Dodge 2006 Ram 3500 Automobile User Manual

IFB/IFW-i&s-05
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 performed by a qualified service
installer, service agency or the gas supplier.
SPECIAL INSTRUCTIONS
TO OWNER
WARRANTY
NOTE:
Factory warranty (shipped with unit) does not apply to units
improperly installed or improperly operated.
This manual supplies information for the installation, operation
and servicing of the appliance. It is strongly recommended that
this manual be reviewed completely before proceeding with an
installation.
Experience has shown that improper installation or system design,
rather than faulty equipment, is the cause of most operating
problems.
1.
2.
Retain this manual for future reference.
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 warranty. (See Water Treatment and
Water Chemistry)
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.
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 manufacturer’s warranty (See Boiler Flow Rates
and Temperature Rise for flow requirements).
1
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
............................................................58
Vent System ............................................................58
Flame Patterns ..........................................................58
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
2
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.
CHECKING EQUIPMENT
Upon receiving equipment, check for signs of shipping damage.
Pay particular attention to parts accompanying 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
received. In case there is damage or a shortage, immediately notify
carrier.
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.
DO NOT
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.
WARNING
WARNING
To minimize the possibility of serious personal injury, fire or
damage to your appliance, never violate the following safety
rules.
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.
1.
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.
2.
WHAT TO DO IF YOU SMELL GAS
3.
•
•
•
•
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.
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.
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.
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.
CODES
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 jurisdiction shall be consulted before
installations 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 authority having jurisdiction, the installation
must conform to American Society of Mechanical Engineers Safety
Code for Controls and Safety Devices for Automatically Fired
Boilers, ASME CSD-1. All boilers conform to the latest edition of
the ASME Boiler and Pressure Vessel Code, Section IV. Where
required by the authority having jurisdiction, 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 manifold and control assembly provided, as specified
in the ANSI standards for gas-fired units, ANSI Z21.13.
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.
3
INSTALLATION PROCEDURE
LOCATION OF UNIT
1.
2.
3.
Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, it is recommended that a suitable drain
pan, adequately 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 connection with this unit, or any of its
components.
The appliance must be installed so that the ignition
system components are protected from water
(dripping, spraying, etc.) during appliance operation and
service (circulator replacement, control replacement, etc.).
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 required
clearances from combustible surfaces.
The
appliance
must
not
be
installed
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 collected, neutralized and
disposed.
TABLE - A
Clearances from
Combustible Construction:
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.
6.
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
4
NOTE
Clearances from combustible construction are noted on the
appliance rating plate.
Maintain minimum specified clearances for adequate operation.
All installations 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.
FIG. 5 Combustion Air Direct from Outside
Multiple appliances may be installed in a modular boiler or water
heater installation. Multiple appliances may be installed side by
side with no clearance between adjacent appliances because this
appliance is approved for zero clearance from combustible surfaces and no service access is required from the sides.
1.
If air is taken directly from outside the building
with no duct, provide two permanent openings:
a.
Consult the venting section of the manual for specific installation
instructions 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 air opening, with a minimum free
area of one square inch per 4000 Btu input
(5.5 cm2 per kW). This opening must be located
within 12" (30 cm) 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 cm2 per kW). This opening must be located
within 12" (30 cm) of the top of the enclosure.
COMBUSTION AND VENTILATION
AIR REQUIREMENTS FOR
APPLIANCES DRAWING AIR FROM
THE EQUIPMENT ROOM
Provisions for combustion and ventilation 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 Equipment, 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. 6 Combustion Air Through Ducts
2.
5
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
Combustion Air Source
Outside Air*
1 - Opening
Inside Air
2 - Openings
Btu/hr
Input
Outside Air*
2 - Openings
1,500,000
375 in2 (2419 cm2)
500 in2 (3226 cm2)
1,500 in2 (9,677 cm2)
1,700,000
425 in2 (2742 cm2)
567 in2 (3658 cm2)
1,700 in2 (10,968 cm2)
2,000,000
500 in2 (3226 cm2)
667 in2 (4303 cm2)
2,000 in2 (12,903 cm2)
*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside 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 requirements for combustion
air.
FIG. 7 Combustion Air from Interior Space
FIG 8 Combustion Air from Outside - Single Opening
3.
4.
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 cm2 per kW) of input,
but not less than 100 square inches (645 cm2).
If a single combustion air opening 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 cm2
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.
6
All dimensions based on net free area in square inches. Metal
louvers or screens reduce the free area of a combustion air opening
a minimum of approximately 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.
from the venting system into an occupied living space can cause a
very hazardous condition that must be immediately 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 appliance 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 combustion air from a
construction site can contain contaminants 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
problems, bad combustion and non-warrantable component failures.
The combustion air supply must be completely 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 appliance stack.
The result is improper combustion and a non-warrantable, premature 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 products
CONSTRUCTION AIR FILTER
2"
EDGE OF SCREEN
C
E
D
MEDIA OVERLAP
B
CABINET AIR
INLET OPENING
FOLD OVERLAP AROUND
EDGE OF SCREEN AS
SHOWN.
ELBOW(S)
NOT
PROVIDED
FRONT
REAR
B
A
MODEL
2.0
19.750 12.250
19.250 10.750
1.7
1.5
18.750 9.250
C
4.875
4.375
3.875
D
E
9.000
7.500
6.000
15.000
14.500
14.000
BAND CLAMP
REAR
24.000
24.000
24.000
PUSH FILTER ONTO AIR
INLET AND FASTEN WITH
CLAMP AS SHOWN.
2"
FIG. 9 Construction Air Filter
7
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 systems have specific requirements for a
special combustion air duct from the outside that is directly
connected to the appliance. See the requirements for this
combustion air duct in the venting section for each specialized
vent system.
General
Vent installations for connection to gas vents or chimneys must be
in accordance with Part 7, “Venting of Equipment,” of 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 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 Equipment, or applicable provisions of the local
building codes.
CONSTRUCTION AIR FILTER KITS
TABLE - C
Input
Btu/hr
Construction
Air Filter Kit
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 Appliances and Equipment.
1,500,000
KIT4000
________________________
________________________
1,700,000
KIT4001
________________________
________________________
2,000,000
KIT4002
Vent connection is made directly to the flue outlet opening on the
back of the unit. The connection from the appliance vent to the
stack must be made as direct as possible.
VENTING
IMPORTANT
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 terminates both the flue and air inlet in the same
pressure zone. The flue outlet and combustion air intake may
terminate 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.
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
8
Flue Size
1,500,000
________________________
1,700,000
________________________
6"
________________________
7"
_______________________
2,000,000
8"
The flue products in the vent system may be cooled below their
dew point and form condensate in the flue. The
materials 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 venting system.
Category IV Venting
A CATEGORY IV POSITIVE
PRESSURE VENTING SYSTEM
Category IV Flue Pipe Materials
Select venting material from the following 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)
FIG. 10 Basic Category IV Venting - Vertical
Or other listed Category IV vent systems suitable for a condensing,
positive pressure gas fired appliance.
Venting Guidelines for a Category IV Vent
The connection from the appliance vent to the stack or vent
termination outside 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.
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 venting 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 exhausts the flue products from
the building. The Category IV flue from this appliance can NOT
be combined with the vent from any other appliance. The Category
IV flues from multiple appliances 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 appliance must
have all vent joints and seams sealed gas-tight. A Category IV
vent system has specific vent material and installation requirements.
9
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 concealed plumbing or electrical wiring inside walls,
floors or ceilings. Locate the appliance as close as possible 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 condensate 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 fireplace 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 connections should be secured
and sealed per the vent manufacturers specifications.
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 exterior surfaces or on the vent
cap. Frozen 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 resistant sheet metal plate.
The manufacturer shall NOT be held liable for any personal injury
or property damage due to ice formation or the dislodging of ice
from the vent system or the vent termination.
Drain Tee Installation
Vent connectors serving appliances vented by natural draft shall
not be connected to any portion of the Category 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.
WIRE TIE
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.
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 equivalent 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 vertically 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 distance is maintained from electric meters,
gas meters, regulators and relief equipment.
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 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 gravity air inlet into any building.
10
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 condensate
drain must be routed to the condensate neutralization system or a
suitable drain for disposal of condensate 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.
VERTICAL VENTING
TERMINATIONS
Follow all General Category IV Vent Termination Clearances.
10' OR LESS
2' MIN
3' MIN
RIDGE
MASONRY CHIMNEY
INSTALLATIONS
A standard masonry chimney must NOT be used to vent the
products of combustion from the flue of a Category IV,
positive pressure appliance. If a masonry chimney is to be used,
the chimney MUST use a sealed, metallic, corrosion
resistant 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 resistant chimney liner
systems are typically made from a high grade of corrosion 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
requirements or the advisability of using a masonry chimney
with a sealed corrosion resistant liner system.
CHIMNEY
FIG. 13 Vent Termination from Peaked Roof - 10 Feet or Less
from Ridge
MORE THAN 10'
10'
RIDGE
2' MIN
3' MIN
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 insertion of a corrosion resistant liner system,
consult with local code officials.
CHIMNEY
FIG. 14 Vent Termination from Peaked Roof - 10 Feet or
More from Ridge
The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61 m) above the highest point of the roof within
a 10 foot (3.05 m) radius of the termination.
The vertical termination must be a minimum of 3 feet (0.91 m)
above the point of exit.
11
10' OR LESS
2' MIN
2' MIN
3' MIN
CHIMNEY WALL OR
CHIMNEY
PARAPET
FIG. 15
Vent Termination from Flat Roof - 10 Feet or
Less from Parapet Wall
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 installer must supply suitable vent pipe
material. The sidewall vent cap is available from the appliance
manufacturer as a vent kit.
10' OR MORE
3' MIN
WALL OR
PARAPET
NOTE: NO HEIGHT
ABOVE PARAPET
REQUIRED WHEN
DISTANCE FOR
WALLS OR PARAPETS
IS MORE THAN 10'>
CHIMNEY
FIG. 16
Vent Termination from Flat 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.
FIG. 18 Sidewall Vent Cap
SIDEWALL VENTING
TERMINATIONS
TABLE - E
Sidewall Vent Cap Kits
This venting system uses the appliance’s internal combustion air
blower to force the flue products out of a horizontally-terminated
flue. This blower generates a positive pressure in the flue.
Combustion air is drawn from the equipment room (see
Combustion and Ventilation Air Requirements) unless the
appliance is equipped with an optional Direct Vent or Intelli-Vent
System.
Input Btu/hr
Flue Size
Sidewall Vent
Cap Kit
1,500,000
________________
1,700,000
________________
6"
_____________
7"
_____________
SVK3026
_________________
SVK3027
_________________
2,000,000
8"
SVK3028
The sidewall vent cap kit includes the wall penetration assembly
and the discharge screen assembly. All required Category IV vent
pipe and fittings must be purchased locally.
12
The installed sidewall vent cap assembly may be painted to match
the exterior color. The opening through the wall for installation 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 installed vent pipe to
the sidewall cap.
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.
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.
The vent shall not terminate directly above a public walkway due
to the normal formation of water vapor in the combustion process.
Horizontal terminations must not be located over areas of
pedestrian or vehicular traffic.
Follow all requirements in the General Category IV Venting
sections for venting 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.
The vent terminal shall not be installed closer than 3 feet
(0.91 m) from an inside corner of an L-shaped structure.
LOCATION OF A SIDEWALL
VENT TERMINATION
Follow all General Category IV Vent Termination Clearances.
Do not terminate the vent in a window well, stairwell, alcove,
courtyard or other recessed area. The vent cannot terminate below
grade.
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 adjacent to public walkways.
The vent cap should have a minimum clearance of 4 feet
(1.22 m) horizontally from and in no case above or below, unless
a 4-foot (1.22 m) horizontal distance is maintained from electric
meters, gas meters, regulators and relief equipment.
Flue gas condensate can freeze on exterior 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 manufacturer to ensure proper operation. Locally
purchased or fabricated sidewall vent caps should not be used.
DIRECT VENT AND
INTELLI-VENT SYSTEMS
3' MIN.
10' MIN.
HORIZONTALLY
FIG. 19
4' MIN.
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.
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 different pressure zones. The
flue outlet and combustion air intake may terminate with either a
sidewall or a rooftop termination.
The vent cap MUST NOT terminate below a forced air intake at
any distance.
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
installation requirements must be followed.
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 Direct Vent and Intelli-Vent Systems require the installation of
an additional pipe to supply combustion air from outdoors directly
to the appliance.
13
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.
•
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 appliance and the plastic air
inlet pipe.
CAUTION
WARNING
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.
Using vent or air intake materials other than those specified,
failure 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 certification
of the appliance.
TABLE - F
Direct Vent and Intelli-Vent Flue
and Air Inlet Pipe Sizes
Input Btu/hr
Flue Size
NOTE:
Air Inlet
Pipe Size
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 combustion air.
1,500,000
6"
6"
________________
______________
________________
1,700,000
7"
7"*
________________
_____________
________________
2,000,000
8"
8"
*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.
Sealing of Type “B” double wall vent material or galvanized vent
pipe material used for air inlet pipe on a sidewall or vertical roof top
Combustion Air Supply System.
Length of Air Inlet Pipe
The maximum total length of the sidewall or vertical roof top
combustion 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 equivalent length for each 45° elbow installed in the air inlet
pipe system.
Do not exceed limits for the combustion air inlet piping lengths.
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
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 silicone sealant to all screws
or rivets installed in the vent pipe.
d.
Ensure that
supported.
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).
the
air
of
inlet
vent
pipes
pipe
are
on
the
properly
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
14
sealant to ensure a proper seal at the appliance connection 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 supplied in proper volume.
3'
12"
When a sidewall or vertical roof top combustion air supply
system is disconnected for any reason, the air inlet pipe must be
resealed to ensure that combustion air will be free of
contaminants 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 products and carbon monoxide emissions
causing severe personal injury or death.
Combined Combustion Air Inlet Points
The air inlet pipes from multiple appliances 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 in2 (324.5 cm2) area each] have a
total area of 100.6 in2 (645.2 cm2) requires a 12" (30.5 cm) [113.1
in2 (729.7 cm2] common air inlet pipe.} The air inlet point for multiple boiler air inlets must be provided 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 inlet. This exterior opening
for combustion 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.
FIG. 20
Vertical Direct Vent Installation with Rooftop
Combustion Air Inlet
Follow all requirements in the General Category IV Venting
sections for proper installation and of venting flue products
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 specified
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 installed 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.
VERTICAL DIRECT VENT SYSTEMS
A Vertical Direct Vent System is installed with a Category IV flue
and a separate combustion air pipe to the outdoors. The Direct Vent
system terminates both the flue and air inlet in the same pressure
zone. The flue outlet and combustion air intake must both terminate
on the rooftop.
15
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 property damage.
VERTICAL COMBUSTION AIR INLET
Multiple Vertical Direct Vent Installations
FIG. 21 Air Inlet Cap for Rooftop Termination
The air inlet cap for the vertical roof top air inlet is assembled
from components 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 installed 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 between the two elbows, it should not exceed 6" (150 mm)
in length. The termination 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 combustion 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 rooftop 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 Combustion and Ventilation Air). To prevent
recirculation of flue products in to the combustion air inlet, follow
all instructions in this section.
16
FIG. 22 Multiple Vertical Direct Vent Installations
The combustion air inlet caps for multiple 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 installed 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 section and the applicable portions of the general Category
IV venting section must be maintained on multiple appliance
installations.
HORIZONTAL DIRECT VENT
For venting flue products horizontally to the outdoors, follow all
requirements 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 terminates both the flue and air inlet in the same pressure
zone. The flue outlet 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 products to the
outdoors with a sidewall termination. 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 specified
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 installed 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. Subtract 2 1/2 feet (0.7 m) of equivalent length for
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. 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 special combustion air inlet cap for installation 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
Input
Btu/hr
FIG. 23 Horizontal Direct Vent Installations with Sidewall
Combustion Air Inlet
Flue
Cap
Size
Air Inlet
Cap
Size
Sidewall Air
Inlet & Flue
Cap Kit
1,500,000
___________
1,700,000
___________
6"
__________
7"
__________
6"
__________
8"*
__________
HDK3018
______________
HDK3019
______________
2,000,000
8"
8"
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.
SIDEWALL COMBUSTION
AIR INLET
Location of a Sidewall Air Inlet Cap
Horizontal Direct Vent systems installed 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 available as
a vent kit.
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 property damage.
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 accumulation.
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.
17
The combustion air inlet caps for multiple 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 section and the
applicable portions of the general Category IV venting section
must be maintained on multiple appliance installations.
INTELLI-VENT SYSTEMS
FIG. 25 Air Inlet Cap for Sidewall Termination
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 assembly 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 Combustion and Ventilation Air). To prevent
recirculation of flue products into the combustion air inlet, follow
all instructions in this section.
Multiple Horizontal Direct Vent Installations
An Intelli-Vent system is a Category IV flue installed with 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 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 requirements
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 products 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 specified
materials.
FLUE OUTLETS
3' HORIZONTALLY
AIR INLET CAP
1' BELOW FLUE
FIG. 26 Multiple Horizontal Direct Vent Caps Installed on a
Sidewall
18
Combined Air Inlet Points
The air inlet pipes from multiple appliances 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 information section.
Termination point for the flue products must follow the clearance
requirements in the Vertical Vent Termination section 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.
Maximum Length of an Intelli-Vent System
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 installed 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.
SIDEWALL COMBUSTION
AIR INLET
VERTICAL INTELLI-VENT WITH
SIDEWALL COMBUSTION AIR
FIG. 28 Air Inlet Cap for Sidewall Termination
The air inlet cap for the sidewall air inlet must be purchased from
the appliance manufacturer.
FIG. 27 Vertical Intelli-Vent Installation - Sidewall Combustion
Air Inlet
The part numbers for the required sidewall air inlet cap kit are listed
by unit size. The appliance manufacturer, 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.
Intelli-Vent systems are installed with a Category IV flue and a
separate combustion air pipe to the outdoors. The Vertical
Intelli-Vent system terminates the flue at the rooftop and air inlet
at the sidewall. The flue outlet and combustion air intake terminates
in different pressure zones.
TABLE - H
Follow all requirements in the General Category IV Venting
sections for proper installation and venting of flue products
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.
Input
Btu/hr
Flue
Size
Air Inlet
Pipe
Size
Sidewall
Air Inlet
Cap Kit
1,500,000
___________
1,700,000
___________
6"
___________
7"
___________
6"
___________
7"*
___________
SAK3000
___________
SAK3001
___________
2,000,000
8"
8"
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.
19
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 Horizontal 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.
Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air). To prevent
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 property damage.
HORIZONTAL INTELLI-VENT WITH
VERTICAL COMBUSTION AIR
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 Termination section
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.
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 appliance manufacturer as a vent kit.
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.
12" MIN.
TABLE - I
Air Inlet
Pipe
Size
Sidewall
Vent
Cap Kit
6"
___________
7"
___________
6"
___________
7"*
___________
SVK3026
____________
SVK3027
____________
8"
8"
SVK3028
Input
Btu/hr
Flue
Size
1,500,000
___________
1,700,000
___________
2,000,000
*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.
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 products
horizontally to the outdoors. All other general installation
requirements must be followed.
20
VERTICAL COMBUSTION
AIR INLET
HORIZONTAL INTELLI-VENT
WITH SIDEWALL 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 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.
Follow all requirements in the General Category IV Venting
sections for proper installation and of venting flue products
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.
FIG. 30 Air Inlet Cap for Rooftop Termination
The air inlet cap for the vertical roof top air inlet is assembled from
components 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 installed 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 between the
two elbows, it should not exceed 6 inches (150 mm) in length. The
termination 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
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 property damage.
FIG. 31 Horizontal Intelli-Fin Installation with Sidewall
Combustion Air in a Different Pressure Zone
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.
Termination point for the flue products must follow the clearance
requirements
in
the
Horizontal
Sidewall
Vent
Termination section of the Category IV Venting.
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.
The rooftop combustion air inlet cap and the sidewall flue gas outlet
are located in different pressure zones in an Intelli-Vent system.
Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air). To prevent
recirculation of flue products in to the combustion air inlet, follow
all instructions in this section and related Direct Vent sections.
21
TABLE - J
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
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 available as a vent
kit.
Input
Btu/hr
Flue
Cap
Size
Air Inlet
Cap
Size
Sidewall Air
Inlet & Flue
Cap Kit
1,500,000
___________
1,700,000
___________
6"
_______
7"
_______
6"
_______
8"*
_______
HDK3018
________________
HDK3019
________________
2,000,000
8"
8"
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
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 Horizontal Direct Vent section of the venting
instructions.
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 requirements, must furnish both the sidewall air inlet and
flue cap. Each kit includes the both the special combustion air
inlet cap and the sidewall flue cap for installation on an exterior
sidewall. The sidewall air inlet cap supplied in the kit is sized to
provide combustion air for a single appliance only.
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.
Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air). To prevent
recirculation of flue products in to the combustion air inlet, follow
all instructions in this and related sections.
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 property damage.
22
GAS SUPPLY
GAS PRESSURE TEST
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 manifold. 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
Max. (Inches-Water Column)
______________________________
Min. (Inches-Water Column)
Natural
Gas
L. P.
Gas
10.5"
w.c.
________
4.0" w.c.
13.0" w.c.
_________
4.0" w.c.
1.
The appliance must be disconnected from the gas
supply piping system 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 connection
leak-tested before placing it in operation.
TABLE - L
Nominal Manifold Pressure
Settings at Full Fire
Input Btu/hr
1,500,000 - 2,000,000
Natural
Gas
L. P.
Gas
3.5" w.c.
3.5" w.c.
be
GAS CONNECTION
1.
Safe operation of unit requires properly sized gas
supply piping. See gas line sizing data.
2.
Gas pipe
connection.
3.
Installation of a union at the appliance gas line
connection is required 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 provided in the inlet of
the gas connection to the appliance.
6.
The diaphragm gas valve has a bleed port that
requires
venting
to
atmosphere,
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.
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 pressure 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 reference 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.
Adjustment 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 adjustment of the ratio gas valve may cause
incomplete combustion or non-warrantable burner damage.
must
23
size
may
be
larger
than
appliance
TABLE - M
Recommended Gas Pipe Size
Single Appliance Installations
Distance from Meter
Btu/hr
0 - 50 ft.
51 - 100 ft.
101 - 200 ft.
1,500,000
2"
2 1/2"
3"
1,700,000
2 1/2"
2 1/2"
3"
3"
3 1/2"
2,000,000
2 1/2"
3"
3"
3 1/2"
4"
201 - 300 ft.
301 - 500 ft.
3 1/2"
For each elbow or tee, add equivalent straight pipe to total length from TABLE - O.
TABLE - N
Multiple Appliance Installations Gas Pipe Size Chart
Length of Pipe in Straight Feet
Nominal
Iron Pipe Size,
Inches
10
20
30
40
50
60
70
80
90
100
125
150
175
200
369
256
205
17 4
155
141
128
121
113
106
95
86
79
74
1
697
477
384
328
29 2
267
246
256
210
200
179
164
149
138
1 1/4
1 1/2
2
2 1/2
3
4
1,400
2,150
4,100
6,460
11,200
23,500
97 4
1,500
2,820
4,460
7,900
16,100
789
1,210
2,260
3,610
6,400
13,100
677
1,020
1,950
3,100
5,400
11,100
595
923
1,720
2,720
4,870
10,000
543
830
1,560
2,460
4,410
9,000
502
76 9
1,440
2,310
4,000
8,300
472
707
1,330
2,100
3,800
7,690
44 1
666
1,250
2,000
3,540
7,380
410
636
1,180
1,900
3,300
6,870
369
564
1,100
1,700
3,000
6,150
333
51 3
974
1,540
2,720
5,640
308
472
871
1,400
2,500
5,130
287
441
820
1,300
2,340
4,720
3/4
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"
4"
5"
Equivalent Length of Straight Pipe (feet)
2'
2'
3'
4'
5'
10'
14'
20'
24
GAS PIPING
GAS INLET
All gas connections must be made with pipe joint compound
resistant to the action of liquefied petroleum and natural gas. All
piping must comply with local codes and ordinances. Tubing
installations must comply with approved standards and practices.
Install Piping to Control
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.
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 appliance 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.
9.
For LP gas, consult your LP gas supplier for expert
installation.
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 burner. 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 input. The manifold pressure supplied to the
burner is a differential pressure. This pressure is the result of the
difference in two gas pressure measurements. 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 procedure 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.
FIG. 34 Gas Line Connection to Unit with Sediment Trap
and Manual Main Gas Shut-off Valve
2.
Connect gas pipe to inlet of appliance. Use wrench to
support gas manifold on the appliance.
GAS MANIFOLD
PRESSURE ADJUSTMENT
TRAP
1.
8.
CHECKING GAS SUPPLY PRESSURE
FIG. 35 Gas Supply Pressure Measurement
25
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 appliance. 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” position 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 input. 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” position.
12.
Shut off gas supply at the manual gas cock in the
gas piping to the appliance. 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.
26
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 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 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 manifold pressure.
5.
The differential manifold gas 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 manifold pressure 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
column natural gas (13.0" w.c. for propane) while
the appliance is firing at 100% of rated input.
7.
WATER CONNECTIONS
AIR INLET
This is a reference pressure only and is not field
adjustable. An
appliance
supplied
with
a
minimum of 4 inches water column of gas supply
pressure will operate at the correct manifold
pressure as the burner input varies 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.
GAS
WATER OUTLET
WATER INLET
IMPORTANT
FLUE OUTLET
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.
FIG. 37 Water Connections
3.5" W.C.= Pgas
MANIFOLD GAS PRESSURE
– – – – = FIELD CONNECTED
FIG. 36 Manifold Gas Pressure Measurement
27
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
connection 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 piping requirements in the heating boiler or water heater
section of this manual. Consult factory if longer piping distances
are required for a specific application.
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 circulating pump ensures proper water flow
over the heat transfer surfaces during burner operation. Water
temperatures in the primary heat exchanger are controlled by the
operation of the automatic 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 exchanger surfaces.
SECONDARY HEAT EXCHANGER
PRIMARY HEAT EXCHANGER
FIG. 39 Secondary 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 appliance.
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
28
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 horizontal finned copper tubes. The secondary heat exchanger is
mounted in the discharge of the flue products from the primary heat
exchanger. This allows additional heat to be absorbed from the flue
products exhausted from the combustion 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 temperatures are below approximately 130° F (54.4°C), the
flue products passing over the secondary heat exchanger may be
cooled below their dewpoint resulting in the formation of
condensate. The secondary heat exchanger has a special high
INTEGRAL BYPASS
HOT
WATER
OUTLET
BYPASS VALVE
PRIMARY
HEAT
EXCHANGER
PUMP
SECONDARY
HEAT
EXCHANGER
COLD
WATER
INLET
FIG. 40 Bypass Piping with Valve Actuator and Pump
temperature conformal coating to prevent any corrosive damage to
the copper tubes or cast iron headers 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 condensate and
discharge it from the jacket.
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
This appliance contains an integral bypass and circulating pump
that connects 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 controller
senses inlet water temperature to the primary heat exchanger and
provides 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
temperatures in the primary heat exchanger above the dewpoint
prevents formation of flue gas condensate on the primary heat
exchanger. The Excel 10 establishes 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 position 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 temperature 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
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 operation. 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 response to variation in inlet water temperature. The bypass
valve operates best when it can start operation from a full closed
position. A status point mode of Byp Synch will be indicated in
the Command Display as the actuator on the bypass valve is
overdriven to the closed position for synchronization.
29
BYPASS PIPING ASSEMBLY
The primary and secondary heat exchangers 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
temperature sensors and a relief valve(s).
INTEGRAL CIRCULATOR
FIG. 41 Bypass Valve and Actuator Assembly
The appliance has an integral circulating 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”
position. 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 chamber before the pump is
turned off. If the ambient temperature at the temperature 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 internal heat exchangers must be manually set before the
automatic operation of the bypass begins.
30
Setting temperature rise on an Intelli-Fin with an automatic bypass
is accomplished 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 appliance is operating or if there is any torque on
the bypass valve by the actuator. 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 actuator handle till it is perpendicular to the
piping. This fully closes the bypass 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 exchanger 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 Display). Adjust the
field-installed ball valve in the outlet piping from the appliance 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 - P
Temperature Rise At Full Rate Fire
Bypass Manually Fully Closed
Btu/hr Input
Temperature Rise
1,500,000
_______________________
1,700,000
_______________________
31.5°F (17.5°C)
_______________________
35.7°F (19.8°C)
_______________________
2,000,000
42.0°F (23.3°C)
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 temperature 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 temperature 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 moving toward
full closed to sustain the water temperature above
the dewpoint of the flue products.
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.
10.
Operation of the bypass valve
temperatures above the dew point
at the primary heat exchanger
condensate
formation
occurs
secondary heat exchanger.
maintains water
of flue products
to ensure that
only
on
the
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 maintain water temperatures.
CAUTION
BYPASS OPERATION
1.
Main burner ignition is achieved.
2.
Integral bypass begins the adjustment process to
control inlet water temperature to the primary heat
exchanger.
3.
The Excel 10-controller senses inlet
temperature to the primary heat exchanger.
water
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 control point is programmed into the software in
the Excel 10 controller.
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 operation of the bypass and allows all condensate formation
to occur on the secondary 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 products. Operation of
the appliance at a temperature below the specified minimum set
point temperature will result in non-warrantable operational
problems from the condensate formation on the primary heat
exchanger.
31
TABLE - Q
Minimum Inlet Water Temperatures
Input
Btu/hr
Minimum Return
Temperature
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.
Minimum
Setpoint
1,500,000 ____________________
50°F (10°C)
105°F (40.6°C)
___________
_______________
1,700,000 ____________________
50°F (10°C)
90°F (32.2°C)
___________
_______________
2,000,000
50°F (10°C)
70°F (23.9°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.
WATER FLOW SWITCH
A water flow switch is factory installed in the internal bypass piping
on all heating boilers, hot water supply 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 requirements 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 condition as sensed by the flow switch.
LOW WATER CUTOFF
(If Equipped)
If this boiler is installed above radiation 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 available 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
ORIFICE
DIAPHRAGM
VALVE
RATIO VALVE
FIG. 42 Gas Train Assembly
32
RELIEF VALVE
This unit is supplied with a relief valve(s) sized in accordance with
ASME Boiler and Pressure Vessel Code, Section IV (“Heating
Boilers”). The relief valve(s) is installed in the
vertical 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
couplings 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:
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 opening 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 indicate the position of the valve seat. Operation of the gas valve
in combination 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 additional upstream constant gas pressure
regulator internally to the appliance as long as the gas supply is
maintained within the specified minimum and maximum 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 measured, follow
the “Gas Manifold Pressure Measurement Procedure” for proper
measurement.
There are no serviceable parts on the ratio gas valve actuator.
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.
DIAPHRAGM GAS VALVE
RATIO GAS VALVE
FIG. 44 Diaphragm 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 restriction in the gas supply line as a
function of the pressure difference across the combustion air supply
to the burner. The actuator maintains a constant air to gas ratio as
the volume of air changes based on the operation of the combustion
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 operational sequence to ignite the
burner.
33
Venting of Gas Valves and Pressure Switches
The diaphragm type gas valve and optional gas pressure switches
are provided with threaded termination points to be vented to the
atmosphere, outside the building. The gas pressure regulation
function is provided by the ratio gas valve which does not require
installation of a vent line. The diaphragm gas valve and optional
gas pressure 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 responsibility of the installing
contractor.
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).
.
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. Serious damage
may result if the appliance is operated without
proper flow.
ELECTRICAL CONNECTIONS
4.
ELECTRICAL
JUNCTION BOX
CONTROL
PUMP
5.
Provide the
protection.
appliance
with
proper
overload
TABLE - R
AMP DRAW DATA
1,000,000 through 2,000,000 Btu/hr Models
Btu/hr
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 appliance 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.
APPROXIMATE TOTAL
Blower &
Pump
Amps
Controls
FLA
@ 120 AC
1,500,000
__________
1,700,000
__________
6.7
____________
7.2
____________
8.8
__________
8.8
__________
15.5
____________
16
____________
2,000,000
7.2
8.8
16
JACKET ASSEMBLY
Inner Jacket - The inner jacket assembly is constructed from a
special corrosion resistant stainless steel. This includes both the
front primary heat exchanger chamber and the rear secondary heat
exchanger chamber. All screws and fasteners used for assembly of
34
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 damaged by the flue product
condensate when used on the inner jacket assemblies.
Outer Jacket - The outer jacket assembly is constructed from steel,
galvanized on both sides. The galvanized surface is specially
prepared and phosphate 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. 46 Component and Auxiliary Controls Connections with Junction Box
FIG. 47 Front Control Panel Locations
35
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
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 relay, an alarm relay, an ignition
relay, gas valve relay, pump relay, louver relay and VFD power
relay.
FIG. 50 Variable Frequency Drive
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
36
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
variable frequency drive is driven to 100% during the pre-purge
portion of the start-up sequence. The variable frequency 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 desired set point and the various operating
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.
A differential air pressure switch is used to prove operation of the
combustion 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. Correct 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)
The voltage output from the variable frequency drive to the
combustion air blower is 230 volt 3 phase. Avoid contact
with high voltage wiring.
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 pressure
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.
LOW AIR PRESSURE SWITCH
EXCEL 10
CAUTION
PRESSURE SWITCH
~ ~
BLOWER
TRANSITION
~~
BURNER
FIG. 51 Low Air Pressure Switch
FIG. 52 Excel 10 Control Module
37
Excel 10 Boiler Interface Controller - The boiler interface
controller for this appliance is based on the Excel 10 controller
platform with unique software customized for operation 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 interface with the
Excel 10 controller. Local communication, programming and a
digital display of the appliance functions 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 multiple 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 heaters.
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 ordered as a heating
boiler must be applied 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 floating point bypass valve, control of water temperature set
points, and monitoring 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 failure, high temperature alarm, and boiler
not operational. A boiler that is not equipped with the outdoor reset
function 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 diagnostic 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
connection of all components. The multiple termination points are
located on two printed circuit boards mounted on either side of the
Excel 10 controller. Use caution when connecting or disconnecting
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 numerical 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
38
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 reference.
The Excel 10 may have values for the control points specified at the
time the control is configured at the factory. If exact control
settings are not specified at the time an appliance is ordered, the
Excel 10 controller will be pre-programmed with the following
default values as shipped from the factory. Special arrangements
should be made with the factory during the ordering process to have
job site specific values programmed into the control. These values
are different for boiler and water heater applications.
TABLE - S
Default Values
Pre-programmed in the Excel 10
Point
_______________
Setpoint Temp
_______________
Boiler
_______________
130.0°F
_______________
Water Heater
_______________
120.0°F
_______________
O.A. Lockout
_______________
O.A. Max
_______________
70.0°F
_______________
60.0°F
_______________
N/A
_______________
N/A
_______________
O.A. Min
_______________
Max Setpoint
_______________
10.0°F
_______________
220.0°F
_______________
N/A
_______________
190.0°F
_______________
Min. Setpoint
_______________
Operating
Sensor
_______________
100.0°F
_______________
Return/Inlet
_______________
50.0°F
_______________
Return/Inlet
_______________
Heater I.D.
Boiler
Water Heater
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.
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”.
2. 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
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.
FIG. 54 Command Display Panel
39
The Command Display provides a communication 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.
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.
On the lower right side is a back key which moves the display to
the previous screen and a select key which highlights 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
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 button provides access to a
“setup” screen that allows the user to adjust such items as:
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 operating 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 configuration settings of the Command Display. The third
level of password allows the password to be changed.
TABLE - T
DISPLAY DEFAULT VALUES
____________________
Contrast
____________________
Default
_____________
50%
_____________
Option
_____________
0 - 100%
_____________
Backlight Mode
____________________
Beep on New Alarm
____________________
AUTO
_____________
OFF
_____________
OFF/ON
_____________
ON
_____________
Beep Rate
____________________
Time Format
____________________
4.0s
_____________
12
_____________
0 - 60s
_____________
24
_____________
Date Format
____________________
Engineering Units
MM/DD/YY
_____________
English
DD/MM/YY
_____________
S.I.
ACCESSING THE SIX
CHANGEABLE POINTS FROM
THE COMMAND DISPLAY
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 Display 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 password 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 password screen
will stay in place.
When the “CHANGE” button on the right side of the control is
pressed, a password 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 cursor 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.
40
to drop lower (Changeable
Command Display).
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.
2.
3.
4.
5.
Calculated Set Point — The water temperature as
adjusted by an optional outdoor reset function
used on a heating 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.
Supply/Outlet Temp — The temperature of the
water leaving the boiler or water heater, a basic
thermometer function to display outlet water
temperature.
Temp. Rise — The difference between inlet and
outlet water temperature 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 outdoor 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 lockout and not
fire.
8.
9.
O.A. Max — The warmest outdoor air
where the boiler reset function will
function and operate the boiler at
set point temperature. The boiler set
increase based on a corresponding drop
temperature below this temperature.
temperature
begin to
the initial
point will
in outdoor
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 temperature continues
from
the
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.
Set Point Temp — The desired water temperature
as adjusted by the owner/operator. This becomes
the lowest boiler operating temperature when an 14.
optional outdoor reset function is used (Changeable Point
from the Command Display).
Return/Inlet Temp — The temperature of the water
entering the boiler or water heater, a basic thermometer
function to display inlet water temperature.
Point
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 indicate a specified function of
the unit.
17.
Percent Bypass — The percent that the bypass valve is
open to allow heated 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% indicates that the valve is fully open.
The percentage will vary with valve operation.
18.
Bypass Temp.
temperature in
exchanger after
water from the
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” status 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).
41
— A display of the water
the inlet to the primary heat
being mixed with hot discharge
bypass piping when the bypass
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
42
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 displayed. This feature is used for
performing factory tests.
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.
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
presence 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.
43
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 individual 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 displaying 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.
OUTDOOR RESET FUNCTION
SELECTIONS
(Optional on Heating Boilers Only)
As an option, the Excel 10 control may be equipped with an outdoor
reset function. 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 specific settings are not available the default values will be
programmed into the Excel 10 at the factory. The operating parameters
for the reset function are:
O.A. Lockout — The maximum outdoor 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 lockout and not fire. The default setting if not specified is
70.0°F (21.1°C). This setting should be specified 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
corresponding drop in outdoor temperature below this temperature.
The default setting if not specified is 60.0°F (15.6°C).
FIG. 57 Command Display Data Screen
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 outdoor air sensor.
Max. SetPoint — The maximum water temperature that the boiler or
water heater may be set to operate at. The default 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.
44
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 temperature as adjusted by the
optional outdoor air reset function used on a heating 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.
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 sequencing of the boilers or
water heaters 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 efficiency.
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 Equalization —
This is the same as “Efficiency 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.
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 specific 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 ordered. The desired
method of sequencing 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.
45
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.
INTERFACING MULTIPLE
APPLIANCES
PARALLEL CONNECTION
FTT networks are flexible and convenient to install and maintain.
However, it is imperative to plan the network layout and to create
and maintain accurate documentation. Careful planning and up to
date documentation facilitates compliance verification and future
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 locations, and
misplaced or missing terminations.
Wire to the terminal blocks as follows:
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.
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
provided on the rear of each appliance. The minimum
specification for the communication wire is for a Level IV,
22 AWG (0.034 mm2) 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
TABLE - W
Daisy-Chain Doubly Terminated FTT Network Bus Topology Specifications
Maximum FTT network Bus length
Maximum node-to-node length
for segment(s) in feet (meters)
for segment(s) in feet (meters)
Wire/Cable Type
_________________________________
___________________________________
__________________________________
_
Level IV 22 AWG unshielded, twisted
pair, stranded communications wire (use
plenum rated wire where required)
4593 (1400)
3773 (1150)
TABLE - X
Singly Terminated FTT Network Bus Topology Specifications
Maximum node-to-node length
Maximum FTT network Bus length
for segment(s) in feet (meters)
Wire/Cable Type
for segment(s) in feet (meters)
___________________________________
__________________________________
_________________________________
_
Level IV 22 AWG unshielded, twisted
pair, stranded communications wire (use
plenum rated wire where required)
1640 (500)
46
1312 (400)
STRIP 1/2"
FROM WIRE
TO BE ATTACHED.
1/2" (13MM)
INSERT TWISTED WIRES
UNDER TERMINAL AND
TIGHTEN. CHECK FOR
A GOOD MECHANICAL
CONNECTION.
TWIST WIRES
TOGETHER WITH
PLIERS (MINIMUM
OF THREE TURNS)
FIG. 60 Wire Termination for E-Bus Connection
1.
Strip 1/2 in. (13 mm) insulation 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.
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
Wire Requirements
The minimum type and grade of wire required to “network” 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 communication wire. The
following manufacturers supply communication 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
__________________________________________________
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 LonSpecTM
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.
Lucent Technologies
(305) 569-3600
www.lucent.com/netsys/
systimax
__________________________________________________
Windy City Wire
(800) 379-1191
www.smartwire.com
__________________________________________________
47
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 Display. Additional
switches, alarm indicating lights and optional low water cut-off
control switches are also located on this panel. The setting of this
control knob limits maximum discharge water temperature. A red
reset button, 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.
FIG. 62 High Water Temperature Control
A red indicating light is illuminated when the water temperature
exceeds the setting of the high limit control. A status 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.
48
HOT SURFACE IGNITION SYSTEM
IGNITION CONTROL MODULE
OEM unit only. An OEM specification igniter and ignition control
module for this specific unit is available from your local distributor.
DO NOT use general purpose field replacement ignition modules
or igniters. Each appliance has one ignition module and one hot
surface igniter.
Ignition Module Lockout Functions
DIAGNOSTIC STATUS CODES
FIG. 63 Hot Surface Ignition Control Module
This appliance uses a proven hot surface 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 lockouts 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 displayed 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 surface igniter. The electronic ignition module is not
repairable. Any modification or repairs will invalidate the warranty
and may create hazardous conditions 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
The ignition module may lockout in either a hard lockout condition
requiring 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 condition. 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 cycling 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 lockout. 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 condition
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 ignition
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
sequence. 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 condition 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 control module has gone into
a soft lockout condition.
FIG. 64 Hot Surface Igniter
49
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 operation of this LED
indicates the diagnostic status of the ignition control module. The
following listing gives the flashing diagnostic status codes as
signaled by the ignition module.
Proven Pilot Hot Surface Ignition System
Pre-purge Time
15 Seconds
D. C. MICROAMP METER
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
IGNITION
MODULE
FIG. 65 Flame Current Measurement on the HSI Module
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.
_________________________________________________________________________________________________________
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.
_________________________________________________________________________________________________________
One Flash
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.
_________________________________________________________________________________________________________
Two 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.
_________________________________________________________________________________________________________
Three 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.
_________________________________________________________________________________________________________
Four Flashes
Five Flashes
Power supply problem, check for low supply voltage or transformer output less than 18 VAC.
_________________________________________________________________________________________________________
Six Flashes
Replace ignition module, internal fault.
50
OPERATION/DIAGNOSTIC
LIGHTS, RESETS AND SWITCHES
ADJ
HI-LIMIT
BURNER
CIRCUIT
BREAKER
ALARM
RESET
ALARM
SOUND
ALARM
POWER
SILENCE
LOW WATER CUT-OFF
AUTO
RESET
TEST
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.
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.
51
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
material that forms the burner port surface. 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 operation 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.
COMBUSTION AIR BLOWER
This appliance uses a sealed air blower to provide combustion air
for the burner 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
enclosed 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 rating 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
NOTE:
An index mark is provided on the burner flange to ensure
proper orientation when removing and reinstalling the
burner. A properly indexed burner will ensure correct
location of the combustion air blower and adequate
clearances from other components in the top jacket
chamber.
The burner is designed to operate from 100% of rated input down
to 25% of rated input in normal operation. Burner 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.
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 operation 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 contaminated
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.
FIG. 68 Combustion Air Blower
52
FILTER
FIG. 70
ACCESS PLATE
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 condensate
formed from this high efficiency heat transfer process is mildly acidic.
The condensate will typically have a pH ranging from 4.0 to 5.0 as it
is discharged from the condensate drain on the rear of the appliance.
The internal jacket area where the condensate is collected (secondary
heat exchanger) is constructed from a special corrosion resistant
stainless steel. All materials external to the appliance in contact with
the condensate 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 mounted on the same level or lower than the bottom of the
appliance cabinet. All condensate piping and connections must be
easily accessible for routine maintenance and inspection. Sufficient
lengths of tubing and barbed connectors are supplied in the kit to allow
the neutralizer reservoir to be positioned to the right, left or rear of the
appliance.
Cleaning the Internal Combustion Air Blower Inlet
Filter
CONDENSATE MANAGEMENT
SYSTEM (Optional)
FIG. 72
FIG. 71 Location and Connection of Neutralization Reservoir
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
53
1,500,000
_______________________
1,700,000
_______________________
7.3
_______________________
8.3
_______________________
2,000,000
9.7
Many codes will require the acidic condensate to be
neutralized 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 management system consists 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 neutralizer 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
venting 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 assembly. Ensure that a
trap is provided in the drain line from the flue to prevent flue gases
from escaping with the condensate. 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.
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).
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.
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.
Condensate Testing
The initial fill of reagent grade calcium carbonate should sustain
neutralization for 3 months of operation. An appliance operating
at higher temperatures will produce condensate at lower levels
allowing the calcium carbonate to remain effective 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 condensate.
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.
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).
54
 WARNING
LIGHTING INSTRUCTIONS
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.
FOR YOUR SAFETY,
READ BEFORE
OPERATING
Failure to follow this warning could result in product damage
or improper operation, personal injury, or death.
NOTE:
WARNING
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.
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.
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.
• 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
neighbors phone.
• Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call
the fire department.
FIG. 73 Install Condensate Trap
55
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. Immediately call a qualified
service technician to inspect the boiler. 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.
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.
LIGHTING INSTRUCTIONS
1.
STOP! Read the safety information.
2.
Set the Temperature Set Point function 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.
1.
Set the Temperature Set Point function of the
Command Display to the lowest setting.
Turn the main manual gas cock handle clockwise to the
“OFF” position.
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.
5.
TO TURN OFF GAS TO APPLIANCE
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.
Wait five (5) minutes to clear out any gas. If you
smell gas, STOP! Follow “B” in the safety
information. If you don’t smell gas go on to the
next step.
3.
Turn electric power on.
4.
Set run/stop switch to “RUN” position.
Turn the main manual gas cock
counterclockwise to the “ON” 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.
TURN TO OFF POSITION
FIG. 74 Gas Cock with Handle in “OFF” position
6.
7.
TURN TO ON POSITION
handle
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 operate properly, repair work
must be performed by a qualified serviceman or
installer.
FIG. 75 Gas Cock with Handle in “ON” position
56
SEQUENCE OF OPERATION
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 control junction
box and to the integral pump.
3.
120 VAC Power is supplied to the
Transformer, Ignition Module and Excel 10.
will
synchronize
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.
control
The bypass
startup only.
5.
24 VAC is supplied to all low voltage controls.
22.
Burner is now in a soft start firing at 50% of rated input.
6.
Integral pump starts and is proven by a Flow
Switch.
23.
Excel 10 Controller signals the Variable Frequency
Drive to adjust blower speed based on desired
water temperature Set Point.
7.
Command
Display
Set
Temperature) is set to call for heat.
24.
8.
Excel 10 Controller initiates a start-up sequence
by checking the Temperature Sensors and input
signals from the safety controls.
Burner input rate is variable down to 25% of rate
or up to 100% of rate as required to satisfy the
Set Point programmed 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 maintains water
temperatures above the dew point of flue products
to ensure that condensate formation occurs only
in the Secondary Heat Exchanger.
Point
on
Relay contacts prove operation of the Igniter, Gas
Valves and Safety Switches to the Excel 10.
4.
9.
valve
18.
initial
(Operating
Excel 10 enables the Ignition Module.
10.
Ignition Module enables the Variable Frequency
Drive.
11.
Excel 10 Controller drives the Variable Frequency
Drive.
12.
The Variable Frequency Drive supplies the
Combustion Air Blower with 230 VAC 3 phase
power.
13.
Combustion Air Blower starts operation 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.
Hot Surface Igniter proves 1800°F (982°C)
Ignition Temperature by current draw through the
Ignition Module.
16.
17.
Heat Transfer Process
28.
Burner Input continues to increase until
temperature reaches the Set Point temperature.
29.
Burner Input may stabilize at a fixed rate where
demand equals input.
30.
Burner Input will
temperature exceeds
demand.
31.
Heated products of combustion pass over the
Primary Heat Exchanger transferring heat to the
water.
The Ignition Module supplies voltage to the
Variable Ratio Gas Valve and the Redundant Gas
Valve.
57
water
decrease rate when water
temperature Set Point and
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.
NORMAL BURNER FLAME
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”.
ABNORMAL BURNER FLAME
MAINTENANCE
Listed below are items that must be checked to ensure safe reliable
operations. Verify proper operation after servicing.
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 required. Have the entire system, including the
venting system, periodically inspected by a qualified service
agency.
B. VISUALLY CHECK MAIN BURNER FLAMES at each
start up after long shutdown periods or at least every six
months. A burner viewport is located on the burner mounting
flange.
WARNING
FIG. 76 Flame Pattern
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.
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 cleaning. The following
cleaning procedure must only be performed by a qualified
serviceman or installer. Proper service is required to maintain safe
operation. Properly installed and adjusted units seldom need flue
cleaning.
The area around the burner viewport is hot and direct
contact could result in burns.
58
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
boiler/water heater.
The burner should be removed for inspection 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 contamination. 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.
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.
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 without a combustion air filter installed will
probably require a thorough cleaning before the unit is placed into
normal 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.
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 burner 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.
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
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.
inlet
pipe
connection
to
the
* Insulation jacket is tucked under the control panel assembly and
cannot be “removed” without removing the control panel.
59
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 blockage 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.
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.
The burner may best be cleaned by immersing the burner port
area in a solution of dishwashing detergent and hot water. Do
not use chlorine based solvents or cleaning agents on the burner.
Allow the burner to remain in the solution 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 solution and
rinsing to prevent any oxidation or rusting of the ferrous
components in the burner port material.
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.
8.
Check the replacement
damage before installing.
igniter
for
cracks
or
60
FIG. 77 Location of Primary Heat Exchanger
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.
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 exchanger must be cleaned and
problem corrected.
6.
Remove burner as described in Burner Maintenance
procedure.
7.
Check “V” baffles on the exchanger.
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.
Remove and
FIG. 78 Location of Secondary Heat Exchanger
1.
Turn off all power to the appliance.
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.
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.
10.
Ensure that any soot present on
removed. See Burner Cleaning Procedure.
is
6.
Check “V” baffles on the exchanger.
clean if necessary.
11.
Carefully reinstall the heat exchanger
baffles if removed from the appliance.
“V”
7.
12.
Reinstall inner jacket panels, burner, manifolds,
wires and hoses.
Use new gasket material to
ensure a proper air seal.
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.
the
burner
and
13.
Reassemble all gas and water piping. Test for gas leaks.
14.
Reassemble outer jacket panels.
15.
Cycle unit and check for proper operation.
61
Remove and
10.
Carefully reinstall the heat exchanger if removed
from the appliance.
ORIFICE
GAS
Reinstall inner rear jacket panels, bypass piping
and condensate hoses. Use new gasket material
to ensure a proper air seal.
AIR BOX
(FRONT VIEW)
BLOWER
9.
GAS
AIR
11.
Reassemble all water piping. Test for leaks.
12.
Reassemble rear outer jacket panels.
GAS
3.5" W.C. = Pair
GAS
13.
AIR
GAS VALVE
(TOP VIEW)
Cycle unit and check for proper operation.
MANIFOLD AIR PRESSURE
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 component section for
cleaning procedure. The motor and bearings on the combustion
air blower are sealed and permanently 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 lubricant
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 construction phase.
AIR
BURNER
GAS
– – – – = FIELD CONNECTED
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 adjustable. 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
pressure 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.
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 problems. A 5 AMP circuit breaker is provided on
the secondary side of the transformer. 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.
62
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.
FREEZE PROTECTION
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 recommended for the mechanical room. Damage to the
appliance by freezing is non-warrantable.
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.
1.
Pump Operation - MOST IMPORTANT - This
appliance is designed for continuous 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)].
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.
3.
Caution - A mechanical room operating 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.
8.
Close the two air pressure test cocks on the
pressure test tree and remove the hoses to the
manometer.
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.
9.
Close the front control panel.
5.
Freeze protection for a heating boiler or hot water
supply boiler using an indirect coil can be provided by
using hydronic system antifreeze. Follow 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:
L. COMBUSTIBLE MATERIALS
CAUTION
Keep appliance area clear and free from combustible
materials, gasoline and other flammable vapors and
liquids.
(a) Shut off gas supply.
(b) Shut off water supply.
(c) Shut off electrical supply.
63
(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.
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
Use only properly diluted inhibited 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 approximately -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.
WARNING
The drawings in this section show typical 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 service.
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 Installation 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 NONWARRANTABLE FAILURE.
Local codes may require a back flow preventer or
actual disconnect from city water supply when
antifreeze is added to the system.
WATER CONNECTIONS
HEATING BOILERS ONLY
WATER TREATMENT
In hard water areas, water treatment should be used to reduce the
introduction of minerals to the system. Minerals in the water can
collect in the heat exchanger tubes and cause noise on operation.
Excessive build up of minerals in the heat exchanger can cause
a non-warrantable failure.
64
All boilers have 3 inch (76.2mm) copper pipe inlet and outlet
connections. Installed piping to and from the boiler must be a
minimum of 3 inches (76.2mm) diameter and must not exceed the
maximum specified 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 exchanger
damage.
PIPING LENGTHS
PRIMARY LOOP CIRCULATOR
PUMP SPECIFICATIONS
The boiler’s integral circulator provides the water flow from the
primary boiler piping, through the boiler and back to the primary
system. Pipe diameter 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 piping 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 boiler 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
system, through the boiler and back to a primary boiler system piping.
Pipe diameter and length are critical to ensure proper flow through
the boiler and secondary piping. The boiler primary piping system
must have a primary circulator 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 installed secondary loop
to the boiler. Pipe diameter and length are critical to ensure proper
flow through the boiler and secondary piping. Temperature 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 temperature 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 recirculated back into the
primary heat exchanger. Operation of the bypass will yield higher
discharge temperatures from the boiler.
1.
Maximum operating pressure for the pump must exceed
system operating pressure.
2.
Maximum water
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.
temperature
should
not
exceed
CIRCULATOR PUMP OPERATION
(Heating Boilers Only)
The boiler pump should run continuously when the boiler is firing.
External wire leads are furnished in the electrical junction box to
allow separate power supplies to the pump and boiler controls or the
two circuits (pump and controls) can be combined for connection
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 burner 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 satisfied. This will remove any residual heat from the
combustion chamber before turning the pump off. See wiring diagram shipped with the unit.
PUMP MAINTENANCE: Inspect the pump every 6 months and
oil as necessary. 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 direction when installed in 3" (76.2 mm) diameter 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 installed
fittings.
65
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 system should be a
maximum of 12" (0.30 m) (or 4 pipe diameters) apart to ensure
connection 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.
FROM SYSTEM
CAP EACH MANIFOLD
The installer must ensure that the boiler has adequate flow
without excessive 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 diameter pipe
reduces head loss and increases flow.
CAUTION
TO SYSTEM
FIG. 81 Primary/Secondary Piping of Multiple Boilers
At no time should the system pressure be less than
12 PSIG.
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.
Condensation on the primary heat exchanger can cause operational
problems, bad combustion, sooting, flue gas spillage and reduced
service life of the related components.
66
The automatic bypass system allows part of the boiler discharge water
to be mixed with the inlet water to the primary 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 discharge,
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 temperatures 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.
THREE WAY VALVES
The installation of a three way valve on this boiler is not
recommended because 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 conditions 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
TABLE - CC
Minimum Inlet Water Temperatures
Input
Btu/hr
Minimum Return
Temperature
Minimum
Setpoint
1,500,000
_________
1,700,000
_________
50°F (10°C)
__________________
50°F (10°C)
__________________
105°F (40.6°C)
______________
90°F (32.2°C)
______________
2,000,000
50°F (10°C)
70°F (23.9°C)
90 GPM
If higher flow rates are required through the boiler, an optional
Cupro-Nickel heat exchanger is available. Consult the factory for
specific application requirements.
The heat exchanger is capable of operating 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 temperature rise through the boiler
when it is firing at full rate input. See Bypass-Initial Setup for
adjustment procedure.
CAUTION
BOILER TEMPERATURE
RISE CHART
A boiler allowed to operate at set point temperatures below
the specified minimum settings may experience 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
spillage. Operation at lower than specified water
temperatures may cause hazardous conditions that result in
non-warrantable damage to the appliance.
TABLE - DD
Temperature Rise at Full Rate Fire
Bypass Fully Closed and 90 GPM Flow
67
Btu/hr Input
Temperature Rise
1,500,000
_______________________
1,700,000
_______________________
31.5°F (17.5°C)
________________________
35.7°F (19.8°C)
________________________
2,000,000
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 outlet 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
temperature/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
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 electrical service for
both the boiler controls and pump. Ensure that the
electrical service(s) is adequately sized.
12.
Review wiring to an energy management system
and wiring to any remote temperature sensors.
Boiler Set-Up
General Plumbing Rules
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.
Always pipe pressure relief valve to an open drain.
14.
Check system for any water leaks.
4.
Locate system air vents at highest point of system.
15.
5.
Expansion tank must be installed near the boiler
and on the suction side of the system pump.
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.
1.
Check all local codes.
2.
For serviceability of boiler, always install unions.
3.
6.
Support all water piping.
Boiler Operational Checks
PLACING THE BOILER
IN OPERATION
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.
Ensure that the boiler condensate drain and all vent
system condensate drains are properly routed to
an acceptable floor drain or neutralization system.
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 level, high water
temperature and flame failure.
4.
Ensure that an optional condensate neutralization
system is properly installed if required by codes.
22.
5.
Review the vent termination point for proper
location and clearances.
Carefully follow the bypass adjustment procedure
to set maximum flow to the boiler at 90 GPM. Verify
by checking temperature rise while burner is firing at
100% of rated input.
6.
Ensure that proper volumes of combustion and
ventilation air are provided to the mechanical room.
If a separate combustion air pipe is used, ensure
that it is properly sized, sealed and terminated.
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.
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.
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
boiler set-up.
Pre-Start Check List
1.
2.
3.
8.
Review the location of the boiler, clearances from
combustible surfaces and available service
clearances.
Review the installed Vent System. Ensure that all
vent components are Category IV material with
adequate clearance from combustibles.
Ensure that a properly sized primary system pump
is installed with an expansion tank.
68
wiring
disconnected
during
the
Boiler Operation
28.
Turn the run/stop switch to the “RUN” position to
start boiler operation.
29.
Push the resets for low water level, 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 minimum inlet temperatures to the
primary heat exchanger.
34.
Ensure that inlet water temperature does not fall
below the specified minimum 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 combustion air blower will run
for a post purge operation before the boiler shuts
down.
INSTALLATION WITH A
CHILLED WATER SYSTEM
EXPANSION
TANK
HEATING AND
COOLING COIL
GAS SUPPLY
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 operation. Also, omit thermostat flow
checks as the boiler is cold when heating thermostat is satisfied.
This provides greater economy over maintaining 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 temperature sensor may
generally require a lower temperature set point on the operating
control to achieve the desired discharge water temperature from the
boiler. The return/inlet sensing element location 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 temperature 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
temperature setting programmed into this standard Excel 10
control is 100°F (37.7°C).
PUMP
WATER
SUPPLY
CHILLER
FIG. 82 Installation with a Chilled Water System
69
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 velocity 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
COLD WATER SUPPLY
BUILDING
HOT WATER SUPPLY
RELIEF VALVE
TO DRAIN
MIXING
VALVE
LOCK-TEMP
STORAGE TANK
DRAIN
BUILDING RETURN
FIG. 83 Typical Water Heater Piping with Storage Tank
This section contains specific instructions for those appliances
used to supply domestic hot water. All warnings, 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 important for correct operation
of your water heater or hot water supply boiler.
WATER VELOCITY CONTROL
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 internal heat exchangers must be manually set
before the automatic operation of the bypass begins.
IMPORTANT
CAUTION
To ensure proper velocity through the heat exchangers, it
is necessary to regulate the temperature rise across the
heat exchanger from inlet to outlet. This must be done on
initial installation and periodically rechecked. 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.
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.
70
TABLE - EE
TABLE - FF
Maximum Flow Rate
Temperature Rise At Full Rate Fire
Bypass Manually Fully Closed
Btu/hr Input
1,500,000 - 2,000,000
Maximum Flow
Btu/hr Input
90 GPM
If higher flow rates are required through the water heater, an
optional Cupro-Nickel heat exchanger is available. Consult the
factory for specific application requirements.
The heat exchanger is capable of operating 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 allowable flow rate through the water
heater. The maximum flow through the water heater 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
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 accomplished 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 appliance
is operating or if there is any torque on the bypass valve by the
actuator. 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 actuator handle till it is perpendicular to the piping. This
fully closes the bypass 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 exchanger 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 Display). 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.
Temperature Rise
1,500,000
_______________________
1,700,000
_______________________
31.5°F (17.5°C)
_______________________
35.7°F (19.8°C)
_______________________
2,000,000
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.
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 temperatures. Temp Rise
in the Command Display 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 Command
Display when the burner is firing at 100% of rated
input.
4.
Compare the temperature rise on the Command
Display with the required temperature rise. Should
adjustment be needed, proceed as follows:
If the temperature rise is too high, the water velocity is too
low. Adjust as follows:
71
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.
6.
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.
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 properly 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.
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
exceeding 350 ppm. Consult the manufacturer when heating
potable water exceeding 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 revised 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 because
heated water increases the rate of corrosive chemical reactions.
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.
72
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
MIXING VALVE
COLD WATER SUPPLY
LOCK-TEMP
STORAGE TANK
BUILDING
HOT WATER SUPPLY
RELIEF VALVE
TO DRAIN
MIN. 3” (75mm) COMMON
MANIFOLD SIZE
DRAIN
BUILDING RETURN
FIG. 85 Multiple Water Heater Piping with Single Storage Tank
COLD WATER SUPPLY
MIXING VALVE
BUILDING HOT
WATER SUPPLY
RELIEF VALVE
TO DRAIN
LOCK-TEMP
STORAGE TANK
MIN. 3” (75MM) COMMON
MANIFOLD SIZE
DRAIN
BUILDING RETURN
FIG. 86 Multiple Water Heater Piping with Multiple Storage Tanks
73
6.
TABLE - GG
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.
Number of Units
Common Manifold
Size (Min)
1
_______________________
2
_______________________
3"
_______________________
4"
_______________________
3
_______________________
4
_______________________
4"
_______________________
5"
_______________________
5
_______________________
6
6"
_______________________
6"
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.
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 storage tank to achieve proper operation. As
shipped from the factory, the operating 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 temperature 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
installation of a single storage tank and heater in close proximity.
If the number of fittings and straight pipe exceeds the specified
maximum equivalent number of straight feet for a specified diameter
of pipe, non-warrantable 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:
2.
The internal pump is sized to the heater input and
water chemistry specifications noted in “Water
Chemistry.”
Minimum pipe diameters and maximum length
specifications must be per the requirements in this section.
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.
HEAT EXCHANGER
4.
The pump must run continuously when the water
heater or hot water supply boiler is firing. This is the
standard operating system for a water heater 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 combustion 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 surfaces 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 contaminants in suspension. This “scouring
action” provides greater cost savings for owners. Tubes are always
able to transfer heat at peak efficiency. Every surface within this
water containing 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 models, header inspection plugs in the primary heat exchanger
can be removed for field inspection and cleaning of copper tubes.
Each of the heat exchangers may be removed from the unit.
74
THERMOSTAT SETTINGS
1.
2.
TABLE - HH
Minimum Inlet Water Temperatures
The Excel 10 temperature controller is adjusted
to a low test setting when shipped from the factory.
Input
Btu/hr
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 Return
Temperature
Minimum
Setpoint
1,500,000
___________
1,700,000
___________
50°F (10°C)
____________________
50°F (10°C)
____________________
105°F (40.6°C)
_______________
90°F (32.2°C)
_______________
2,000,000
50°F (10°C)
70°F (23.9°C)
CAUTION
MINIMUM WATER TEMPERATURES
(Domestic Hot Water Use)
An appliance allowed to operate with return temperatures
set point below the specified minimum settings may experience 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 spillage. Operation at lower than specified
water temperatures may cause hazardous conditions that
result in non-warrantable damage to the appliance.
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 exchanger can cause
operational problems, bad combustion, sooting, flue gas spillage
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 operation of the bypass and allows all condensate
formation to occur on the secondary 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 specified
minimum will result in non-warrantable operational problems from
the condensate formation on the primary heat exchanger.
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 II) 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 - II
APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS
• 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).
FIG. 87 Warning Label
75
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
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 temperature increases the ability
of the water heater to supply desired quantities of hot
water, however rememberIncorrect 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 installation drawings provided with the unit for
correct piping. Higher water temperatures reduce the volume of
condensate formed.
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 indicating lights and optional low water
cut-off control switches are also located on this panel. The setting of
this control knob limits maximum discharge water temperature. The
water heater or hot water supply boiler temperature limit control is
adjustable up to a fixed maximum setting of 200°F (93°C). A red
reset button, 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 setting of the high
limit control. A status 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.
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 bacteria. 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.
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
applicable 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 periodically 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 installed in the cold water supply, shall be
provided with means to control expansion. 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 extremely flammable. To prevent the possibility of
injury under these conditions, 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.
76
Ladder Diagram
1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models
WARNING:To avoid possible shock hazard, disconnect power before servicing.
HOT
NEUTRAL
UNIT POWER 120VAC 15AMP
GROUND
M
VFD
GND
NO
G
COM
T1
T2
T3
L1
BLOWER
ASSEMBLY
L2
POWER
SWITCH
N
7
2
C
VFD POWER
RELAY
3
NO
R
L1
PUMP POWER
120VAC 15AMP
L2
OPTIONAL
S1
GROUND
PUMP MOTOR
S2
M
IGNITION
MODULE
COM
1
2
COM
EXT. GAS VALVE
CONTROLLER HSI
NO
LOW VOLTAGE
TRANSFORMER
LV1
COMMAND DISPLAY
EBUS
TO
OVERRIDE
TOGGLE
SWITCH
VENT VALVE
NO
HOT
SURFACE
IGNITER
NO
COM
120VAC GAS VALVE
120
VAC
GROUND
GAS VALVE RELAY
R
LV2
24 VAC
EBUS
COMMUNICATION
CABLE #1
EARTH 24VAC 24VAC
Back
24VAC SOLENOID VALVE
Select
IGNITION
MODULE
F2
GROUND
F1
7
R
PUMP RELAY
8
CONTROLLER INPUTS
9
4
5
6
1
2
3
1
2
11
3
10
IGNITION
RESET
CONTROLLER OUTPUTS
9
8
7
6
T
5
24 VAC
4
Y
3
6
3
5
2
4
1
1
3
2
C
O/BK
RESET J2
PU
J4
NO
NC
NC
3
NC
NO
NC
NC
GND
P
High
Gas
NC
C
Low
Gas
NO
C
FLOW
SWITCH
CONTROLLER
INPUTS
PU
2
CONTROLLER
VFD
1
R
LOUVER RELAY
2
1
3
3
24 VAC
LWCO
2
1
4
5
4
J1
OPTIONAL
J3
T
LWCO
PROBE
OPTIONAL
Louver
Proving Sw
NO
C
Blocked
AIR
Drain
SWITCH
NO
C
NO
C
5
BL
O.C.
1
TEST
SWITCH
~~
~~~~~~
~~~~
2
T
+
N/A
TH
PI
LV2
RESET
LV1
MV
PS
FF
M/S
FF
G
O
PU
STD.
ALARM
COM
NO
COM
NO
COM
CHASSIS
GROUND
RESET
STD.CONTACTS
ALARM
INDICATOR
NO
HI-LIMIT
STD.
REAR
COMMUNICATION
CABLE CONNECTION
OVER TEMP
INDICATOR
COM
NO
SILENCE SWITCH
ALARM
24VAC OUT
LOUVER
RELAY
CONTACTS
NC
COM
NC
COM
R
ALARM RELAY
R
1 2
3
1 2
3
IGNITION RELAY
CONTROL PANEL
COMMUNICATION
CABLE CONNECTION
HI-LIMIT ALARM
RELAY
R
BYPASS
VALVE
1
2
HSI
28
2
2
29
VOLTS
AMPS
HERTZ
8888
2
1
31
3
GAS
ON
DIP SWITCH IN 01
DOWN
POSITION
S
N
K
L2
Low Wtr Flow
Flame Failure
11
14 15
Inlet Water Sensor
JACK
J3
14
15
BLK DRAIN
13
12
1
LO AIR
3
LOUVER
4
GAS HI/LO
9
10
11
2
8
5
3
BYPASS SENSOR
2
2
BYPASS
SENSOR
1
1
1
S/S
LED
1
2
1
1
OA
SENSOR
2
1
OA SENSOR
OPTIONAL
2
1
1
1
ENABLE
SWITCH
INLET
SENSOR
OUTLET
SENSOR
G BK BK
FLOW
FLAME
FAILURE
Outlet Water Sensor
Gas Valve
OUTLET
SENSOR
INLET SENSOR
CHASSIS
02
S
R
C
L1
HSI
30
INPUTS
PROG
OA Sensor
Bypass Water Sensor
1
7
24 V
P wr
1
RUN
FWD
REV
Pump Relay
6
24VAC
INPUTS
5
22
21
2
LowAir/Block Drain
n/a
25
1
26
C om
S IG
+
S IG
-
PWM
CONV.
Hi-LoGas/
Louver
Ignition Enable
23
FACTORY
CALIBRATED .
DO NOT
ADJUST .
Float Open
24
NOTICE:
7
24
24
1
VAC
DI-4 GND DI-3 DI-2 GND DI-1 VAC
COM OUT
mA
Ou t
Volts Out
mA Out
Com
24V Pwr
SIG IN +
SIG IN -
ENABLE
Dial Alarm
Float Close
4
OUTPUTS
3
3
VFD
ENABLE
COMMUNICATION
CABLE #2
2
2
1
E
GND
MU X
AD D R
Vo lts
Out
2
PWM/4-20ma
n/a
A1-1 GND A1-2 A1-3 GND A1-4 A1-5 GND A1-6 22VDC E-BUS
OHM
OHM OHM
OHM V/ma
V/ma OUT
16
TIME
B A SE
1
3
17
6
18
5
19
4
20
9
3
4
5
6
7
8
OUT OUT OUT OUT OUT OUT
8
2
OUT
MODE
MA NU A
L
OVE R RI D E
PUMP
7
1
CONTROLLER
DIP SWITCH #5 ON
E-BUS
CONTROLLER 24VAC
OVERRIDE TOGGLE SWITCH GROUND
RUN/STOP SWITCH
TO PUMP
RELAY COIL
OPTIONAL:
50 Hz Limit Resistor
1.2K Ohm
T1 T2 T3
LBL20021 REV B
77
Wiring Diagram
1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models
BK
W
CHASSIS
GROUND
BL
BR
GY
GY
FAN
CIRCUIT
BREAKER
VFD POWER RELAY
BK
R
NO
BK/W
COM
BL
PUMP
POWER
120VAC
15AMP
BL
PU
OVER TEMP
INDICATOR
Y
NC
R
NO
PU
BL/
BK
HI-LIMIT ALARM RELAY
BK W G
ALARM
INDICATOR
BL/W
Y
PU
ALARM RELAY
~
~~~
~~
~
~~
~~~
STD.
BL/W
NO
R BL BL/W SILENCE
Y
ALARM
24VAC OUT
BL/W
R
BL
BL/BK
COM
BL/BK
BL/BK
1 2 3
O
NO
M
16
3
18 17
2
O
19
1
23 22
21
20
VFD
ENABLE
2
24VAC
1
Y
2
CHASSIS
GROUND
BL Y
P BL P DIP SWITCH #5 ON
1
INPUTS 1
PROG
3
W
MUX
A DDR
Ignition Enable
LowAir /Block Drain
n/a
Pump Relay
OA Sensor
Bypass Water Sensor
Outlet Water Sensor
HSI
Inlet Water Sensor
Low Wtr Flow
Flame Failure
S/S
LED
PU
PU
R
V olts
Out
mA
Out
Com
24V
P wr
S IG
+
S IG
-
LINE
BK
L2
TIME
BASE
14
11
15
S
R
C
PK
GY
L1
Hi-LoGas/
Louver
02
01
Y
T1
T2
W
T3
Volts Out
mA Out
Com
24V Pwr
SIG IN +
SIG IN -
S
N
K
Float Open
MODE
M ANUA
L
OV E RRI DE
DIP SWITCH IN
DOWN
POSITION
Float Close
Gas Valve
1
2
Dial Alarm
28
GY
n/a
30 29
2
1
26
HSI
GY
PWM/4-20ma
25 24
1
GY
VOLTS
AMPS
HERTZ
6
BL
Y
8888
1
2
1
Y
RUN
FWD
REV
9
5
1
3
TO 1.2K
RESISTOR
TO MANUAL
O’RIDE SW
P
Y
8
4
8
7
6
5
4
3
OUT OUT OUT OUT OUT OUT
GY
W
BR
BL
7
FLOAT
FLOAT CLOSE
31
W BK
T
PUMP
3
2
1
BYPASS COMMON
2
OUT
OUTPUTS
O
O
W/BK
PU
P
DRIVE
T
BL
R
PUMP RELAY
G
CHASSIS
RESET GROUND
CONTROLLER
NO
CHASSIS
GROUND
O/
PU
BK
W BK
G
J4
PU
W
BK COM
1
G
7
24
24
VAC 1
DI-4 GND DI-3 DI-2 GND DI-1 VAC
COM OUT
BK
2
4
O
PUMP MOTOR
ALARM
5
GND
P
T
G
3
RESET
J2
IGNITION RELAY
HI-LIMIT
G
LWCO
PROBE
SWITCH
BL
BL
J3
T
PU
R
Y
O.C.
T
T
6
COM
NC
TEST
SWITCH
ALARM
STD.CONTACTS
COM
BL
COM
Y
Select
Back
BL
Y
G
LOW VOLTAGE
TRANSFORMER
BL
COM
Y
24 VAC
JACK
J3
BK
EARTH 24VAC 24VAC
BL
BL
EBUS
EBUS
E-BUS
W
COMMAND DISPLAY
120
BK VAC W
A1-1 GND A1-2 A1-3 GND A1-4 A1-5 GND A1-6 22VDC E-BUS
V/ma OUT
OHM V/ma
OHM OHM
OHM
TWO 15 AMP CIRCUITS
OR ONE 30 AMP CIRCUIT
POWER SWITCH
W
N 7
2
BK/W
BK
3
NO
C
E
GND
W BK
G
J1
UNIT POWER
120VAC
15AMP
PWM
CONV.
NOTICE:
FACTORY
CALIBRATED .
DO NOT
ADJUST.
G
GROUND
T
2
1
BYPASS
VALVE
2
1
2
3
Y BK BL
NEUTRAL
T
1
OPTIONAL
T
3
GND
REAR WIRING
CONNECTIONS
OA
SENSOR
OPEN
COMMON
CLOSE
24VAC ALARM
OUT
BL/W Y
BR
1
4
2
5
2
PU
3
6
3
T
4
BK
BK
PU PU
ALARM CONTACTS
78
LOUV
1
5
Wiring Diagram (continued)
1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models
BK
W
Y
BL
BR
BR
Y
LOUVER
RELAY
WARNING:To avoid possible
shock hazard, disconnect power
before servicing.
BR
S1
W
GY
L2
4
L1
2
S2/FS
N/A
TH
PI
LV2
RESET
LV1
MV
PS
FF
M/S
FF
11
O
10
9
8
Y
7
J3
AIR
Blocked
SWITCH Drain
OPTIONAL
High
O
NO
Gas
T
NC
C
NO O/ C
O
O
C
BK
NC
NO
NC
Low
Gas
FLOW
SWITCH
1
NO
O
C
O/BK
O
NC
P
U
PU
PU
PU
C
BL
Louver
Proving Sw
NO
NO
C
6
5
T
4
3
2
BR
W
BK
1
F1
STATUS
LED
1
24 VAC
2
F2
IGNITION
MODULE
5
NEUTRAL LINE
GY
GY
BK
COMMUNICATION
CABLE #1
3
LOUVER
RELAY
CONTACTS
BK
STD.
BK
FC-FC+
GY
BL
COM
BR
NO
GY
GY
HOT
SURFACE
IGNITER
R
+
Y
BL/BK
BL
R
IGNITION
RESET
NC
OPTIONAL
NC
R
TOGGLE
SWITCH
MANUAL
OVERRIDE
PU
PU
PU
C 1
2
Y
R
W R BK
1
2
3
1
2
3
W
OR
24VAC GAS
VALVE
W BK R
4
3
2
BYPASS
VALVE
BL
W/BK
AT OPEN
R
R GAS VALVE RELAY
Y
Y
R
R
J3
50 Hz Limit
Resistor
1.2K Ohm
PU
P
Y
15
14
13
OUT
TO VFD
TERMINAL
NUMBER 14
PU
PU
PU
PU
Y
1
12
V/m a
1
11
10
3
9
4
TO VFD
TERMINAL
NUMBER 15
OPTIONAL 50 Hz LIMIT RESISTOR
1
OUTLET
SENSOR
2
1
1
OA SENSOR
OUTLET SENSOR
BK
2
2
1
1
INLET SENSOR
REAR
COMMUNICATION
CABLE CONNECTION
RUN/STOP SWITCH
CHASSIS
GROUND
W
BK
Y
NOTE: DO NOT DISCONNECT
Y
CABLE FROM BLOWER.
RO
TA
TI
O
N
7
6
4
1
INLET
SENSOR
G BK
2
COMMUNICATION
CABLE #3
OPTIONAL
1
NO
120VAC GAS
VALVE
BK
2
ENABLE
SWITCH
1
OHM
1
2
3
1
2
2
1
1
OA
SENSOR
5
OHM OHM
1
1
W
EXT. GAS VALVE
M
R
O
TA
TI
ON
GND
1
BYPASS SENSOR
2
2
VENT VALVE
BK
Y
3
BYPASS
SENSOR
COM
COM
8
5
NO
BK
INPUTS
2
OHM V/ma
OPTIONAL
COMMUNICATION
CABLE #2
CONTROL PANEL
COMMUNICATION
CABLE CONNECTION
Y
OPTIONAL
R
COMMUNICATION
CABLE #1
BL
BLOWER
ASSEMBLY
2
COMMON
CLOSED INPUT
1
OPEN INPUT
3
LOUVER
CONTACTS
4
2
BK
120VAC
OUT
W
1
BLOCKED
DRAIN
1
2
3
T PU BR
OPEN
INLET
SENSOR
COMMON
EXT. GAS
VALVE
BLOCKED
UVERS
NOTES:
(1) WARNING: To avoid possible shock hazard, disconnect power before servicing.
(2) Where possible, switches and circuitry are shown in power off state.
(3) When replacing wiring, use wire of equal or higher temperature and gage.
(4) Schematic shows electrical connections only. Please refer to wiring diagram in
owner's manual for routing and pin-outs for all connector blocks.
(5) Pump delay is standard on water heaters.
LBL90002 REV A
79
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.
80
1/09-Printed in U.S.A.