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

Hot water heating boilers domestic hot water supply boilers 1,500,000 — 1,700,000 — 2,000,000 btu/hr models
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INSTALLATION AND SERVICE MANUAL
FIG. 1 Front View
Installation and service must be per formed by a qual i fied service
in stall er, service agency or the gas supplier.

WARRANTY

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
build-up in the copper tube is not the fault of the
equipment
and
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).
Hot Water Heating Boilers
Domestic Hot Water Supply Boilers
1,500,000 — 1,700,000 — 2,000,000 Btu/hr Models
hardness
causing
a
is
not
covered
under
Intelli-Fin
®
FIG. 2 Rear View
SPECIAL INSTRUCTIONS
NOTE:
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.
lime/scale
the
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.
1
TO OWNER
Retain this manual for future reference.
WARNING
IFB-IFW-I-S-06

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Summary of Contents for Intelli-Fin 1,500,000 Btu/hr

  • Page 1: Warranty

    IFB-IFW-I-S-06 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 FIG. 1 Front View FIG. 2 Rear View Installation and service must be per formed by a qual i fied service SPECIAL INSTRUCTIONS in stall er, service agency or the gas supplier.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Warranty ................1 Temperature Adjustment........39 Safety Warnings .............. 3 Command Display ..........39 Codes ................3 Password ............40 Installation Requirements ..........4 Changeable Points ........40 Location ..............4 Data Points in Display........41 Clearances ..............4 Status Points — Operation ......43 Combustion/Ventilation Air Requirements ....

  • Page 3: Safety Warnings

    A gas appliance that draws combustion air from the equipment CHECKING EQUIPMENT room where it is installed must have a supply of fresh air circulating Upon receiving equipment, check for signs of ship ping damage. around it during burner operation for proper gas combustion and Pay par tic u lar attention to parts ac com pa ny ing the boiler, which proper venting.

  • Page 4: Installation Requirements

    6. The appliance must in stalled carpet. INSTALLATION PROCEDURE LOCATION OF UNIT 7. The appliance must be installed indoors where it protected from exposure wind, rain weather. 1. Locate the appliance so that if water connections should leak, water damage will not occur. When such lo ca tions 8.

  • Page 5: Combustion/Ventilation Air Requirements

    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.
  • Page 6 TABLE - B Minimum Recommended Combustion AIR SUPPLY TO MECHANICAL ROOM Combustion Air Source Btu/hr Outside Air* Outside Air* Inside Air 2 - Openings Input 1 - Opening 2 - Openings 1,500,000 375 in (2419 cm 500 in (3226 cm 1,500 in (9,677 cm 1,700 in...

  • Page 7: Construction Air Filter

    All dimensions based on net free area in square inches. Metal from the venting system into an occupied living space can cause a louvers or screens reduce the free area of a com bus tion air opening very hazardous condition that must be im me di ate ly corrected. If a a minimum of ap prox i mate ly 25%.

  • Page 8: Venting Systems

    The construction air filter MUST be removed from the General appliance’s air inlet before the appliance is placed in normal operation. Once the construction air filter is removed, ensure that Vent installations for connection to gas vents or chimneys must be either the equipment room is supplied with combustion air from in ac cor dance with Part 7, “Venting of Equip ment,”...

  • Page 9: Category Iv Venting

    FIG. 11 Basic Category IV Venting - Horizontal dedicated flue stack using a properly sealed vent adapter provided by the vent manufacturer. The flues from multiple Intelli-Fin A Category IV venting system for the flue products is required on appliances may only be combined when using an engineered vent all models of this appliance.

  • Page 10: Vent Length Requirements

    Any vent materials specified must be listed by a nationally Do not terminate the vent in a window well, stairwell, alcove, recognized test agency for use as a Category IV vent material. courtyard or other recessed area. The vent cannot terminate below grade.

  • Page 11: Vertical Terminations

    the tee. The drain tubing must have a trap provided by a 4" VERTICAL VENTING (10.2 cm)-diameter circular trap loop in the drain tubing. Prime TERMINATIONS 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 Follow all General Category IV Vent Termination Clearances.

  • Page 12: Sidewall Terminations

    10' OR LESS 2' MIN 2' MIN 3' MIN WALL OR CHIMNEY CHIMNEY PARAPET FIG. 15 Vent Termination from Flat Roof - 10 Feet or FIG. 17 Sidewall Venting Installation Less from Parapet Wall The connection from the appliance flue outlet to the sidewall vent 10' OR MORE cap MUST be made with listed type Category IV vent materials and accessories.

  • Page 13: Direct Vent Systems

    The installed sidewall vent cap assembly may be paint ed to match The sidewall vent termination must be at least 8 feet (2.4 m) the exterior color. The opening through the wall for instal la tion of horizontally from any combustion air intake located above the the sidewall vent cap must provide an air space clearance of sidewall termination cap.

  • Page 14: Air Inlet Pipe Materials

    In cold climates, the use of type “B” double wall vent pipe or an • Galvanized steel vent pipe with joints and seams insulated single wall pipe for combustion air is recommended to sealed as specified below. help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.

  • Page 15: Vertical Direct Vent

    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.

  • Page 16: Multiple Direct Vent Installations

    Incorrect installation and/or location of the air inlet cap can allow VERTICAL COMBUSTION AIR INLET 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.
  • Page 17 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.

  • Page 18: Multiple Direct Vent Installations

    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...

  • Page 19: Vertical Flue - Sidewall Air

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

  • Page 20: Sidewall Flue - Rooftop Air

    Location of a Sidewall Air Inlet Cap The Intelli-Vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the Installation, location and clearance requirements for the sidewall appliance. air inlet cap in an Intelli-Vent application are the same as the installation, location and clearance requirements for the sidewall In cold climates, the use of type “B”...

  • Page 21: Sidewall Flue - Sidewall Air

    12 inches (0.30 m) above the roof or above normal levels of snow accumulation. Location of a Rooftop Air Inlet Cap FIG. 31 Horizontal Intelli-Fin Installation with Sidewall Incorrect installation and/or location of the air inlet cap can allow Combustion Air in a Different Pressure Zone the discharge of flue products to be drawn into the combustion process on the heater.
  • Page 22 TABLE - J CAUTION Flue Air Inlet Sidewall Air Input Inlet & Flue Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air Btu/hr Size Size Cap Kit inlet pipe connected to the appliance. 1,500,000 6"...

  • Page 23: Gas Supply

    GAS SUPPLY GAS PRESSURE TEST Verify that the appliance is supplied with the type gas specified on 1. The appliance must be dis con nect ed from the gas the rating plate. Consult factory for installations at altitude. supply piping sys tem during any pressure testing of that system at a test pressure in excess of 1/2 INLET PRESSURE: Measured at the inlet pressure tap on the PSIG (3.5kPa).

  • Page 24: Multiple Installations Gas Pipe Size Chart

    TABLE - M Recommended Gas Pipe Size Single Appliance Installations Distance from Meter Btu/hr 0 - 50 ft. 51 - 100 ft. 101 - 200 ft. 201 - 300 ft. 301 - 500 ft. 1,500,000 2" 2 1/2" 3" 3 1/2" 1,700,000 2 1/2"...

  • Page 25: Supply Pressure Measurement

    GAS MANIFOLD TRAP 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.

  • Page 26: Manifold Pressure Measurement

    Turn the main power switch to “OFF” position. Check burner performance by cycling the system while you observe burner response. The burner Shut off gas supply at the manual gas cock in the as should ignite promptly. Flame pattern should be piping to the ap pli ance.

  • Page 27: Water Connections

    supply pressure and adjust to ensure a supply WATER CONNECTIONS pressure between 10.5 inches water col umn natural gas (13.0" w.c. for propane) while the appliance is firing at 100% of rated input. AIR INLET This is a reference pressure only and is not field adjustable.

  • Page 28: Heat Exchangers

    Inlet and Outlet Connections 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 For ease of service, install unions on inlet and outlet of the the burner.

  • Page 29: Integral Bypass

    INTEGRAL BYPASS WATER OUTLET BYPASS VALVE PRIMARY PUMP HEAT EXCHANGER SECONDARY HEAT EXCHANGER COLD WATER INLET FIG. 40 Bypass Piping with Valve Actuator and Pump temperature conformal coating to prevent any corrosive damage to rarely below 125°F (51.7°C). The actuator on the bypass valve will the copper tubes or cast iron head ers from the low pH condensate.

  • Page 30: Set-Up Maximum Flow

    (100% of input as shown on the Command Dis play). Adjust the On initial start-up of the Intelli-Fin the maximum water flow to field-installed ball valve in the outlet piping from the appliance to the two in ter nal heat exchangers must be manually set before the achieve the proper tem per a ture rise for your specific model.

  • Page 31: Bypass Operation

    The Excel 10 provides 24 VAC to operate a high TABLE - P torque motor in the actuator, which adjusts the Temperature Rise At Full Rate Fire position of the floating-point bypass valve. Bypass Manually Fully Closed The actuator for the bypass valve adjusts in as Btu/hr Input Temperature Rise many as 500 micro-steps to achieve the desired...

  • Page 32: Flow Switch

    A boiler installed above radiation level must be provided with a TABLE - Q low water cutoff device either as part of the unit or at the time of Minimum Inlet Water Temperatures installation. Input Minimum Return Minimum WATER FLOW SWITCH Btu/hr Temperature Setpoint...

  • Page 33: Relief Valve

    air blower. The valve is a 1:1 differential pressure air/gas ratio RELIEF VALVE controller. The valve adjusts the same pressure difference on the gas side as it senses on the air side. The valve performs the This unit is supplied with a relief valve(s) sized in accordance with functions of safety shutoff, constant pressure regulation and air/gas ASME Boiler and Pressure Vessel Code, Sec tion IV (“Heating ratio control.

  • Page 34: Electrical Requirements

    Venting of Gas Valves and Pressure Switches 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 The diaphragm type gas valve and op tion al gas pressure switches edition of the National Electrical Code ANSI/NFPA No.

  • Page 35: Components And Controls

    the inner jacket and secondary heat exchanger chamber are also Outer Jacket - The outer jacket as sem bly is constructed from steel, stainless steel. The stainless steel screws are identified by a sealing gal va nized on both sides. The galvanized surface is specially washer mounted on each screw.

  • Page 36: Variable Frequency Drive

    FIG. 48 Transformer and Relay Locations VARIABLE FREQUENCY DRIVE FIG. 49 Internal Control Panel Location A transformer and relay mounting panel is located above the front FIG. 50 Variable Frequency Drive control panel, underneath the curved exterior front jacket panel. This panel contains a 100 VA transformer to drop 120 VAC to This appliance uses a variable frequency drive (VFD) to control 24 VAC for internal control operation, an optional electronic low...

  • Page 37: Low Air Pressure Switch

    blower from 25% up to 100% of capacity corresponding to the A differential air pressure switch is used to prove operation of the same variation in burner input. The output from the Excel 10 to com bus tion air blower. The pressure switch sensing points are the variable frequency drive ensures that combustion air and gas installed across the point of pressure drop as the air moves into the are always supplied in the proper ratio for clean combustion.

  • Page 38: Excel 10 Boiler Interface Controller

    There is a bar code label on the back of the Intelli-Fin near the potable water heater must be applied as a water heater. The Excel terminal connections.

  • Page 39: Manual Override Control

    is unique to each Excel 10 and must be placed into the network of To Activate the Manual Override: an energy management system so that the Excel 10 can be 1. In the event of a failure of the primary control, move the recognized by the system.

  • Page 40: Password

    Pressing this but ton provides access to a PASSWORD FUNCTION “setup” screen that allows the user to adjust such items as: On initial operation of the Intelli-Fin the owner may enter three TABLE - T levels of password with the Command Display to limit access to DISPLAY DEFAULT VALUES the changeable op er at ing parameters in the Excel 10.

  • Page 41: Data Points In Display

    drop lower (Change able Point from NOTE: Command Display). Temp. — A display outdoor O.A. Allow 10 seconds for data shown in the display screens to temperature as sensed by the optional outdoor air update when viewing or making adjustments to any of the reset sensor.
  • Page 42 FIG. 56a Command Display Data Screen FIG. 56d Command Display Data Screen FIG. 56b Command Display Data Screen FIG. 56e Command Display Data Screen FIG. 56c Command Display Data Screen FIG. 56f Command Display Data Screen...

  • Page 43: Status Points - Operation

    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.

  • Page 44: Status Points - Alarm

    Pressing the Back key will return you to the Heat Source display. OUTDOOR RESET FUNCTION The up and down arrow keys can be used to scroll the cursor up SELECTIONS and down to the various heat sources (boilers or water heaters) at this location.

  • Page 45: Multiple Appliance Installations

    Setpoint Temp — This is the lowest boiler operating temperature that NOTE: 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. Separate sequencers are required to control multiple boilers and water heaters.

  • Page 46: E-Bus Connection

    Consult factory for additional information on interface PARALLEL CONNECTION 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.
  • Page 47 The minimum type and grade of wire required to “net work” the required provide communication between Intelli-Fin to other units or LonMark ® devices is a Level IV, E-Bus and either a PC serial port or an approved modem using the 22 AWG (0.034 mm ) plenum or non-plenum rated (as applicable), SLTA-10 EIA-232 port.

  • Page 48: Temperature Limit Control

    FIG. 61 Typical Building Management System Diagram HIGH WATER TEMPERATURE LIMIT 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.

  • Page 49: Hot Surface Igniter

    OEM unit only. An OEM specification igniter and ignition control HOT SURFACE IGNITION SYSTEM module for this specific unit is available from your local dis tributor. DO NOT use general purpose field replacement ignition modules IGNITION CONTROL MODULE or ig nit ers. Each appliance has one ignition module and one hot surface igniter.
  • Page 50 Diagnostic Status Indication TABLE - Y Ignition and Control Timings The ignition module has an LED that indicates the status of the ignition safety circuits. The flashing op er a tion of this LED Proven Pilot Hot Surface Ignition System indicates the di ag nos tic status of the ignition control module.

  • Page 51: Operation/Diagnostic Lights And Switches

    OPERATION/DIAGNOSTIC BURNER LIGHTS, RESETS AND SWITCHES CIRCUIT BREAKER HI-LIMIT ALARM RESET ALARM POWER SOUND ALARM SILENCE LOW WATER CUT-OFF RESET TEST AUTO MANUAL FIG. 66 Exterior Control Panel FIG. 67 Burner Assembly The control panel has a lighted ON/OFF power switch and 11 indicating lights and switches to show operation, control sensed malfunctions and diagnostics.

  • Page 52: Combustion Air Blower

    230 VAC, 3 Phase electric motor. This motor has a 3/4 HP to a mixing tube. The top side of the mixing tube provides the rating on the 1,500,000 Btu/hr model and a 1 HP rat ing on the transition which mounts the discharge from the combustion air 1,700,000 and 2,000,000 Btu/hr models.

  • Page 53: Condensate Management System

    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.

  • Page 54: Condensate Trap Installation

    Many codes will require the acidic condensate to be Condensate Trap Installation neu tral ized before it can be placed in a drain system. The optional 1. Locate the condensate trap kit shipped loose with the condensate management system consists of a neutralizer kit to appliance.

  • Page 55: Lighting Instructions

    LIGHTING INSTRUCTIONS 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 FOR YOUR SAFETY, spillage of flue products from the condensate trap. READ BEFORE Failure to follow this warning could result in product damage or improper operation, personal injury, or death.
  • Page 56 LIGHTING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE STOP! Read the safety information. Set the Temperature Set Point function of the Command Display to the lowest setting. Set the Temperature Set Point func tion of the Command Display to the lowest setting. Turn off all electric power to the appliance if service is to be performed.

  • Page 57: Sequence Of Operation

    Excel 10 enables the Ignition Mod ule. Burner Input may stabilize at a fixed rate where demand equals input. Ignition Module enables the Vari able Frequency Drive. Burner Input will decrease rate when water temperature exceeds tem per a ture Point Excel 10 Controller drives the Variable Frequency demand.

  • Page 58: Maintenance And Annual Startup

    • Check wiring and connections • Check automatic air vents • Perform start-up checkout and performance • Test low water cutoff (if used) verification per Intelli-Fin Installation and Operation Manual. • Reset button (low water cutoff) • Flame inspection (stable, uniform) •...

  • Page 59: Condensate Testing

    A pH meter or indicating test strips may be used to monitor the C. FLUE PASSAGEWAYS CLEANING PROCEDURES: Any sign of soot around the inner jacket, relative acidity of the condensate. When the pH of the condensate outer jacket, flue pipe connections, burner or in the areas discharged from the reservoir cannot be maintained above a pH of between the fins on the copper heat exchanger indicates a need 6.0, the calcium carbonate must be recharged.
  • Page 60 Remove the hot surface igniter. The hot surface igniter is 8. Check the replacement igniter for cracks or damage before fragile. Use care to prevent impact damage to the silicon installing. carbide igniter surface when removing the igniter. 9. Ensure that the fiber gasket used to seal the base of the igniter m.

  • Page 61: Heat Exchanger Inspection

    G. SECONDARY HEAT EXCHANGER INSPECTION 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. PRIMARY HEAT EXCHANGER INSPECTION Turn off all power to the appliance. Turn off main gas to appliance.

  • Page 62: Lubrication

    9. Carefully reinstall the heat ex chang er if removed from the appliance. ORIFICE 10. Reinstall inner rear jacket panels, bypass piping AIR BOX (FRONT VIEW) and condensate hoses. Use new gasket material to ensure a proper air seal. 11. Reassemble all water piping. Test for leaks. 12.

  • Page 63: Freeze Protection

    As the appliance comes on and fires, record the FREEZE PROTECTION inches of water column of displacement on both sides of the manometer. The sum of these two Installations are not recommended in areas where the danger of readings as they are effected by the two air freezing exists.

  • Page 64: Heating Boiler

    (d) Drain the unit completely. Remove the caps from the WARNING two drains located on the rear of the appliance. Open the relief valve and manually open the bypass valve to allow DO NOT attempt to fire this appliance without completely air into the system so the water will drain out.

  • Page 65: Piping Length And Diameter

    PIPING LENGTHS PRIMARY LOOP CIRCULATOR PUMP SPECIFICATIONS The boiler’s integral circulator pro vides the water flow from the primary boiler piping, through the boiler and back to the primary Maximum operating pressure for the pump must exceed system. Pipe di am e ter and length are critical to ensure proper flow system operating pressure.

  • Page 66: Primary/Secondary Piping

    PRIMARY/SECONDARY BOILER PIPING TO SYSTEM TO EXPANSION TANK AND MAKEUP WATER SYSTEM 12” MAX. FROM SYSTEM FIG. 80 Primary/Secondary Piping of a Single Boiler MAKE-UP WATER 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"...

  • Page 67: Three Way Valves

    The automatic bypass system allows part of the boiler discharge water THREE WAY VALVES 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 The installation of a three way valve on this boiler is not prevent the products of combustion from condensing on the primary recommended be cause most piping methods allow the three way heat exchanger.

  • Page 68: Placing The Boiler In Operation

    Check system pressure. Ensure a minimum of 12 TEMPERATURE/PRESSURE GAUGE PSI and not more than the rated pressure of the relief valve. This boiler is equipped with a dial type temperature/pressure gauge. This gauge is factory installed in the out let side of the Review the installed gas piping from the meter to boiler bypass piping.

  • Page 69: Boiler Temperature Control

    Boiler Operation Pipe refrigeration systems in parallel. Install duct coil downstream at the cooling coil. Where the hot water heating boiler is connected Turn the run/stop switch to the “RUN” position to to a heating coil located in the air handling units which may be start boiler operation.

  • Page 70: Water Heater/Domestic Hot Water Supply Boiler

    BYPASS - Initial Set-up of Maximum Water Flow of your water heater or hot water supply boiler. On initial start-up of the Intelli-Fin the maximum water flow through the two in ter nal heat exchangers must be manually set WATER VELOCITY CONTROL before the automatic operation of the bypass begins.

  • Page 71: Temperature Rise

    The pump must run continuously when the burner is firing. Setting temperature rise on an Intelli-Fin with an automatic bypass is ac com plished by disconnecting the power leads to the actuator, With the pump running and the burner in the water...

  • Page 72: Water Chemistry

    Be sure the pipes between the water heater or hot WATER CHEMISTRY water supply boiler and storage tank are not less than 3 inch (76.2 mm) diameter for up to 70 NOTE: equivalent feet (21.2 m) of pipe to and from the heater.

  • Page 73: Piping Requirements

    PIPING - MULTIPLE UNIT INSTALLATIONS MIXING VALVE BUILDING HOT WATER SUPPLY RELIEF VALVE TO DRAIN LOCK-TEMP STORAGE TANK COLD WATER SUPPLY DRAIN BUILDING RETURN FIG. 84 Single Water Heater Piping with Two Storage Tanks COLD WATER SUPPLY MIXING VALVE LOCK-TEMP STORAGE TANK BUILDING HOT WATER SUPPLY...

  • Page 74: Pump Operation

    The operating temperature sensor for a water TABLE - HH heater or hot water supply boiler is installed in Common Water Manifold Size inlet piping to the water heater or hot water supply boiler. For Multiple Water Heater Hot Water Supply Boiler Installations The operating sensor must be installed in the tapping provided in the lower 25% of the stor age tank to achieve proper operation.

  • Page 75: Temperature Adjustment

    THERMOSTAT SETTINGS TABLE - II Minimum Inlet Water Temperatures The Excel 10 temperature con trol ler is adjusted to a low test setting when shipped from the factory. Input Minimum Return Minimum Btu/hr Temperature Setpoint Using Command Display, adjust temperature set point to the lowest settings which 1,500,000 50°F (10°C) 105°F (40.6°C)

  • Page 76: Risk Of Scald Warnings

    NOTE: HIGH WATER TEMPERATURE LIMIT CONTROL (1) This water heater, when set at the lower temperature A Manual Reset High Limit control is located on the left front of the setting, is not capable of producing hot water of sufficient left front side of the control panel, beside the Command Display.

  • Page 77: Ladder Diagram

    Ladder Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models...

  • Page 78: Wiring Diagram

    Wiring Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models...
  • Page 79 Wiring Diagram (continued) 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models...

  • Page 80: Revision Notes

    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.

This manual is also suitable for:

2,000,000 btu/hr1,700,000 btu/hr000 btu/hr

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