiring diagram in

ner's manua

l fo

r r

uting an

pin-outs for all connector

blocks

)

ARNING:

id possible shock hazard

, di

onnect po

er be

for

e se

icing.

NPUT

NOTE:

DO NOT DI

CONN

CABLE FROM

ER.

OUTLE

T S

SOR

COMMUNICATION

CABLE #1

PU PU

OMMUNICATION

CAB

(5) Pum

lay

standard on water

heaters

OGG

TCH

ANUAL

VERRI

BLOCKED

DRAIN

COM

BLOCKED

PEN

P U

24 VAC

8/09-Printed in U.S.A.

Revision Notes: Rev. 4 (IFB/IFW-i&s-04) reflects additional text on Page 39, changes made to Figures 47 & 48, Table AA (Page 51), and LBLs on Pages 77-79.

Revision 5 (ECO #C02870) reflects changes made to the scald section, pages 70, 73, and 75, the addition of a mixing valve to the piping diagrams (FIG’s 83 - 86), edits made to FIG. 80 (pg. 66), and a title change on FIG.’s 3 and 4 on page 4.

Revision 6 (ECO #C04349) reflects the addition of a maintenance table and a condensate testing section.

Intelli-Fin 1, 500, 000 Btu/hr, 2, 000 Installation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual