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INSTALLATION AND SERVICE MANUAL

1. t 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 ntelli Fin The Excel 10 is also compatible with LonWorks building management systems All ofthe 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 ntelli Fin appliances are to be installed in a single application see Multiple Appliance Installations for information on interfacing sequencing and display of multiple ntelli 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 wate
2. 37 Excel 10 Boiler Interface Controller 37 Manual Override Control 39 Temperature Adjustment sse 39 Command Display see 39 Password eerte nun eranl 40 Changeable Points esses 40 Data Points in 41 Status Points Operation 43 Status Points Alarm 44 Outdoor Reset Function 44 Multiple Appliance Installations 45 Sequencing 45 E Bus Connection 46 Temperature Limit Control 48 Hot Surface Ignition Control 48 Hot Surface 49 Diagnostic Status LED 49 Operation Diagnostic Lights and Switches 50 Burner Assembly 51 Combustion Air Blower sees 52 Condensate Management System 53 Installation and Operation 53 Condensate Trap Installation 54 Lighting Instructions ee 55 Sequence of Operation sene 57 Maintenance trt 57 Maintenance and Annual
3. 18 Vertical Flue Sidewall Air 19 Sidewall Flue Rooftop 20 Sidewall Flue Sidewall Air 21 Gas Supply i5 HIR 23 Gas Pressures and 23 Manifold Pressure sse 23 Supply Pressure Measurement 25 Manifold Pressure Measurement 26 Water Connections 27 Heat Exchangets 5 sectis ie ens 28 Integral 88 tesiri sesiis 29 Valve and Pump enenatis 29 Synchronization iisi 29 Set up Maximum Flow esses 30 Bypass Operation 31 Minimum Water Temperatures 31 Flow Switch iiti cease ete ete tae ete ebrei ne 32 Low Water Cut Off niece 32 Gas TANT GS ecco EHE USA CO UO MEE Ys 32 Relief HUP UHR 33 Ratio Gas Valve sss 33 Diaphragm Gas Valve ee 33 Electrical Requirements ren rre tede 34 duin DE 34 Components and Controls 35 Variable Frequency Drive esses 36 Low Air Pressure Switch sss 37 Gas Pressure Switches
4. 76 Ladder Diagram eere rove 77 Wiring Diagram eee een 78 Revision Notes sesseeeR Back Cover 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 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 WARNINGA If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be p
5. CHIMNEY 7 FIG 13 Vent Termination from Peaked Roof 10 Feet or Less from Ridge MORE THAN 10 10 CHIMNEY FIG 14 Vent Termination from Peaked Roof 10 Feet or More from Ridge The vent terminal should be vertical and exhaust outside the build ing at least 2 feet 0 61 m above the highest point ofthe 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 0 OR d CHIMNEY WALL CHIMNEY PARAPET FIG 15 Vent Termination from Flat Roof 10 Feet or Less from Parapet Wall lt 10 ORMORE NOTE NO HEIGHT ABOVE PARAPET REQUIRED WHEN DISTANCE FOR WALLS OR PARAPETS IS MORE THAN 10 gt 4 PARAPET qm 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 SIDEWALL VENTING TERMINATIONS 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 Combusti
6. 58 Vent Syste M 58 Flame Patterns nisiodo tt 58 Condensate Testing 59 B rner Cleanings petia 59 Heat Exchanger Inspection eee 61 EubfiCatioBl 62 Combustion Air Measurement 62 Freeze Protectio we oes eben neret tta 63 Heating Boiler eee 64 Piping 64 Piping Length and Diameter 65 Integral Pump Limitations esess 65 Boiler Pump 65 Primary Secondary 66 Minimum Water Temperatures 66 Three Way Valves Sueco orien ed 67 Boiler Flow Rates esses 67 Placing the Boiler in Operation 68 Boiler Temperature Control 69 Water Heater Domestic Hot Water Supply Boiler 70 Typical Pipihg eise etin 70 Set up Maximum Flow eee 70 Temperature Rise ceres 71 Water Chenu iis idein ipd ep 72 Piping Requirements eee 73 P rmp Operation oett 74 Temperature Adjustment sess 75 Minimum Inlet Temperatures 75 Risk of Scald Warnings 76
7. cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier TABLE OF CONTENTS ERR TIE ID DET 1 Safety Warnings oii 3 enn EE 3 Installation Requirements sese 4 WO CANONS eR 4 Clearances sisi oatienitenc thoi orem ie na 4 Combustion Ventilation Air Requirements 5 Construction Air Filter necesse 7 Venting Systems sss 8 Category IV Venting titredi inei 9 Flue Pipe Materials ets 9 Installation Guidelines sussss 9 Vent Length Requirements sess 10 Drain Tee Installation siiis 10 Vertical Terminations sss 11 Sidewall Terminations sss 12 Direct Vent Systems essere 13 Air Inlet Pipe Materials 14 Air Inlet Pipe Length Requirements 14 Vertical Direct Vent 5 rene emeeteren 15 Location 15 Multiple Direct Vent Installations 16 Horizontal Direct Vent sese 16 Location Requirements 16 Multiple Direct Vent Installations 18 Intelli Vent Systems entente 18 Materials ect vicerit eter teni na 18 Length Requirements
8. 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 15 VERTICAL COMBUSTION AIR INLET FIG 21 Air Inlet Cap for Rooftop Termination The air inlet cap for the vertical roof top air inlet is assembled from 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 1s 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 inl
9. aoc NCO RESET NO C o 24VAC GAS VALVE BYPASS R pm VALVE R GAS VALVE RELAY OR eS AT OPEN SO Oe e OPTIONAL COMMUNICATION ITEM E CABLE 1 Resistor CONTROL PANEL No VENT VALVE 5 1 2K Ohm COMMUNICATION COM W h COMMUNICATION CABLE CONNECTION EXT GAS VALVE 14 al CABLE 2 ES eus ret BK 120VAC GAS D 215 as 14 TO VFD NO VALVE Pw B TERMINAL COM o BK o o dhe e a tecceesccoesss BK purs fire n pas COMMUNICATION NOTE DO NOT DISCONNECT Y PASS SENSOR OASENSOR CABLE 3 CABLE FROM BLOWER E o 2 Tie OPTIONAL ie ES ca OUTLET SENSOR ourier ip a iy SWITCH SENSOR ENSOR C 2 INLET SENSOR G BKLBK REAR cHassisp 1 297 RUN STOP SWITCH COMMUNICATION GROUND o CABLE CONNECTION ASSEMBLY EXT G INLET BLOCKED OTES IVERS E SENSOR DRAIN 1 WARNING To avoid possible shock hazard disconnect power before servicing MEG 2 Where possible switches and circuitry are shown in power off stat
10. Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade The vent shall not terminate directly above a public walkway due to the normal formation of water vapor in the combustion process Horizontal terminations must not be located over areas of pedestrian or vehicular traffic The vent system shall terminate at least 1 foot 0 30 m above grade above normal snow levels and at least 7 feet 2 13 m above grade when located adjacent to public walkways The vent terminal shall not be installed closer than 3 feet 0 91 m from an inside corner of an L shaped structure 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
11. Float Close 5 GROUND re 8 5 r Float Open B 1 1 Ignition Enable ERIT S 8 41 n a LowAir Block Drain 22 P Resistor amp 5 1 Pump Relay OA Sensor 22 Y p ANUN T ET Rag Bypass Water Sensor 22 Y Bl gt amp X HSI Outlet Water Sensor PH h CHASSIS GY NM hes SED BL v GROUND 1 E amp xX Gas Valve Inlet Water Sensor BL P DIP SWITCH 5 ON weurs 1 2 Low Wtr Flow sis B d m 8 8 LED 0080000 Ix Es eae Ov m i Flame GA t Tarega Se FU bs R oOoeoe POSITION voog gt NOTICE UN 22 Bypass 24VAC ALARM PWM DO NOT OPTIONAL VALVE OUT LOUV ADJUST BLIW Y CONV D d BR Y BKBL OA OHT REAR WIRING SENSOR oN ST CONNECTIONS LOSE RE ALARM CONTACTS 78 Wiring Diagram continued 1 500 000 1 300 000 2 000 000 Btu hr Models BK LOUVER STD RELAY BK CONTACTS IGNITION MODULE F1 WARNING To avoid possible shock hazard disconnect power before servicing GY HOT SURFACE GY o IGNITER Y COMMUNICATION NEUTRAL LINE 1 STATUS FS CABLE 1 Mu AIR vo BL OPTIONAL eT Pocke i Euver 8 Low High s Drain Proving Sw T Mns ica 10 G IGNITION UMS
12. c k Disconnect the power wire to the hot surface igniter 59 Remove the hot surface igniter The hot surface igniter is 8 Check the replacement igniter for cracks or damage before fragile Use care to prevent impact damage to the silicon installing carbide igniter surface when removing the igniter m EM B ES 9 Ensure that the fiber gasket used to seal the base of the igniter m Remove the 8 nuts holding the burner to the heat exchanger to the burner flange is reinstalled to seal the base of the n The burner can now be lifted vertically out of the heat replacement igniter exchanger cavity 10 Carefully insert the igniter into the mounting point on the Use to prevent damage to the woven burner port surface burner flange and position on the mounting studs l 11 Reinstall the two wing nuts and tighten by hand Over Insulation jacket is tucked under the control panel assembly tightening the wing nuts may break the ceramic mounting and cannot be removed without removing the control panel flange NOTE 12 Ensure that the igniter gasket is properly installed and seals the z point of contact between the igniter and burner mounting When the combustion air blower is removed for any flange reason the inlet to the burner must be covered to prevent 13 Reconnect the power leads to the igniter foreign objects from falling into the burner A foreign object such as a nut bolt wire or other m
13. 30 cm of the ceiling 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 non warrantable 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 prema ture failure of the appliance EXHAUST FANS Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and or cause a downdraft in the venting system Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected Ifa 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
14. INLET SENSOR cuassisr 7 OVERRIDE TOGGLE SWITCH GROUND o RUN STOP SWITCH TO PUMP RELAY COIL f OPTIONAL o 50 Hz Limit Resistor i 42K Ohm x 1 LBL20021 REV B 77 Wiring Diagram 1 500 000 1 300 000 2 000 000 Btu hr Models UNIT POWER 120VAC CHASSIS 15AMP a 4 GROUND W BK POWER SWITCH COMMAND DISPLAY 25 3 g ciRc ur p VFD POWER RELAY BREAKER tm E ii o ax i 24 VAC T N xS See lo BKiw LOW VOLTAGE 2 E TRANSFORMER 9 BL r Fo OVER TEMP INDICATOR com IXE rt oTo PUMP COM Nc INDICATOR POWER 7 O BL W sLwt y Y 120VAC o NO ALARM pu R BL BL WsILENCE pavac OUT BL W gt ALARM RELAY SWITCH 15AMP BL Y BK HI LIMIT ALARM RELAY A IGNITION RELAY cassis RESET GROUND BKWG BL HI LIMIT oJ G PUMP MOTOR BYPASS COMM FLOA SET ume umm BK sii CONTROLLER zg 25 e 35 PWRWA 20n a 5 G WBK aM OUTPUTS 8 11 2 5 1 Dial Alarm CHASSIS 8
15. cause sudden relief valve discharge CAUTIONA 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 TODRAIN ay LOCK TEMP STORAGE TANK COLD WATER SUPPLY COLD WATER SUPPLY LOCK TEMP STORAGE TANK BUILDING HOT WATER SUPPLY RELIEF VALVE TO DRAIN MIN 3 75mm COMMON MANIFOLD SIZE BUILDING RETURN MIXING VALVE BUILDING HOT WATER SUPPLY RELIEF VALVE TO DRAIN LOCK TEMP STORAGE TANK MIN 3 75MM COMMON MANIFOLD SIZE BUILDING RETURN FIG 86 Multiple Water Heater Piping with Multiple Storage Tanks 73 6 The operating temperature sensor for a water TABLE HH heater or hot water supply boiler is installed in Common Water Manifold Size inlet piping to the water heater or hot water supply For Multiple Water Heater boiler Hot Water Supply Boiler Installations 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 m 2 well mounted in the inlet piping to the water heater When the Pipe sizing chart provides minimum pipe size for pump cycles off in normal operation this sensor location may not common manifold piping to ensure adequate flow adequately sense a quick drop in temperature fr
16. 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 When the condensate level in the reservoir raises to the drain the pH is controlled to a range of 6 5 to 7 before exiting the system A pH of 7 is neutral As the pH number increases in numerical value the relative acidity of the discharge decreases The neutralized condensate may then be discharged into a suitable drain system without fear of damage to the drain system Ensure that the top remains on the reservoir keeping it sealed to prevent any contamination to the treatment process Condensate Testing The initial fill of reagent grade calcium carbonate should sustain neutralization for 3 months of operation An appliance operating at higher temperatures will produce c
17. gas piping to the appliance If fuel supply is LP point cocks hut off ly at the tank 3 Set the Command Display to a set point which will Remove the manometer and related fittings from fire the burner at 100 of rated input test rt at the inlet 1 E E 4 As the appliance comes on and fires record the dus ferons psi Bud ti inches of water column of displacement both pug in gas p P m sides of the manometer The sum of these two Turn on gas supply at the manual valve turn on readings wd ee e ide by the two gas LP gas at tank if required pressures is the differential manifold pressure 5 The differential manifold gas pressure should be T th tch to ON tion en te DONSDSONENUIO NY 3 5 inches of water column 0 1 w c when the Adjust the temperature setpoint on the Command burner is firing at 100 of rated input Displ to th 1 ter t t th play uo Ue temperature Tue 6 If the differential manifold pressure is not 3 5 appliance will call for heat 26 inches water column 0 1 w c recheck the gas pressure between 40 and 105 inches wor ROOTES RESTE S D NE pressure between 4 0 and 10 5 inches water WATER CONNECTIONS column natural gas 13 0 w c for propane while the appliance is firing at 100 of rated input 7 This is a reference pressure only and is not field AIRINLET adjustable An appliance supplied with a minim
18. purchased or fabricated sidewall vent caps should not be used DIRECT VENT AND INTELLI VENT SYSTEMS Direct Vent and Intelli Vent Systems are installed with a Category IV flue and a separate combustion air pipe to the outdoors The Direct Vent System terminates both the flue and combustion air inlet in the same pressure zone The Intelli Vent System terminates the flue and combustion air inlet in different pressure zones The flue outlet and combustion air intake may terminate with either a sidewall or a rooftop termination Follow all requirements in the General Category IV Venting sections for proper installation and venting of flue products vertically or horizontally to the outdoors other general installation requirements must be followed 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 double wall vent pipe or an Galvanized steel vent pipe with joints and seams insulated single wall pipe for combustion air is recommended to sealed as specified below help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe Type B double wall vent with joints and seams sealed as specified below Termination point for the flue products must follow the clearance requirements in the Vertical or Horizontal Vent Termination Plastic pipe m
19. 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 If air is taken from another interior space each of two 4 If a single combustion air opening is provided to openings specified above should have a net free area of one bring combustion air in directly from the outdoors square inch for each 1000 Btu 22 cm per kW of input the opening must be sized based on a minimum but not less than 100 square inches 645 cn free area of one square inch per 3000 Btu 7 cm per kW This opening must be located within 12 30 cm of the top of the enclosure CAUTIONA Under no circumstances should the mechanical room ever be under a negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the unit All dimensions based on net free area in square inches Metal louvers or screens reduce the free area of a 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
20. FIG 77 Location of Primary Heat Exchanger Locate the Hot Surface Igniter Disconnect the two power leads to the hot surface igniter Loosen and remove the two wing nuts that mount the igniter a t D Liftthe igniter vertically out of the burner mounting flange Use care do not hit or break the silicon carbide igniter 60 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 offall 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 Remove and clean if necessary 8 Remove soot from heat exchanger with stiff FIG 78 Location of Secondary Heat Exchanger bristle brush Use a vacuum to remove loose soot from surfaces and inner chamber 1 Turn off all power to the appliance 9 The heat exchanger be removed by 2 Tum offmain gas to appliance disconnecting all water piping to the bypass and secondary heat exchanger removing the screws holding the heat exchanger to t
21. LBL9058 REV A ACCESSORY INTERFACE DETAIL REAR VIEW FIG 46 Component and Auxiliary Controls Connections with Junction Box o o mim mame O o o o m ee Q s e e ALARM SOUND ALARM POWER gt K C ici gt T o SILENCE o o o o C LOW WATER CUT OFF AUTO RESET TEST o o o RUN STOP 2 g Prom o o o o FIG 47 Front Control Panel Locations 35 HI LIMIT RELAY ALARM RELAY IGNITION RELAY TRANSFORMER MAIN GAS amp VENT OPTIONAL LOW VALVE RELAY PWM CONV WATER CUTOFF TRANSFORMER LOUVER RELAY VFD ps RELAY i t fe 0 00 5 oJ oJ o ET o url _ _ DEG Z 2z Zj 1 1 ed c p STR g a aaa C CAT CA EN o a FIG 48 Transformer and Relay Locations HM it fi lis 49 Internal Control Panel Location A transformer and relay mounting panel is lo
22. TT PTT o BE pa 29 591 mus XB 5 als 215 H o RA CAP ELE EE TUE EE EE TTT TITLE HEEL UE UE IEEE UE UE UE EEUU ELE 39 Secondary Heat Exchanger A secondary heat exchanger is mounted in an inner jacket chamber at the rear of the appliance The secondary heat exchanger is constructed from two glass lined cast iron headers and multiple hor izontal 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 BYPASS VALVE PRIMARY HEAT EXCHANGER FIG 40 Bypass Piping with Valve Actuator and Pump temperature conformal coating to prevent any corros
23. 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 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 gt 04 zi p 00000 2206 E BUS OUT
24. a higher than programmed temperature has been reached Setpoint Temp This is the lowest boiler operating temperature that the boiler will maintain when the outside air temperature is at the O A Max This setting is a Changeable Point from the Command Display Calculated Set Point The water 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 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 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 t
25. any building Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade The bottom of the vent terminal shall be located at least 12 inches 30 cm above grade and above normal snow levels To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc Flue gases from this appliance may contain large amounts of water vapor that will form a white plume in winter Plume could obstruct a window view Flue gas condensate can freeze on 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 WIRE TIE 4 T d 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
26. appliance off Remove the four 4 screws securing the top cover to the condensate trap and remove the cover Figure 73 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 1t and drain Verify there is nothing under the ball causing it to not seat properly Replace the top cover on the condensate trap Re install the four 4 screws removed in Step 9 to secure the top cover A 1 2 pipe connection is supplied on the condensate trap Connect a suitable pipe or tube to this connection see Figure 73 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 Failure to follow this warning could result in product damage or improper operation personal injury or death NOTE Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 13 Slope the condensate line down and away from the appliance into a drain or condensate neutralizing filter Do not expose the condensate line to freezing temperatures NOTE The condensate line must remain unobstructed
27. boiler controls and pump Ensure that the electrical service s is adequately sized Review wiring to an energy management system and wiring to any remote temperature sensors Boiler Set Up 13 14 15 16 Ensure that the boiler and piping system are full of water Bleed all air from the secondary loop and bypass piping on the boiler Check system for any water leaks Check system for installation of glycol or water treatment Turn on power to the primary system pump and the integral boiler secondary pump and verify operation Boiler Operational Checks 17 18 19 20 2 22 23 24 25 26 27 Turn the boiler main power switch to the ON position and the run stop switch to the STOP position Verify operation of the Excel 10 and Command Display Program the adjustable points from the Command Display Turn the run stop switch to the RUN position to start boiler operation Note The bypass must go through synchronization process before start up begins Push the resets for low water level high water temperature and flame failure 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 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 Verify operation of safe
28. fire department 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 attempted repair may result in a fire or explosion 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 LIGHTING INSTRUCTIONS STOP Read the safety information 1 Set the Temperature Set Point function of the Command Display to the lowest setting 2 Turn Off all electrical power to the appliance This appliance is equipped with an ignition device which automatically lights the burner DO NOT try to light the burner by hand Turn the main manual gas cock handle clockwise to the OFF position 1 2 3 4 5 6 TURN TO OFF POSITION ae FIG 74 Gas Cock with Handle in OFF position 8 Wait five 5 minutes to clear out any gas If you smell gas STOP Follow B in the safety 9 information If you don t smell gas go on to the next step 10 T Turn the main manual gas cock handle counterclockwise to the ON position 11 1 TURN TO ON POSITION 4 FIG 75 Gas Cock with Handle in ON position 5 8 Tu
29. 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 CAUTIONA FIG 81 Primary Secondary Piping of Multiple Boilers TO SYSTEM 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
30. heads with caulking Install the screen assembly using the stainless steel screws provided in the kit Install the Category IV vent pipe from the appliance to the vent cap The installed vent pipe must protrude at least 2 inches 5 1 cm into the screen area beyond the thimble portion of the sidewall cap assembly See detailed instructions packed with the sidewall vent kit Follow all requirements in the General Category IV Venting sections for 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 LOCATION OF A SIDEWALL VENT TERMINATION Follow all General Category IV Vent Termination Clearances 10 MIN HORIZONTALLY FIG 19 Sidewall Venting Installation with Clearances from Vent Cap The vent cap shall terminate at least 3 feet 0 91 m above any forced air inlet within 10 feet 3 05 m horizontally The vent cap MUST NOT terminate below a forced air intake at any distance The vent shall terminate at least 4 feet 1 22 m below 4 feet 1 22 m horizontally from or 1 foot 0 30 m above and 2 feet 0 60 m horizontally from any door window or gravity air inlet to the building The sidewall vent termination must be at least 8 feet 2 4 m horizontally from any combustion air intake located above the sidewall termination cap
31. maximum total length of the sidewall or vertical roof top UL Standard 723 or 181A P or a high quality combustion air inlet pipe as installed from the appliance to the air UL Listed silicon sealant such as those inlet cap must not exceed 100 equivalent feet 30 5 m in length manufactured by Dow Corning or General Subtract 5 feet 1 52 m of equivalent length for each 90 elbow Electric 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 b Do not install seams of vent pipe on the pipe system bottom of horizontal runs Do not exceed limits for the combustion air inlet piping lengths c Secure all joints with a minimum of three sheet metal screws or pop rivets Apply aluminum Air Inlet Pipe Materials foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe The air inlet pipe s must be sealed Choose acceptable combustion air inlet pipe materials from those specified in this section d Ensure that the air inlet pipes are properly supported The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used The PVC CPVC PVC CPVC or ABS 6 7 or 8 LD ABS Dryer Vent or Flex Duct air inlet pipe should use a silicone Select air inlet pipe material from the following specified materials Dryer Vent or Seal
32. 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 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 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 OF
33. 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 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
34. placed into normal service 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 cannot be maintained above a pH of 6 0 the calcium carbonate must be recharged Recharge packages of reagent grade calcium carbonate are available from your distributor WARNINGA Use a level to ensure that the condensate trap is level on its base Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap Failure to follow this warning could result in product damage or improper operation personal injury or death NOTE Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 OR D2845 Cement and prime must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement BURNER REMOVAL AND CLEANING Access to the burner will require the following s
35. potable water exceeding these specifications Heating of high hardness and or high total dissolved solids water may require a 1 Temperature rise can be increased by slowly larger circulating pump an optional cupro nickel heat exchanger closing the field installed ball valve in the outlet piping from the water heater to the storage tank to achieve the proper temperature rise 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 Once temperature rise has been properly set 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 WARNINGA 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 Moving the bypass handle while appliance is firing can result in abnormally high water temperature that may
36. presence of an Optional Sequencer if equipped BOILER 12 SETPOINT TEMP MAX SETPOINT MIN OPERATING SENSOR 1501 F 220 0 F 101 F RETURN IN EFF OPT RT BOILER 12 SEQUENCING TYPE HEATER 1 0 Back Select SCREEN 9 FIG 57 Command Display Data Screen OUTDOOR RESET FUNCTION SELECTIONS Optional on Heating Boilers Only As an option the Excel 10 control may be equipped with an outdoor reset 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 Max The warmest outdoor air temperature where the boiler reset function will begin to func
37. 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 The appliance has an integral circulating pump mounted in the bypass piping The pump has a 3 4 H P motor
38. section Chemistry 3 The diameter and length of the piping installed HEAT EXCHANGER between the storage tank s and water heater must be properly sized based on the equivalent length This is a highly sophisticated heat exchanger system designed to specifications carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build up of impurities The 4 The pump must run continuously when the water Straight line four pass design of the tubes sends water into the heater or hot water supply boiler is firing This is the headers at a properly rated velocity The configuration of the standard operating system for a water heater or hot headers in turn creates a high degree of turbulence which is water supply boiler sufficient to keep all contaminants in suspension This scouring action provides greater cost savings for owners Tubes are always An intermittent pump control function with an all bronze pump able to transfer heat at peak efficiency Every surface within this is installed as standard equipment on all water heater systems Water containing section is of a non ferrous material providing The pump will operate only while there is a Call for Heat and Clear clean rust free hot water Straight copper tubes finned on for a timed period after the water temperature set point is satisfied the outside for maximum heat transfer and glass lined cast iron to remove any residua
39. that condensate formation occurs only Electrical shock hazard Turn off power to the boiler before in the Secondary Heat Exchanger any service operation on the boiler except as noted otherwise in this instruction manual Failure to turn off Heat Transfer Process electrical power could result in electrical shock causing severe personal injury or death 28 Burner Input continues to increase until water temperature reaches the Set Point temperature 57 MAINTENANCE amp ANNUAL STARTUP TABLE CC SERVICE amp MAINTENANCE SCHEDULES Service technician Owner maintenance General Check boiler area Address reported problems Check pressure temperature gauge Inspect interior clean and vacuum if necessary Inspect and clean condensate trap Check for leaks water gas flue condensate Bde vent piping Verify flue and air lines in good condition and Check air piping sealed tight Check air and vent termination screens Check system water pressure system piping expansion tank Check relief valve Check control settings Monthly Check ignition and flame sense Check condensate drain system Check wiring and connections Check automatic air vents Perform start up checkout and performance verification per Intelli Fin Installation and Test low water cutoff if used Operation Manual ANNUAL START UP Reset button low water cutoff Flame inspection stable uniform Flame signal atleast 7
40. 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 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 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 d
41. 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 CONSTRUCTION AIR FILTER 2 EDGE OF SCREEN 7 i
42. valve stuck in the open position air venting burners and the combustion process Blower will remain on Three Flashes Lockout due to flame failure push reset button on inner control panel after correcting ignition problem Initial heater start up without properly bleeding air from the gas line may require multiple reset functions to achieve proper ignition Four Flashes Igniter failure igniter will not maintain minimum 2 7 amp current draw caused by low voltage bad wiring continuity high resistance or igniter failure Five Flashes Power supply problem check for low supply voltage or transformer output less than 18 VAC Six Flashes Replace ignition module internal fault 50 OPERATION DIAGNOSTIC LIGHTS RESETS AND SWITCHES BURNER ADJ CIRCUIT HHLIMIT BREAKER ALARM SOUND SILENCE LOW WATER CUT OFF AUTO RESET TEST FIG 66 Exterior Control Panel The control panel has a lighted ON OFF power switch and 11 EEG Gt Burner Assembly indicating lights and switches to show operation control sensed malfunctions and diagnostics Indicator Power Alarm Silence Alarm Light High Limit Light High Limit Knob High Limit Reset Circuit Breaker Low Water Cut Off Test Switch Reset Switch Command Display Run Stop Switch Ignition Control Flame Failure Re
43. wash the tubes to ensure that all surface deposits are removed from the exterior of the heat exchanger surfaces 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 9 Carefully reinstall the heat exchanger if removed from the appliance 10 Reinstall inner rear jacket panels bypass piping and condensate hoses Use new gasket material to ensure a proper air seal 11 Reassemble all water piping Test for leaks 12 Reassemble rear outer jacket panels 13 Cycle unit and check for proper operation H LUBRICATION Combustion Air Blower Each combustion air blower should be checked every 6 months Clean internal filter to blower as required when installed in a dust or dirt contaminated location See Combustion Air Blower in the 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 ap
44. 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 1s 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 FIG 41 Bypass Valve and Actuator Assembly 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 p
45. with return temperatures set point below the specified minimum settings may experi ence operational problems with the operating controls and safety switches obstruction of the flue gas passages on the primary heat exchanger incomplete combustion and possible flue gas spillage Operation at lower than specified water temperatures may cause hazardous conditions that result in non warrantable damage to the appliance 105 F 40 6 C 1 700 000 90 F 32 2 C The maximum temperature set point that can be programmed into the Excel 10 controller from the Command Display for water heater operation is 190 F 87 8 C The Excel 10 control is factory pre set at approximately 120 F 48 9 C Facilities with small children or invalids may require 120 F 48 9 C or lower temperature setting to reduce risk of scald injury Some states may require a lower temperature setting Check with your gas supplier for local requirements governing the temperature setting Remember no water heating system will provide exact temperature at all times Allow a few days of operation at this setting to determine the correct temperature setting consistent with your needs The following chart Table JJ details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications TABLE JJ APPROXIMATE TIME TEMPERATURE RE LATIONSHIPS IN SCALDS 120 F Mor
46. AK3002 Flue Size Input Btu hr 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 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 Intelli Vent systems are installed with a Category IV flue anda separate combustion air pipe to
47. Air Blower Inlet Filter CONDENSATE MANAGEMENT conan roe SYSTEM Optional 4 NEUTRALIZER RESERVOIR Lal 3 4 HOSE OMITTED FOR CLARITY FIG 72 Condensate Drain Location On Rear of the Appliance Operation of the appliance in a full condensing mode for extended periods of time may produce flue gas condensate in amounts up to the following volume FIG 71 Location and Connection of Neutralization Reservoir TABLE BB Approximate Maximum Condensate Volumes Model Input Btu hr Gallons Per Hour 1 500 000 1 700 000 2 000 000 53 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
48. ECKING 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 E 1 Open the front controls panel and swing the utility gas supplier quaes Installer r controls out Locate the pressure test tree on the agency to stapa to provide front edge of the combustion air blower The positive and negative gas pressure terminals will be used to ias check differential gas pressure from the gas manifold i qu SUDO and the air box Each gas pressure connection t t 1 proceed 1o pos os Mo and Pipe point will have a small manual cock to attach a hose pressure tap fittings in the gas piping to the appliance 2 Connect a hose from the positive gas and the negative Turn the power switch to OFF position gas to each of the two sides of a manometer This will P P allow the two pressure points to be measured at Shut off gas supply at the manual gas cock in the the same time Open the two gas pressure test
49. F 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 Ifthe 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
50. IFB IFW I S 06 INSTALLATION AND SERVICE MANUAL FIG 1 Front View Installation and service must be performed by a qualified service installer service agency or the gas supplier WARRANTY Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 Excessive water hardness causing lime scale build up in the copper tube is not the fault of the equipment and is covered under manufacturer s warranty See Water Treatment and Water Chemistry 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 Intelli Fin Hot Water Heating Boilers Domestic Hot Water Supply Boilers 1 500 000 1 700 000 2 000 000 Btu hr Models CERTIFIED FIG 2 Rear View SPECIAL INSTRUCTIONS TO OWNER NOTE Retain this manual for future reference 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 WARNINGA IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE can
51. ILER 10 FLAME FAIL MAX SETPOINT BOILER 11 STANDBY MIN SETPOINT V_ MORE V CONFIGURE V_ MORE V CONFIGURE Back Select Back Select SCREEN 2 SCREEN 5 FIG 560 Command Display Data Screen FIG 56e Command Display Data Screen HEAT SOURCE BOILER 12 BOILER 12 STANDBY TOTAL RUN TIME 987 00 HR BOILER 13 STANDBY SEQUENCING TYPE EFF OPT RT BOILER 14 H20FLOW OK PERCENT MODULATION 0 00 BOILER 15 AIRPRES OK AUXILIARY RELAY OFF BOILER 16 OFF LINE PERCENT BYPASS 50 00 BYPASS TEMP 1502 F v NORE V CONFIGURE MORE V CONFIGURE Back Select Back Select SCREEN 3 SCREEN 6 FIG 56c Command Display Data Screen FIG 56f Command Display Data Screen 42 BOILER 12 OPERATING SENSOR RETURN IN HEATER PUMP OFF HEATER 1 BOILER 12 CONFIGURE Back Select SCREEN 7 FIG 56g Command Display Data Screen STATUS POINTS In the screen display for a specific boiler or water heater there will be a Status indication The status point details the operational mode of the appliance or in the event of a control sensed failure a status point alarm The status point alarm mode indicates the reason for the control sensed shut down of the appliance POWER UP AND NAVIGATION BETWEEN THE SCREENS OF THE COMMAND DISPLAY The first screen is viewable on the Command Display as it is powered up This Command Display screen gives the current software version running on the Excel 10 This screen goes away after 60 seconds The am
52. N OF UNIT 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 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 DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present 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 The appliance must be installed indoors where it is protected from exposure to wind rain and weather This appliance may
53. Sw a FF High NO PROBE 24 VAC FLOW No c 2 SWITCH Gaso c 1 c CONTROLLER o 1 NC tof NCL we VFD RESET re TO vo NC i R NC a on CONTROLLER H LOUVER RELAY ee INPUTS d S b a e RELAY RESET GROUND STD CONTACTS NO CONTACTS ALARM mDicAroR STD REAR i OVER TEMP COMMUNICATION INDICATOR CABLE CONNECTION No SILENCE SWITCH ALARM NC 24VAC our o 1 CONTROL PANEL R ALARM COMMUNICATION ALARM RELAY RELAY CABLE CONNECTION R BYPASS IGNITION RELAY VALVE 0 CONTROLLER 24VAC DIP SWITCH 5 ON CONTROLLER COMMUNICATION B H PWMH 20nfa CABLE 2 e of 8 nla se s o art lee perro mE Ju BEI 8 4 Dial Alarm INPUTS 8 Float Close qs B 2 lt 5 14 Float Open Hi LoGas desees BLK DRAIN CES amp 8 1 i Ignition Enable Pose g NOTICE ENABLE 3114 na LowAir Block Drain 6 ET g sey 5 PumpRelay OA Sensor or seme d gil 24VAC p B ADJUST P s r A Hes Bypass Water Sens O 1 BYPASS SENSOR BYPASS Outlet Water Sensor 2 oO Senso E 814 SENSOR OPTIONAL InletWaterSensor CO toi IER ei Low Wtr Fk 5 5 UEM B OUTLET OUTLET Flame Fail ugg A SENSOR SENSOR SENSOR G
54. The differential air pressure should be 3 5 inches of water column 0 1 w c when the burner is firing at 10096 of rated input If the differential air pressure is not 3 5 inches 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 1 Pump Operation MOST IMPORTANT This water column 0 1 w c review the installation appliance is designed for continuous pump Check for proper installation of the venting operation when the burners are firing The integral system Review the venting requirements this circulating pump will run continuously when the power manual for the specific venting system installed switch is in the ON position and the run stop switch is with this appliance Correct as required Ensure in the RUN position As an optional feature an that an adequate supply of combustion air is intermittent pump control system can be provided The supplied to the appliance If a separate pipe is used intermittent pump option allows the integral circulating to supply combustion air ensure that it is installed system pump to be c
55. 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 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 24 hour time period If no opportunity is given to cycle the control will not interrupt action to equalize runtime None This is the default for any boiler or water heater control which has not purchased one of the Sequencing Option Packages 45 INTERFACING MULTIPLE star loop and or bus wiring The maximum number of nodes per segment is 60 The maximum number of nodes in a two segment APPLIANCES FTT network is 120 when using a repeater between the two segments Consult factory for additional information on interface wiring of multiple ntelli Fin appliances connected to an EMS 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 loc
56. ages 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 105 F 40 6 C 1 700 000 90 F 32 2 C 2 000 000 70 F 23 9 C 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 non warrantable failures of the boiler MAXIMUM FLOW FOR HEATING BOILER CAUTIONA The maximum flow rate through the boiler with a copper heat exchanger must not exceed the following Btu hr Input Maximum Flow 1 500 000 2 000 000 90 GPM If higher flow rates are required through the boiler an optional Cupro Nickel heat exchanger is available Consult the factory for specific 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 r
57. 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 REMOVE SCREWS QTY 4 REMOVE COVER CHECK PLASTIC BALL FOR SEDIMENT BUILDUP AND PROPER SEATING BLOCKED DRAIN SWITCH lt CONDENSATE TRAP ATTACH HOSES TO BARB WIRE HARNESS CONNECTIONS CONNECTOR TO THE ON THE BLOCKED DRAIN SWITCH 4 amp MOUNTING BRACKET CONDENSATE TRAP ATTACH MOUNTING BRACKET TO THE BACK OF THE APPLIANCE USING THE 2 SCREWS PROVIDED IN THE KIT FIG 73 Install Condensate Trap FOR YOUR SAFETY READ BEFORE OPERATING WARNINGA 55 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 automati cally lights the burner Do not try to light the burner by hand BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbors phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the
58. asic may vaty from 25 up to 10076 of rate based on demand thermometer function to display outlet water 16 Auxiliary Relay The ON or OFF status of an temperature additional relay to indicate a specified function of Temp Rise The difference between inlet and the unit outlet water temperature at the boiler or water 17 Percent Bypass The percent that the bypass valve is heater to show the water temperature rise open to allow heated discharge water to be Status Displays current status of the control as recirculated into the inlet of the primary heat exchanger the appliance is going through its firing sequence in order to control formation on the primary and possible faults that could occur and the heat 0 indicates that the valve is fully condition of cach See Statis Point Modes and closed and 100 indicates that the valve is fully open Alarms The percentage will vary with valve operation Lockout The maximum outdoor air 18 Bypass Temp NS A display of the water temperature where the boiler will continue to temperature the inlet to the primary heat operate When the outdoor temperature rises exchanger after being mixed with hot discharge above this setting no heat should be needed for water from the bypass piping when the bypass the building and the boiler will lockout and not valve is open fire 19 Operating Sensor A display which indicates O A Max The warmest outdoor air tempera
59. ate 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 BOILER TEMPERATURE RISE CHART TABLE EE Temperature Rise at Full Rate Fire Bypass Fully Closed and 90 GPM Flow Btu hr Input Temperature Rise 1 500 000 31 5 F 17 5 C 1 700 000 35 7 F 19 8 C 2 000 000 42 0 F 23 3 C 67 TEMPERATURE PRESSURE GAUGE im 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 General Plumbing Rules 1 Check all local codes 2 For serviceability of boiler always install unions 3 Always pipe pressure relief valve to an open drain 4 Locate system air vents at highest point of system 5 Expansion tank must be installed near the boiler and on the suction side of the system pump 6 Support all water piping PLACING THE BOILER IN OPERATION Pre Star
60. ated at less than 12 PSIG Hot water piping must be supported by suitable hangers or floor stands NOT by the boiler Copper pipe systems will be subject to considerable expansion and contraction Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system Padding is recommended on rigid hangers installed with a copper system The boiler pressure relief valve must be piped to a suitable floor drain See the relief valve section in the In stallation and Service Manual CAUTIONA A leak in a boiler system will cause the system to intake fresh water constantly which will cause the tubes to accumulate a line scale build up This will cause a NON WARRANTABLE FAILURE WATER CONNECTIONS HEATING BOILERS ONLY All boilers have 3 inch 76 2mm copper pipe inlet and outlet connections 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 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 inc
61. ations and misplaced or missing terminations Wire to the terminal blocks as follows NOTE FIG 59 E Bus Connection to Controls When attaching two or more wires to the same terminal twist wires together see Fig 60 Deviation from this rule Connection between multiple Jntelli Fin appliances is can result in improper electrical contact 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 mm plenum or non plenum rated as applicable unshielded twisted pair stranded wire Use plenum rated wire where required See Wire Requirements for a listing of manufacturers who supply communication wire meeting this specification The twisted pair wire is used to make daisy chain connections between the E Bus terminals on multiple appliances The E Bus connection uses a Free Topology Transceiver FTT to support a polarity insensitive free topology wiring scheme for TABLE W Daisy Chain Doubly Terminated FTT Network Bus Topology Specifications Maximum FTT network Bus length Maximum node to node length Wire Cable Type for segment s in feet meters for segment s in feet meters Level IV 22 AWG unshielded twisted pair stranded communications wire use 4593 1400 PRS plenum rated wir
62. ay require an adapter not provided to transition sections of the Category IV Venting between the air inlet connection on the appliance and the plastic air inlet pipe CAUTIONA WARNINGA 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 Air Inlet NOTE Input Btu hr Flue Size Pipe Size The use of double wall vent or insulated material for the 1 500 000 combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air 1 700 000 2 000 000 Piping from the appliance to the air inlet cap may be either 7 Sealing of Type double wall vent material or galvanized vent or 8 An 8 diameter sidewall air inlet cap is provided in the pipe material used for air inlet pipe on a sidewall or vertical roof top vent kat Combustion Air Supply System Length of Air Inlet Pipe a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting The
63. cated 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 e ooo000000000 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 T
64. ch 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 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 TABLE Il Minimum Inlet Water Temperatures Minimum Setpoint Minimum Return Temperature Input Btu hr 1 500 000 50 F 10 C 50 F 10 C 2 000 000 50 F 10 C 70 F 23 9 C CAUTIONA An appliance allowed to operate
65. 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 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 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 IMPORTANT Examine the venting system at least once a year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration Immediately correct any prob lems observed in the venting system TABLE D The Category IV Flue Pipe Sizes Input Btu hr Flue Size 1 500 000 1 700 000 2 000 000 Category IV Venting A CATEGORY IV POSITIVE PRESSURE VENTING SYSTEM FIG 10 Basic Category IV Venting Vertical FIG 11 Basic Category IV Venting Horizontal A Category IV venting system for the flue products is required on all models of this appliance A Category IV venting system operates
66. condense the products of combustion when operating at water temperatures below 130 F 54 4 C Ensure that the appliance is located near acceptable drain where condensate from the heat exchanger and venting system may be properly collected neutralized and disposed TABLE Clearances from Combustible Construction Right Side 0 Rear 9 23 cm Minimum 24 0 61 m suggested for service to pump and components Left Side 0 Front ALCOVE Minimum 24 0 61 m suggested for service Flue 1 25 4 mm Hot Water Pipes 1 25 4 mm An ALCOVE is a closet without a door RECOMMENDED SERVICE CLEARANCES eT 0 LEFT MIN c 24 FRONT MIN MIN RIGHT SIDE Bs 24 REAR MIN FROM PIPING FIG 3 Recommended Service Clearances Front FIG 4 Recommended Service Clearances Rear NOTE Clearances from combustible construction are noted on the appliance rating plate Maintain minimum specified clearances for adequate operation All 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 Multiple appliances may be installed in a modular boiler or water heater
67. cted in Figure 73 Use the pre drilled holes on the appliance to secure the mounting base to the appliance 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 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 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 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 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 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 If spillage is still occurring shut the
68. d 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 Flue Air Inlet Sidewall Air Cap Cap Inlet amp Flue Size Size Cap Kit HDK3018 HDK3019 Input Btu hr 1 500 000 1 700 000 2 000 000 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 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 foo
69. 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 10096 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 TABLE DD Minimum Inlet Water Temperatures Minimum Setpoint Minimum Return Temperature Input Btu hr 1 500 000 50 F 10 C 50 F 10 C 50 F 10 C CAUTIONA 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 pass
70. e COMMON BK a SER 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 CLOSED INPUT 120VAC l owner s manual for routing and pin outs for all connector blocks OPEN INPUT our 5 Pump delay is standard on water heaters Z contacrs LBL90002 REV A OPEN ONTACTS 79 Revision Notes Rev 4 IFB IFW i amp s 04 reflects additional text on Page 39 changes made to Figures 47 amp 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 5 83 86 edits made to FIG 80 pg 66 and a title change on FIG 5 3 and 4 on page 4 Revision 6 ECO C04349 reflects the addition of a maintenance table and a condensate testing section 80 8 09 Printed in U S A
71. e 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 FORA HEATING BOILER SYSTEM If Required 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 CAUTIONA DO NOT use undiluted or automotive type antifreeze 2 A solution of 50 antifreeze will maximum protection of approximately 30 F provide Follow the instructions from the antifreeze manufacturer Quantity of antifreeze required is based on total system volume including expansion tank volume 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 Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system WATER TREATMENT In hard water areas water treatment should be used to reduce the introduction of minerals to the syste
72. e 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 DIAPHRAGM GAS VALVE FIG 44 Diaphragm Gas Valve A diaphragm type gas valve is also provided in the gas train As the second valve seat in the gas train it supplies a redundant safety shutoff valve seat in the gas supply to the burner to ensure safe operation in the remote event of a gas valve failure The diaphragm gas valve is energized with 24 VAC power at the same time the ratio gas valve is powered in the 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 functi
73. e boiler is waiting for a call for heat Checking operation of flow switch to verify water flow from the pump Low air switch verifies operation of combustion air blower Verifies that the condensate drain flow to the optional Condensate Management System is not blocked Verifies gas pressure at optional switch es high and or low Pre purge operation of combustion air blower Hot Surface Igniter On Burner On Temperature is beginning to rise 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
74. e gas train and controls assembly provided on this unit have been tested under the applicable American National Standard to meet minimum safety and performance criteria such as safe lighting combustion and safety shutdown operation RATIO GAS VALVE FIG 43 Ratio Gas Valve The main gas valve supplying gas to the burner on this appliance utilizes a pressure regulating electro hydraulic actuator providing a slow opening fast closing safety shut off and air gas ratio control for the gas combustion process This gas valve controls the pressure difference across the 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 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 valv
75. e 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 ofthe 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 i to drop lower Changeable Point from the NOTE Command Display Allow 10 seconds for data shown in the display screens to 10 Temp A display of the outdoor air temperature as sensed by the optional outdoor air reset sensor update when viewing or making adjustments to any of the six adjustable points past this point as outdoor temperature continues 41 SetPoint maximum water temperature POINTS FROM INFORMATION the boiler or water heater may be set to operate at Changeable from Command Display VISIBLE FROM THE SCREEN OF isplay THE COMMAND DISPLAY 12 Min SetPoin
76. e 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 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 BUILDING HOT WATER SUPPLY RELIEF VALVE TO DRAIN LOCK TEMP STORAGE TANK FIG 83 Typical Water Heater Piping
77. e than 5 minutes 125 F 1 1 2 to 2 minutes 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 remember Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the primary heat exchanger and operational problems The cold water supply piping must be installed in the discharge piping from the heater to the storage tank This allows the cold water to be tempered in the storage tank before entering the heater See typical installation drawings provided with the unit for correct piping Higher water temperatures reduce the volume of condensate formed CAUTIONA 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
78. e 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 31 5 F 17 5 C 1 700 000 35 7 F 19 8 C 2 000 000 42 0 F 23 3 C 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 WARNINGA Moving the bypass handle while appliance is firing can result in abnormally high water temperature that may cause sudden relief valve discharge BYPASS OPERATION 1 Main burner ignition 1s 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 water temperature to the primary heat exchanger 4 Inlet water temperature into the primary heat exchanger is displayed as Bypass Temperature in one of the 21 points on the Command Display 5 The floatin
79. e where required TABLE X Singly Terminated FTT Network Bus Topology Specifications Maximum FTT network Bus length Maximum node to node length Wire Cable Type for segment s in feet meters for segment s in feet meters Level IV 22 AWG unshielded twisted pair stranded communications wire use 1640 500 ee plenum rated wire where required STRIP 1 2 FROM WIRE TO BE ATTACHED TWIST WIRES TOGETHER WITH PLIERS MINIMUM OF THREE TURNS INSERT TWISTED WIRES UNDER TERMINAL AND TIGHTEN CHECK FOR A GOOD MECHANICAL CONNECTION FIG 60 Wire Termination for E Bus Connection 1 Strip 1 2 in 13 mm insulation from the conductor 2 Insert 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 9 Pull on each wire in all terminals to check for good mechanical connection 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 mn plenum or non plenum rated as applicable unshielded twisted pair stranded communication wire The following manufacturers supply communication wire that meets or exceeds th
80. eclutching 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 1s 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 ex changer 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 10096 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 prope
81. ed Flexible Duct not recommended for roof top air inlet 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 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 A 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 in 324 5 cm area each have a total area of 100 6 in 645 2 cm requires a 12 30 5 cm 113 1 in 729 7 cm common air inlet pipe The air inlet point for mul tiple boiler air inlets must be provided with an exterior opening which has a free area equal to
82. er 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 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 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 Turn on gas supply at the field installed manual gas cock turn on LP gas at tank if required Turn the power switch to ON position and ensure that the Run Stop switch is in the Run position Adjust the temperature setpoint on the Command Display to call for heat Observe the gas supply pressure as the burner fires at 10096 of rated input Percent of burner input will be displayed on the Command Display Ensure inlet pressure is within specified range Minimum and Maximum gas supply pressures are specified in Gas Supply section of this manual If gas pressure is out of range contact the gas CH
83. erformed by a qualified installer service agency or the gas supplier OWNER WARNINGA The information contained in this manual is intended for use by qualified professional installers service technicians or gas suppliers Consult your local expert for proper installation or service procedures IMPORTANT Consult and follow local Building and Fire Regulations and other Safety Codes that apply to this installation Contact the local gas utility company to authorize and inspect all gas and flue connections A gas appliance that draws combustion air from the equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting WARNINGA 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 WARNINGA To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules 1 Boilers and water heaters are heat producing appliances To avoid damage or injury do not store materials against the appliance or the vent air intake system Use proper care to avoid unnecessary contact especially children with the appliance and vent air intake components 2 Never cover your appliance lean anything against it store trash o
84. et cap MUST be at least 3 feet 0 91 m below the point of flue gas termination vent cap if it 1s 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 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 Multiple Vertical Direct Vent Installations FIG 22 M
85. etallic items will 14 Replace the insulation blanket flaps cause a rapid non warrantable failure of the burner on 15 Turn on main gas supply operation 16 Turn on main power NOTE 17 Test fire the appliance to ensure proper operation 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 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 Carefully pull back the insulation flaps to expose the burner mounting flange
86. 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 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 FIG 62 High Water Temperature Control temperature has dropped below the set point of the high limit 48 HOT SURFACE IGNITION SYSTEM IGNITION CONTROL MODULE 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
87. g 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 dia gram 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
88. g N CABINET AIR INLET OPENING 24 000 24 000 24 000 2 0 19 750 12 250 1 7 19 250 1 5 18 750 FIG 9 Construction Air Filter MEDIA OVERLAP E FOLD OVERLAP AROUND EDGE OF SCREEN AS SHOWN BAND CLAMP PUSH FILTER ONTO AIR INLET AND FASTEN WITH CLAMP AS SHOWN The construction air filter MUST be removed from the appliance s air inlet before the appliance is placed in normal operation Once the construction air filter is removed ensure that either the equipment room is supplied with combustion air from properly sized combustion and ventilation air openings or a combustion air duct from a Direct Vent or Intelli Vent system is connected to the appliance The optional Direct Vent and Intelli Vent venting 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 CONSTRUCTION AIR FILTER KITS TABLE C Construction Air Filter Kit Input Btu hr 1 500 000 KIT4000 KIT4001 KIT4002 VENTING Vent System Options 1 700 000 2 000 000 This appliance has three venting system options They are A Category IV Venting system with vertical roof top termination or sidewall termination ofthe flue and combustion air supplied from the mechanical room B Direct Ven
89. g 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 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 10 Operation of the bypass valve maintains water temperatures above the dew point of flue products at the primary heat exchanger to ensure that condensate formation occurs only on the secondary heat exchanger The use of a Floating Point Bypass Valve means that there is no fixed open or closed position on the valve If errant hands manual
90. gory 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 dete
91. h 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
92. he 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 TABLE L Nominal Manifold Pressure Settings at Full Fire Natural L P Input Btu hr Gas Gas 23 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 must be leak tested before placing it in operation GAS CONNECTION 1 Safe operation of unit requires properly sized gas supply piping See gas line sizing data 2 Gas pipe size may be larger than appliance connection 3 Installation of a union at the appliance gas line connection is 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 app
93. he 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 3 Break the union pump flange and bypass valve flange to remove the pump and external portion of the bypass assembly 4 Remove the inner jacket door 5 Check the heat exchanger surface for soot or fouling If soot is present heat exchanger must be cleaned and problem corrected 6 Check V baffles on the exchanger Remove and 10 Ensure that any soot present on the burner is clean if necessary removed See Burner Cleaning Procedure y 7 Remove soot from heat exchanger with a soft bristle brush Use care not to damage coating on the exterior of the secondary heat exchanger Use a vacuum to remove loose soot from surfaces and inner chamber 11 Carefully reinstall the heat exchanger and baffles if removed from the appliance 12 Reinstall inner jacket panels burner manifolds wires and hoses Use new gasket material to ensure a proper air seal 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
94. he 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 CAUTIONA The voltage output from the variable frequency drive to the combustion air blower is 230 volt 3 phase Avoid contact with high voltage wiring LOW AIR PRESSURE SWITCH PRESSURE SWITCH BLOWER 9 1 TRANSITION Ei l N BURNER FIG 51 Low Air Pressure Switch 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
95. in 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 CAUTIONA 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 FF Maximum Flow Rate Btu hr Input 1 500 000 2 000 000 90 GPM If higher flow rates are required through the water heater an optional Cupro Nickel heat exchanger 1s available Consult the factory for specific application requirements Maximum Flow 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 ntelli Fin with an automatic bypass is accomplished by disconnecting the power leads to the actuator multi pin connector on rear of appliance d
96. in 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 CHECKING GAS SUPPLY PRESSURE MANOMETER GAS PRESSURE MEASUREMENT FIG 35 Gas Supply Pressure Measurement Turn the main power switch to OFF position 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 Remove the 1 8 hex plug from the gas pressure test port located on the inlet gas supply 17 Check burn
97. in 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 achiev
98. 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 surfac es and no service access is required from the sides 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 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 5 Combustion Air Direct from Outside 1 If air is taken directly from outside the building with no duct provide two permanent ope
99. ional problems with the heater and possible spillage of flue products that can cause personal injury death or property damage Installation location and clearance requirements for the rooftop air inlet cap in an Intelli Vent application are the same as the installation location and clearance requirements for the rooftop air inlet cap in the Vertical Direct Vent section of the venting instructions The rooftop combustion air inlet cap and the sidewall flue gas outlet are located in different pressure zones in an Intelli Vent system 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 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
100. ire cycle Modulating burner control is not available with the manual override In addition the pump will run continuously Intermittent pump operation is not available with the manual override Modulation of the bypass valve may not be available with the manual override If the primary control failure is in a remote Sequencer the bypass valve should modulate If the Excel 10 inside the appliance has failed the bypass valve may not modulate The manual override is located on the back of the appliance below the bypass piping loop To the left of the thermostat is a toggle switch to alternate the control of the appliance from the primary control to the manual override thermostat Some models may have a reduced firing rate when manual override is activated To Activate the Manual Override 1 In the event of a failure of the primary control move the Stop Run switch on the front of the control panel to Stop N Move the toggle switch located on the back of the unit to Manual Override 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 f
101. is 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 amp Cable 800 257 7940 www eastmanwire com Honeywell Inc 800 345 6770 www honeywell com Lucent Technologies 305 569 3600 www lucent com netsys systimax Windy City Wire 800 379 1191 www smartwire com NOTE The minimum specification for Level IV 22 AWG 0 034 mm unshielded twisted pair stranded communication cable must be plenum rated when the wire is routed through air ducts or plenum areas Non plenum rated communication cable is for general use when the wire is not being routed through air ducts or plenum areas ADDITIONAL COMPONENTS USED TO INTERFACE MULTIPLE APPLIANCES Serial LonTalk Adapter SLTA A serial LonTalk adapter is required to provide communication between E Bus and either a PC serial port or an approved modem using the SLTA 10 EIA 232 port The SLTA interfaces with LonSpec software There are specific null modem cable requirements for proper connection to a modem The SLTA has a DB 9 female connection Direct connection to a PC can be made with a DB 9 to DB 9 cable or a DB 9 to DB 25 cable based on the available PC connecti
102. ive damage to the copper tubes or cast iron headers from the low pH condensate The protective coating 1s 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 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 va
103. l heat from the combustion chamber one piece cored headers make up an entirely rust proof unit On all models header inspection plugs in the primary heat exchanger 5 Lubricate pump to manufacturers recommendations can be removed for field inspection and cleaning of copper tubes Pump damage due to inadequate lubrication is Each of the heat exchangers may be removed from the unit non warrantable 74 THERMOSTAT SETTINGS 1 The Excel 10 temperature controller 15 to a low test setting when shipped from the factory adjusted 2 Using the Command Display adjust the temperature set point to the lowest settings which will satisfy hot water demands and prevent a risk of scald injury TEMPERATURE ADJUSTMENT MINIMUM WATER TEMPERATURES Domestic Hot Water Use Inlet water temperatures below the specified minimum recommendations can excessively cool the products of combustion resulting in condensation on the primary heat exchanger The water heater is designed to condense only on the secondary heat exchanger Condensation on the primary heat 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 ea
104. lay to the previous screen and a select key which highlights a field in the display There are also four softkeys along the right side ofthe display A notation on the specific screen defines the function of each of these keys The softkeys may be defined as configure change save cancel to increase a value or to decrease a value on the screen PASSWORD FUNCTION On initial operation of the ntelli 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 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 desi
105. liance 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 when required by local codes building TABLE M Recommended Gas Pipe Size Single Appliance Installations Distance from Meter Dm x s ox ow Lm m o 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 C ec es ri 1x2 2so isoo 12101020 923 s30 769 707 66 amp soa siz 4032 ar 4 zoo 1 100 13 100 11 106 10 000 9 000 8 300 7 690 730 6 870 6 150 5 640 130 4 720 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 ETE TES TESTE Te ede 24 GAS PIPING GAS INLET FIG 34 Gas Line Connection to Unit with Sediment Trap and Manual Main Gas Shut off Valve All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas All piping must comply with local codes and ordinances Tubing installatio
106. ll 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 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 ofthe common pipe as defined in the Direct Vent basic information section 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 VERTICAL INTELLI VENT WITH SIDEWALL COMBUSTION AIR FIG 27 Vertical Intelli Vent Installation Sidewall Combustion Air Inlet Intelli Vent systems are installed with a Category IV flue and a se
107. ly move the bypass adjustment handle it will take longer to adjust to the proper setting but it will still function properly to main tain water temperatures CAUTIONA 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 A boiler installed above radiation level must be provided with a TABLE Q low
108. m 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 WARNINGA 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 non warrantable property damage HEATING BOILER INSTALLATIONS PIPING OF THE BOILER SYSTEM 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 oper
109. microamps at high fire Check boiler piping gas and water for T Every leaks If combustion or performance indicate need 6 months Clean heat exchangers valve Remove and clean burner using compressed End air only of season e Clean the blower wheel months Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Shut boiler down unless boiler used for domestic hot water 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 76 Flame Pattern system as required Have the entire system including the venting system periodically inspected by a qualified service agency NORMAL BURNER FLAME ABNORMAL BURNER FLAME 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 B VISUALLY CHECK MAIN BURNER FLAMES at each partial obstruction of air flow to the burner start up after long shutdown periods or at least every six 3 Yellow Flames Yellow flames can be caused by blockage of months A burner viewport is located on the burner mounting primary air flo
110. 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 FLUE OUTLET 36 MIN iy d 7 AIR INLET 12 MIN FIG 23 Horizontal Direct Vent Installations with Sidewall Combustion Air Inlet SIDEWALL COMBUSTION AIR INLET 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 17 FIG 24 Sidewall Vent Cap The part numbers for the required sidewall air inlet cap kit are liste
111. ner is now in a soft start firing at 50 of rated input throughout this manual and in component literature shipped with the boiler Failure to perform the service and 23 Excel 10 Controller signals the Variable Frequency maintenance could result in damage to the boiler or system Drive to adjust blower speed based on desired Failure to follow the directions in this manual and water temperature Set Point component literature could result in several personal injury 24 Burner input rate is variable down to 25 of rate death or substantial property damage or up to 100 of rate as required to satisfy the Set Point programmed into the Command Display WARNINGA 25 Excel 10 Controller senses Inlet Water Temperature to the The boiler should be inspected annually only by a qualified Primary Heat Exchanger and provides a signal service technician In addition the maintenance and care of to adjust the floating point Bypass Valve the boiler designated in Table CC and explained on the based on return inlet control choice following pages must be performed to assure maximum 26 Bypass Vake to manam an duis boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment temperature to the Primary Heat Exchanger above the failure dew point of flue products 27 Operation of the Bypass Valve maintains water WARNINGA temperatures above the dew point of flue products to ensure
112. nings a Combustion air opening with a minimum free area of one square inch per 4000 Btu input 5 5 cm per kW This opening must be located within 12 30cm of the bottom of the enclosure b Ventilation air opening with a minimum free area of one square inch per 4000 Btu input 5 5 cm per kW This opening must be located within 12 30 cm of the top of the enclosure FIG 6 Combustion Air Through Ducts 2 lfcombustion 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 Input 2 Openings 1 Opening 2 Openings 500 in 3226 cm 1 500 in 9 677 cm 667 in 4303 cm 2 000 in 12 903 cm 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
113. ns must comply with approved standards and practices Install Piping to Control 1 The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier 2 Use new properly threaded black iron pipe free from chips If tubing is used make sure the ends are square deburred and clean All tubing bends must be smooth and without deformation Avoid flexible gas connections Internal diameter of flexible gas lines may not provide appliance with proper volume of gas 3 Install a manual main gas shutoff valve at the units gas inlet outside of the appliance and before the gas valve Install a union at the 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 the units gas inlet see Figure 34 supply line to 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 25 8 Connect gas pipe to inlet of appliance Use wrench to support gas manifold on the appliance 9 ForLP gas consult your LP gas supplier for expert installation GAS MANIFOLD PRESSURE ADJUSTMENT The manifold gas pressure on the Intelli F
114. ntal 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 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 a
115. o 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 NOTE Separate sequencers are required to control multiple boilers and water heaters l 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 First On Last Off This is a simple first on last off without rotation of the lead boiler or water heater 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
116. 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 WARNINGA Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance HIGH WATER TEMPERATURE LIMIT CONTROL A Manual Reset High Limit control is located on the left front of the left front side of the control panel beside the Command Display Additional switches alarm 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 exceed
117. om a draw of hot water from the storage tank Placing the sensor in the tapping ler Inr provided on the storage tank will improve temperature response Number of Units Size Min and prevent short cycles of operation when a water heater is equipped with the optional intermittent pump feature Btu hr Input Temperature Rise 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 PUMP OPERATION that the standard pump supplied on the water heater will maintain l The water heater or hot water supply boiler has a desired flow properly sized integral circulating pump This pump is sized to circulate water between the heater and storage tank only 2 The internal pump is sized to the heater input and Minimum pipe diameters and maximum length water chemistry specifications noted in Water specifications must be per the requirements in this
118. on 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 47 EXCEL 15 REPEATER REMOTE 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
119. on and Ventilation Air Requirements unless the appliance is equipped with an optional Direct Vent or Intelli Vent System A A amp 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 FIG 18 Sidewall Vent Cap TABLE E Sidewall Vent Cap Kits Sidewall Vent Input Btu hr Flue Size Cap Kit 1 500 000 SVK3026 SVK3027 SVK3028 1 700 000 2 000 000 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 ofthe 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 cap is installed from the outside and mounted to the wall with four screws or wall anchors Seal under the screw
120. on 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 ELECTRICAL CONNECTIONS ELECTRICAL JUNCTION BOX BK a CONTROL FIG 45 Electric Power Connections Controls and Pumps 120 VAC 15 Amp 1 ph 60 Hz circuit is required for operation of the integral circulating pump and a 120 VAC 15 Amp 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 The a
121. on of a negative draft flue into the positive pressure stack from this appliance may cause flue products to be discharged into an occupied living space causing serious health injury When a Category IV vent system is 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 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
122. ondensate 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 54 Condensate Trap Installation I 10 12 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 Install the condensate trap mounting base on the rear of the appliance in the lower left hand corner as depi
123. ontrols FLA Amps Btu hr 120 AC 1 500 000 1 700 000 2 000 000 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 ACCESSORY JUNCTION BOX REAR RIGHT VIEW COMMUNICATION OPTIONAL OUTDOOR AIR SENSOR BYPASS VALVE Y BKBL CLOSE COMMON OPEN BL 24VAC Y BELL ALARM OUTPUTS l CONTACTS LOUVER BR COMMON PU CLOSED INPUT OR BK OPEN INPUT LOUVER CONTACTS EXTERNAL GAS VALVE QI s hizovac our O w
124. 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 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 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
125. ot water supply boiler 2 Check diameter and equivalent length of the piping between the storage tank and water heater 3 Be sure all valves are open between the water heater or hot water supply boiler and the storage tank Ensure that all ball valves are fully ported 4 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 5 Be sure the pipes between the water heater or hot CHEMISTRY water supply boiler and storage tank are not less WATER CHEMISTRY than 3 inch 76 2 mm diameter for up to 70 equivalent feet 21 2 m of pipe to and from the NOTE heater If maximum equivalent length for the specified pipe diameter is exceeded larger diameter Water temperature rise and maximum flow data are based pipe may have to be installed to achieve correct flow on heating potable water with a hardness of 5 to 25 grains and temperature rise per gallon and total dissolved solids not exceeding 350 ppm 6 Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tank circulating tappings to ensure proper flow If the temperature rise is too low the water velocity is too high 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 Adjust as follows
126. ouble 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 CAUTIONA 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 1s 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 VERTICAL VENTING TERMINATIONS 11 Follow all General Category IV Vent Termination Clearances 10 OR LESS VAN
127. ount 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 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 Self Test Standby H2OFlow OK Air Press OK Drain OK GasPress OK PrePurge HSI OK Burner ON Heating PostPurge TABLE U Status Point Operational Modes Excel 10 self test period approximately 5 seconds during power up of Excel 10 There is no call for heat and th
128. ous conditions that may result in personal injury or non warrantable damage to the appliance 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 DIAPHRAGM VALVE gt RATIO VALVE gt 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 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 CAUTIONA Avoid contact with hot discharge water NOTE Th
129. p Kit SVK3026 SVK3027 SVK3028 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 20 VERTICAL COMBUSTION AIR INLET HORIZONTAL INTELLI VENT WITH SIDEWALL COMBUSTION AIR 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 Ifa 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 operat
130. p 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 10096 of rated input 62 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
131. parate 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 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 Termination point for the flue products must follow the clearance requirements in the Vertical Vent Termination section of the Category IV Venting CAUTIONZ Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance SIDEWALL COMBUSTION AIR INLET FIG 28 Air Inlet Cap for Sidewall Termination The air inlet cap for the sidewall air inlet must be purchased from the appliance manufacturer 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 TABLE H Air Inlet Pipe Size Sidewall Air Inlet Cap Kit SAK3000 SAK3001 S
132. 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 P d AND MAKEUP WATER SYSTEM 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
133. pliance 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 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 ORIFICE GAS 0 AIR BOX FRONT VIEW BLOWER GAS VALVE TOP VIEW MANIFOLD AIR PRESSURE 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 to
134. ppliance when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes 1 All wiring between the appliance and field installed devices shall be made with type T wire 63 F 35 C rise 2 Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 The pump must run continuously when appliance is being fired The Excel 10 temperature controller will energize the integral circulating pump for continuous operation when the main power switch is in the ON position and the run stop switch is in the RUN position If the internal water temperature drops below 45 F 7 2 C the pump will automatically cycle on to help prevent freezing see Freeze Protection 4 To avoid serious damage DO NOT energize the appliance until the system is full of water Ensure that all air is removed from the bypass piping before beginning initial operation Serious damage may result if the appliance is operated without proper flow 5 Provide the appliance with proper overload protection TABLE R AMP DRAW DATA 1 000 000 through 2 000 000 Btu hr Models APPROXIMATE TOTAL Blower amp Pump C
135. r debris near it stand on it or in any way block the flow of fresh air to your appliance 3 UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance vent air intake system or any location from which fumes could reach the appliance or vent air intake system 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 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 PROCEDURE LOCATIO
136. r heaters Custom software programmed into the Excel 10 will determine the proper operating profile for your specific application Ensure that an ntelli 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 zz s 2 22 20 7 4 GND 0 3 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 ope
137. r 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 71 TABLE GG Temperature Rise At Full Rate Fire Bypass Manually Fully Closed Btu hr Input 1 500 000 Temperature Rise 31 5 F 17 5 C 1 700 000 35 7 F 19 8 C 2 000 000 NOTE The Excel 10 controller makes all internal calculations in C and converts the displayed temperature to F This may 42 0 F 23 3 C limit exact temperature adjustment Setting of temperature rise to the nearest F is acceptable when setting maximum flow The pump must run continuously when the burner is firing 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 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 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 1 Check for restrictions in the outlet of the water heater or h
138. rational 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 15 bar code label on the back of the Jntelli 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
139. red 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 NOTE Once a password is correctly entered it will not have to be reentered unless five minutes of inactivity on the Command Display has elapsed CONFIGURING THE COMMAND DISPLAY When the CONFIGURE button on the right side of the Command Display is pressed a password screen will appear The user must enter the appropriate password and press SAVE to access the changeable screen Pressing this button provides access to a setup screen that allows the user to adjust such items as DISPLAY DEFAULT VALUES Default Option 50 0 100 OFF ON ON Contrast Backlight Mode AUTO Beep on New Alarm OFF Beep Rate 4 0s Time Format 12 24 Date Format MM DD YY DD MM YY Engineering Units English S I ACCESSING THE SIX CHANGEABLE POINTS FROM THE COMMAND DISPLAY 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 b
140. rmine the diameter of the common vent pipe required for a combined vent installation Any vent materials specified must be listed by a nationally recognized test agency for use as a Category IV vent material The venting system must be planned so as to avoid possible contact with 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 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 Connecti
141. rn on all electric power to the appliance 6 9 Set the Temperature Set Point function of the Command Display to the desired setting 7 10 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance g and call your service technician or gas supplier 56 TO TURN OFF GAS TO APPLIANCE Set the Temperature Set Point function of the Command Display to the lowest setting Turn off all electric power to the appliance if service is to be performed Turn the main manual gas cock handle clockwise to the OFF position WARNINGA Should overheating occur or the gas fails to shut off turn off the manual gas control valve to the appliance IGNITION SYSTEM CHECKOUT Set run stop switch to STOP position Set the Temperature Set Point function on the Command Display and high limit controls to the highest setting Turn electric power on Set run stop switch to RUN position Allow bypass to synchronize and safety switches to prove The igniter will cycle on trial for ignition The ignition module will lock out and indicate a flame failure through the appropriate flash code Readjust Temperature Set Point of the Command Display and high limit to normal settings Turn on gas supply Push the reset button to the right of the ignition module on the front control panel to reset ignition module If ignition system fails to operate properly repair work must be performed by a qualified
142. rt material This is normal burner operation FIG 68 Combustion Air Blower 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 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 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 inspec
143. ry 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 1s 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 HOT WATER OUTLET SECONDARY HEAT EXCHANGER 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 ofthe bypass valve actuator assures that water temperature in the primary heat exchanger is maintained high enough to prevent condensate formation on the primary heat exchanger BYPASS VALVE Synchronization As the main power is switched on and or when the run stop switch is placed in the RUN position the bypass valve will go through a synchronization process to establish a reference point for opera tion After the initial synchronization on start up the bypass will
144. s the Setpoint Temperature programmed into the Excel 10 control OPTIONAL RELIEF VALVE This water heater or hot water supply boiler is normally supplied with a temperature and pressure relief valve sized in accordance with 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
145. serviceman or installer SEQUENCE OF OPERATION The power switch is placed in the ON position and the run stop switch is in the RUN position 120 VAC Power is supplied to the control junction box and to the integral pump 120 VAC Power is supplied to the control Transformer Ignition Module and Excel 10 The bypass valve will synchronize on initial startup only 24 VAC is supplied to all low voltage controls Integral pump starts and is proven by a Flow Switch Command Display Set Point Operating Temperature is set to call for heat Excel 10 Controller initiates a start up sequence by checking the Temperature Sensors and input signals from the safety controls 9 Excel 10 enables the Ignition Module 29 Burner Input may stabilize at a fixed rate where 10 Ignition Module enables the Variable Frequency demand equals Drive 30 Burner Input will decrease rate when water 11 Excel 10 Controller drives the Variable Frequency temperature exceeds temperature and i demand Drive 12 The Variable Frequency Drive supplies the 31 xin fide E Seana i Combustion Air Blower with 230 VAC 3 phase 27 ses ene LO eae power water 13 Combustion Air Blower starts operation and drives to 10096 Rate of BUE product movement is controlled by V Baffles on the heat exchanger to maximize speed for prepurge heat transfer 14 Bl akes the i itch contacts t ble th I en Mn d
146. set TABLE AA Diagnostic Lights and Switches Function Lighted ON OFF Main Power Switch Rocker Switch to Silence an Optional Audible Alarm Amber Indicating Light for an Alarm Condition Red Indicating Light for Water Temperature Exceeding Maximum Setting of High Limit Control Adjustable Rotary Knob to Set Maximum Water Temperature Red Push Button to Reset High Limit when High Limit Setting is Exceeded Reset Button for a 5 Amp breaker on the 24 VAC Control Circuit Black Momentary Rocker Switch interrupts the sensing circuit of the Low Water Cut Off to prove operation 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 RUN allows normal operation STOP shuts down operation but allows communication with a network 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 mi
147. 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 Boiler Water Heater 130 0 F 120 0 F N A N A N A Setpoint Temp O A Lockout 70 0 F O A Max 60 0 F O A Min 10 0 F Max Setpoint 220 0 F 190 0 F Min Setpoint 100 0 F 50 0 F Return Inlet Return Inlet Operating Sensor 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 ent
148. soft lockout condition FIG 64 Hot Surface Igniter 49 Diagnostic Status Indication TABLE Y The ignition module has an LED that indicates the status of the Ignition and Control Timings ignition safety circuits The flashing operation of this LED indicates the diagnostic status of the ignition control module The Proven Pilot Hot Surface Ignition System following listing gives the flashing diagnostic status codes as Pre Ti signaled by the ignition module 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 lt 0 5 uA flame current Post purge Time IGNITION 30 Seconds 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 One Flash Low air check air pressure switch and hoses to pressure sensing points blower start up proving blower venting and sealing of pressurized chamber Note Brief flashing normal on blower startup Two Flashes Flame without call for heat check for a gas
149. stion 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 TABLE J Air Inlet Cap Size Sidewall Air Inlet amp Flue Cap Kit HDK3018 HDK3019 Flue Size Input Btu hr 1 500 000 1 700 000 2 000 000 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 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 po
150. 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 temperatur
151. t The minimum water temperature the boiler or water heater may be set to operate at This Calculated Set Point The water temperature as temperature is established in the configuration process adjusted by an optional outdoor reset function at the factory used on a heating boiler only If no outdoor reset function is used this displays the same 13 Total Run Time The accumulated number of temperature as the set point Outdoor Air Reset hours that the boiler or water heater burner has function not available on a water heater application been in operation Time is accumulated in one hour Set Point Temp The desired water temperature increments and can total up to 99 999 hours before as adjusted by the owner operator This becomes rolling over to restart the accumulation process the lowest boiler operating temperature when an 14 Sequencing Type The type of sequencing optional outdoor reset function is used Changeable Point selected for operation of multiple units FOFO from the Command Display FOLO etc when ordered as option See Return Inlet Temp The temperature of the water Sequencing Options Changeable Point from entering the boiler or water heater a basic thermometer the Command Display function to display inlet water temperature 15 Percent Modulation The percent of maximum Supply Outlet Temp The temperature of the input that the Dorner is firing at This water leaving the boiler or water heater a b
152. t 3 05 m radius of the flue outlet 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 IFLUE OUTLETS AIR INLET CAP FIG 26 Multiple Horizontal Direct Vent Caps Installed on a Sidewall 18 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 horizo
153. t Check List 1 Review the location of the boiler clearances from combustible surfaces and available service clearances 2 Review the installed Vent System Ensure that all vent components are Category IV material with adequate clearance from combustibles 3 Ensure that the boiler condensate drain and all vent system condensate drains are properly routed to an acceptable floor drain or neutralization system 4 Ensure that an optional condensate neutralization system is properly installed if required by codes 5 Review the vent termination point for proper location and clearances 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 T Review the water piping from the boiler to the system The boiler must be installed in a primary secondary piping system Review the diameter and equivalent length of the installed piping to and from the boiler to ensure proper flow 8 Ensure that a properly sized primary system pump is installed with an expansion tank 68 10 11 12 Check system pressure Ensure a minimum of 12 PSI and not more than the rated pressure of the relief valve Review the installed gas piping from the meter to the boiler Ensure that the gas pipe meter and any regulators are adequately sized Review the field wiring and electrical service for both the
154. t 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 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
155. tentially 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 L P Gas Natural Gas Max Inches Water Column 13 0 w c Min Inches Water Column 4 0 w c Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment MANIFOLD PRESSURE Manifold pressure is a differential pressure measurement made between the high and low pressure taps at the gas orifice and the 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 t
156. teps a Turn off main electrical power to the appliance b Turn off main manual gas shutoff to the appliance c Remove the outer control panel cover Open the control panel and remove the screws from the lower front edge of the radiused front outer Jacket panel Lift the edge of the radiused panel and locate the internal screws attaching the back edge of the radiused panel Reach through the control panel opening with a 5 16 nut driver and loosen the 2 internal screws holding the rear edge of the radiused panel Pull the panel slightly forward and remove it Remove the screws along the front and rear edge of the top outer jacket panel to remove the jacket top This allows access to the components in the top of the appliance d Disconnect the gas supply connection to the internal gas train at the field installed union Remove the air inlet pipe connection to the boiler water heater 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 Remove the sensing tubes from the air ratio gas valve to the combustion air blower Remove the 6 nuts holding the blower assembly to the blower and remove the blower assembly
157. the outdoors The Horizontal Intelli Vent system terminates the flue at the sidewall and air inlet at the rooftop The flue outlet and combustion air intake terminate in different pressure zones FIG 29 Horizontal Intelli Vent Installation Rooftop Combustion Air Inlet Follow all requirements in the General Category IV Venting sections for proper installation and of venting flue 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 In cold climates the use of type 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 CAUTIONA 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 TABLE Air Inlet Pipe Size Sidewall Vent Ca
158. 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 PRIMARY LOOP CIRCULATOR PUMP SPECIFICATIONS 1 Maximum operating pressure for pump must exceed system operating pressure 2 Maximum water temperature should not exceed nameplate rating 3 Cast iron circulators may be used for closed loop systems 4 A properly sized expansion tank must be installed near the boiler and on the suction side of the pump CIRCULATOR PUMP OPERATION Heating Boilers Only The boiler pump should run continuously when the boiler is firin
159. ties as necessary low water cut off high limit gas pressure etc Turn the run stop switch to the STOP position Verify that all adjustable points in the Command Display are set as required Reconnect the boiler set up any wiring disconnected during 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 WATER SM CHILLER FIG 82 Installation with a Chilled Water System Pipe refrigeration
160. tion 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 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 H20 Flow Low Air Press Low air condition exists Block Drain Blocked condensate drain exists Block Flue Gas Press Fail Flame Fail Soft Lockout Over Temp Low water or flow condition exists Blocked flue or louver proving switch failed to prove Low or high gas pressure condition exists Hard lockout on a flame failure signaled from the ignition control Wait period for the ignition control to recover from soft lockout conditions Indicates that
161. tion port and clean with soapy water or compressed air 52 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 ofthe i cw appliance cabinet All condensate piping and connections must be easily accessible for routine maintenance and inspection Sufficient ACCESS PLATE 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 ofthe appliance FIG 70 Cleaning the Internal Combustion
162. 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 1f longer piping distances are required for a specific application PRIMARY HEAT EXCHANGER FIG 38 Primary Heat Exchanger This appliance uses two finned copper tube heat exchangers to maximize the heat transfer process The primary heat exchanger is mounted in the inner jacket on the front side of the 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 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 PTT TTT
163. to supply combustion air from outdoors directly to the appliance FIG 31 Horizontal Intelli Fin Installation with Sidewall Combustion Air in a Different Pressure Zone In cold climates the use of type double wall vent pipe or an insulated single wall pipe is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe Termination point for the flue products must follow the clearance requirements in the Horizontal Sidewall Vent Termination section of the Category IV Venting CAUTIONA 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 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 combu
164. tside air may be pulled down the flue and freeze direct vent combustion air pipe will operate at the a heat exchanger This condition must be corrected to correct air pressure differential as the burner input provide adequate freeze protection varies with temperature demand 4 A motor driven damper may be installed in the air inlet to Close the two air pressure test cocks on the prevent cold air movement in cold climates The damper pressure test tree and remove the hoses to the MUST be interlocked with boiler water heater controls to manometer open and prove on a call for heat 5 Freeze protection for a heating boiler or hot water Close the front control panel L COMBUSTIBLE MATERIALS 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 CAUTIONA Keep appliance area clear and free from combustible Shut down and Draining If for any reason the unit is to be shut off the following precautionary measures must be taken 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 ofthe appliance Open the relief valve and manually open the bypass valve to allow air into the system so the water will drain out Open th
165. ture the location of the operating sensor in the unit where the boiler reset function will begin to The operating sensor may be in the function and operate the boiler at the initial Return Inlet or Supply Outlet of the boiler or water set point temperature The boiler set point will heater Changeable Point from the Command Display increase based on a corresponding drop in outdoor 20 Heater Pump The ON or OFF status of the temperature below this temperature integral circulating pump for the boiler or water O A Min The coldest outdoor air temperature heater where the boiler reset function will reach a 9 Heater I D An indication of whether the unit maximum boiler water temperature No additional is a boiler or water heater Changeable Point reset increase in boiler temperature will occur from the Command Display HEAT SOURCE BOILER 12 AUX SEQUENCER HEATING CALCULATEDSETPOINT 150 1 F BOILER 01 HS OK SETPOINT TEMP 150 1 F BOILER 02 BURNER ON RETURN INLET TEMP 145 1 F BOILER 403 LOWAIR PRES SUPPLY OUTLET TEMP 150 5 F BOILER 04 LOWH20FLOW TEMP RISE 5 4 DDF BOILER 05 STANDBY STATUS STANDBY V_ MORE V CONFIGURE V_ MORE V CONFIGURE Back Select Back Select SCREEN 1 FIG 56a Command Display Data Screen FIG 56d Command Display Data Screen HEAT SOURCE BOILER 12 BOILER 06 STANDBY LOCKOUT BOILER 07 STANDBY MAX BOILER 08 STANDBY MIN BOILER 09 STANDBY TEMP BO
166. uis doas ge eee 7 Heated products of combustion then pass over the i Secondary Heat Exchanger to absorb additional heat 15 Blower cycles down to 50 speed and the Ignition 4 Flue products pass into the flue collector and Module initiates the heat up sequence of the Hot are exhausted from the unit Surface Igniter 16 Hot Surface Igniter proves 1800 F 982 C End of Sequence OR he 35 Set Point temperature is satisfied Ignition Module 17 The Ignition Module supplies voltage to 28 Eas yah is QUE pO Variable Ratio Gas Valve and the Redundant Gas 37 Combustion Air Blower ramps up to 100 speed Valve and runs for a 30 second post purge timing and 18 Relay contacts prove operation of the Igniter Gas Valves and Safety Switches to the Excel 10 38 Excel 10 is now in a standby mode waiting for the next 19 Variable Ratio Gas Valve senses the pressure from Callot Heal the Combustion Air Blower and supplies gas to the orifice and into the Blower inlet to pre mix MAINTENANCE 20 The Gas Air mixture is forced into the Burner and The following items must be checked to ensure safe reliable out of the Burner Ports under pressure operation Verify proper operation after servicing 21 Hot Surface Igniter lights the Gas Air mixture and then serves as a flame sensor to prove Main Burner Flame WARNINGA by rectification Follow the Service and Maintenance procedures given 22 Bur
167. ultiple 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 ofthe 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
168. um of 4 inches water column of gas supply pressure will operate at the correct manifold pressure as 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 IMPORTANT FLUE OUTLET Upon completion of any testing on the gas system leak test all gas connections with a soap solution while the main FIG 37 Water Connections 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 GAS VALVE TOP VIEW 3 5 W C gas do MANIFOLD GAS PRESSURE 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
169. unction 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 e Release the clutch and leave the valve in this position until the primary control can be replaced Do not reconnect the 3 pin bypass wire harness To Return to the Primary Control 1 After the replacement primary control is installed reconnect the 3 pin bypass wire harness 2 Move the toggle switch to Primary Control 3 Turn the manual override thermostat to the lowest setting 4 Move the Stop Run switch to Run If you have any questions or comments please call the Lochinvar Technical Product Service Line at 1 800 722 2101 TEMPERATURE ADJUSTMENT COMMAND DISPLAY FIG 54 Command Display Panel 39 The Command Display provides a communication interface with the Excel 10 via a series of display screens The front view ofthe display screen shows the digital display with a cluster of arrow keys on the lower left side These directional arrow keys move the cursor in the direction of the arrow On the lower right side is a back key which moves the disp
170. w to the burner or excessive gas input This flange condition MUST be corrected immediately WARNINGA 4 Lifting Flames Lifting flames can be caused by over firing the burner excessive primary air or high draft The area around the burner viewport is hot and direct Ifimproper flame is observed examine the venting system ensure proper tact coul Iti gas supply and adequate supply of combustion and ventilation air 58 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 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 CAUTIONA When a Category IV vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions D BURNER MAINTENANCE The burner should be removed for inspection and cleaning on an annual basis An appliance installed in a dust or dirt contaminated atmosphere will require inspection and cleaning
171. water cutoff device either as part of the unit or at the time of TETTE CMM installation Input Minimum Return Minimum WATER FLOW SWITCH Btu hr Temperature Setpoint A water flow switch is factory installed in the internal bypass piping 1 500 000 50 F 10 C 105 F 40 6 C on all heating boilers hot water supply boilers and water heaters 1 700 000 50 F 10 C 90 F 32 2 C The flow switch is wired in series with the 24 VAC safety control J This wiring connection installs the flow switch in the 24 2 000 000 50 F 10 C 70 F 23 9 C 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 CAUTIONA 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 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 hazard
172. 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 HOT WARNING To avoid possible shock hazard disconnect power before servicing NEUTRAL UNIT POWER 120VAC 15AMP GROUND 1 BLOWER 6 ASSEMBLY VFD POWER RELAY 120VAC 15AMP OPTIONAL GROUND PUMP MOTOR VENT iod IGNITION SURFACE MODULE ee IGNITER CONTROLLER HSI LOW VOLTAGE TRANSFORMER GROUND LVi 24VAC 12 GAS VALVE RELAY 1 COMMAND DISPLAY R 1 EBUS EBUS COMMUNICATION S 24VAC SOLENOID VALVE OVERRIDE EARTH 24VAC 24VAC A 1 o2c IGNITION MODULE F2 l GROUND F1 1 o CONTROLLER INPUTS e qe NA as R oA K PUMP R LAY CONTROLLER OUTPUTS IGNITION ive RESET Rese T s LV1 pa A asvach s mv switcn BL Y EN pA 1 OPTIONAL m 2 ws oc Li locker H A r d OPTIONAL i 5 AR Daina Proving
173. 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 IMPORTANT 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 COLD WATER SUPPLY BUILDING RETURN 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 mainta
174. 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 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 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 Or other listed Cate
175. xing 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 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 10096 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 po
176. ycled on at each call for heat and per the combustion air pipe requirements cycled off when the set point is satisfied The contained in the venting Secun of this manual intermittent pump will operate for a timed period after Correct as required Check the air inlet screen to the burner cycles off to remove residual heat from the the combustion air blower Clean as required combustion chamber area If the operating temperature Check the burner for dirt or contamination and sensor for an intermittent pump system sees a drop in clean as required Recheck for correct differential water temperature to 45 F 7 2 C the integral air pressure after correcting an installation related circulating pump will cycle on This flow of warm boiler problem after cleaning an obstructed water can help prevent freezing component Ensure that combustion air differential of 3 5 inches water column 0 1 w c 2 Location Heating boilers hot water supply boilers is present while the appliance is firing at or water heaters must be located in a room having 100 of rated input a temperature safely above freezing 32 F 0 C This is a reference pressure only and 15 not field 3 Caution A mechanical room operating under a adjustable An appliance supplied with an negative pressure may experience a downdraft in unrestricted supply of combustion air from a the flue of an appliance that is not firing The cold correctly sized combustion air opening or separate ou

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