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

Download or browse on-line these Installation And Service Manual for Intelli-Fin 1 Boiler.

Intelli-Fin 1 Manual Information:

This manual for Intelli-Fin 1, given in the PDF format, is available for free online viewing and download without logging on. The guide contains 80 pages, and the size of the file at download is . The document type is Installation And Service Manual.

Download Manual

Summary of Contents:

[Page 1] Intelli-Fin 1

INSTALLATION AND SERVICE MANUAL Intelli-Fin ® Hot Water Heating Boilers Domestic Hot Water Supply Boilers 1,500,000 — 1,700,000 — 2,000,000 Btu/hr Models IFB-IFW-I-S-06 FIG. 1 Front View FIG. 2 Rear View Installation and service mus...

[Page 2] Intelli-Fin 1

TABLE OF CONTENTS Warranty .......................................................................... 1 Safety Warnings .............................................................. 3 Codes ..............................................................

[Page 3] Intelli-Fin 1

Upon receiving equipment, check for signs of ship ping damage. Pay par tic u lar attention to parts ac com pa ny ing the boiler, which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on packing slip wit...

[Page 4] Intelli-Fin 1

4 1. Locate the appliance so that if water connections should leak, water damage will not occur. When such lo ca tions cannot be avoided, it is recommended that a suitable drain pan, ad e quate ly drained, be installed under the unit. The pan mus...

[Page 5] Intelli-Fin 1

5 NOTE Clearances from combustible construction are noted on the appliance rating plate. Maintain minimum specified clearances for adequate operation. All in stal la tions must allow sufficient space for servicing the vent connections, water pipe con...

[Page 6] Intelli-Fin 1

6 TABLE - B Minimum Recommended Combustion AIR SUPPLY TO MECHANICAL ROOM Btu/hr Input 1,500,000 375 in 2 (2419 cm 2 ) 425 in 2 (2742 cm 2 ) 500 in 2 (3226 cm 2 ) 500 in 2 (3226 cm 2 ) 567 in 2 (3658 cm 2 ) 667 in 2 (4303 cm 2 ) 1,500 in 2 (9,677 cm 2...

[Page 7] Intelli-Fin 1

7 All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a com bus tion air opening a minimum of ap prox i mate ly 25%. Check with louver manufacturers for exact net free area of louvers. Where two...

[Page 8] Intelli-Fin 1

8 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...

[Page 9] Intelli-Fin 1

9 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 ...

[Page 10] Intelli-Fin 1

10 Any vent materials specified must be listed by a nationally recognized test agency for use as a Category IV vent material. The venting system must be planned so as to avoid possible contact with con cealed plumbing or electrical wiring inside wall...

[Page 11] Intelli-Fin 1

11 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...

[Page 12] Intelli-Fin 1

12 CHIMNEY 3' MIN 2' MIN 10' OR LESS CHIMNEY 2' MIN WALL OR PARAPET FIG. 15 Vent Termination from Flat Roof - 10 Feet or Less from Parapet Wall 3' MIN 10' OR MORE CHIMNEY WALL OR PARAPET NOTE: NO HEIGHT ABOVE PARAPET ...

[Page 13] Intelli-Fin 1

13 The installed sidewall vent cap assembly may be paint ed to match the exterior color. The opening through the wall for instal la tion of the sidewall vent cap must provide an air space clearance of 2 inches (5.1 cm) around the flue pipe. The diam...

[Page 14] Intelli-Fin 1

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

[Page 15] Intelli-Fin 1

15 sealant to ensure a proper seal at the appliance con nec tion and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air i...

[Page 16] Intelli-Fin 1

16 VERTICAL COMBUSTION AIR INLET FIG. 21 Air Inlet Cap for Rooftop Termination The air inlet cap for the vertical roof top air inlet is assembled from com po nents purchased locally. The air inlet cap consist of two 90° elbows installed at the po...

[Page 17] Intelli-Fin 1

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

[Page 18] Intelli-Fin 1

18 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 ...

[Page 19] Intelli-Fin 1

19 Combined Air Inlet Points The air inlet pipes from multiple ap pli anc es installed with an Intelli-Vent system can be combined to a single common connection based on the cross sectional area of the common pipe as defined in the Direct Vent ba...

[Page 20] Intelli-Fin 1

20 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 c...

[Page 21] Intelli-Fin 1

21 VERTICAL COMBUSTION AIR INLET FIG. 30 Air Inlet Cap for Rooftop Termination The air inlet cap for the vertical roof top air inlet is assembled from com po nents purchased locally. The air inlet cap consist of two 90° elbows installed at the poi...

[Page 22] Intelli-Fin 1

22 CAUTION Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance. The flue and air inlet duct sizes for a Horizontal Intelli-Vent Installation with Sid...

[Page 23] Intelli-Fin 1

23 GAS SUPPLY Verify that the appliance is supplied with the type gas specified on the rating plate. Consult factory for installations at altitude. INLET PRESSURE: Measured at the inlet pressure tap on the appliance gas man i fold. The pressure tap...

[Page 24] Intelli-Fin 1

24 TABLE - M Recommended Gas Pipe Size Single Appliance Installations Distance from Meter Btu/hr 1,500,000 2" 2 1/2" 2 1/2" 2 1/2" 2 1/2" 3" 3" 3" 3" 3" 3 1/2" 3 1/2" 3 1/2" 4" 1,7...

[Page 25] Intelli-Fin 1

25 GAS PIPING TRAP 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 nat u ral gas. All ...

[Page 26] Intelli-Fin 1

26 1. Turn the main power switch to “OFF” position. 2. Shut off gas supply at the manual gas cock in the as piping to the ap pli ance. If fuel supply is LP gas, shut off gas supply at the tank. 3. Remove the 1/8" hex plug from the gas pressu...

[Page 27] Intelli-Fin 1

27 supply pressure and adjust to ensure a supply pressure between 4.0 and 10.5 inches water col umn natural gas (13.0" w.c. for propane) while the appliance is firing at 100% of rated input. 7. This is a reference pressure only and is not fie...

[Page 28] Intelli-Fin 1

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

[Page 29] Intelli-Fin 1

29 INTEGRAL BYPASS HOT WATER OUTLET SECONDARY HEAT EXCHANGER COLD WATER INLET PRIMARY HEAT EXCHANGER PUMP BYPASS VALVE FIG. 40 Bypass Piping with Valve Actuator and Pump temperature conformal coating to prevent any corrosive damage to the copper ...

[Page 30] Intelli-Fin 1

30 BYPASS PIPING ASSEMBLY The primary and secondary heat ex chang ers are interconnected with a bypass and pump mounted in 2 1/2 inch (63.5 mm) diameter copper pipe. All access to the piping is from the rear of the appliance. On initial start up, a...

[Page 31] Intelli-Fin 1

31 TABLE - P Temperature Rise At Full Rate Fire Bypass Manually Fully Closed Btu/hr Input Temperature Rise 1,500,000 _______________________ 1,700,000 _______________________ 2,000,000 31.5°F (17.5°C) _______________________ 35.7°F (19...

[Page 32] Intelli-Fin 1

32 TABLE - Q Minimum Inlet Water Temperatures Input Minimum Return Minimum Btu/hr Temperature Setpoint 1,500,000 ___________ 1,700,000 ___________ 2,000,000 105°F (40.6°C) _______________ 90°F (32.2°C) _________...

[Page 33] Intelli-Fin 1

33 RELIEF VALVE This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Sec tion IV (“Heating Boilers”). The re lief valve(s) is installed in the ver ti cal position and mounted in the hot water...

[Page 34] Intelli-Fin 1

34 Venting of Gas Valves and Pressure Switches The diaphragm type gas valve and op tion al gas pressure switches are pro vid ed with threaded termination points to be vented to the atmosphere, outside the building. The gas pressure reg u la tion func...

[Page 35] Intelli-Fin 1

35 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 r...

[Page 36] Intelli-Fin 1

36 FIG. 48 Transformer and Relay Locations VARIABLE FREQUENCY DRIVE FIG. 49 Internal Control Panel Location FIG. 50 Variable Frequency Drive A transformer and relay mounting panel is located above the front control panel, underneath the curved ...

[Page 37] Intelli-Fin 1

37 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 combust...

[Page 38] Intelli-Fin 1

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

[Page 39] Intelli-Fin 1

39 is unique to each Excel 10 and must be placed into the network of an energy management system so that the Excel 10 can be recognized by the system. NOTE: If the Excel 10 is ever replaced, a tear-off label on the new Excel 10 must be placed over...

[Page 40] Intelli-Fin 1

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

[Page 41] Intelli-Fin 1

41 NOTE: Allow 10 seconds for data shown in the display screens to update when viewing or making adjustments to any of the six adjustable points. POINTS FROM INFORMATION VISIBLE FROM THE SCREEN OF THE COMMAND DISPLAY 1. Calculated Set Point — The w...

[Page 42] Intelli-Fin 1

42 FIG. 56a Command Display Data Screen FIG. 56b Command Display Data Screen FIG. 56c Command Display Data Screen FIG. 56d Command Display Data Screen FIG. 56e Command Display Data Screen FIG. 56f Command Display Data Screen ...

[Page 43] Intelli-Fin 1

43 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 sense...

[Page 44] Intelli-Fin 1

44 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 di...

[Page 45] Intelli-Fin 1

45 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 ...

[Page 46] Intelli-Fin 1

46 INTERFACING MULTIPLE APPLIANCES PARALLEL CONNECTION FIG. 59 E-Bus Connection to Controls Connection between multiple Intelli-Fin appliances is accomplished via an E-Bus connection. An E-Bus terminal is provid ed on the rear of each appliance...

[Page 47] Intelli-Fin 1

47 STRIP 1/2" FROM WIRE TO BE ATTACHED. 1/2" (13MM) TWIST WIRES TOGETHER WITH PLIERS (MINIMUM OF THREE TURNS) INSERT TWISTED WIRES UNDER TERMINAL AND TIGHTEN. CHECK FOR A GOOD MECHANICAL CONNECTION. FIG. 60 Wire Termination for E-Bus Co...

[Page 48] Intelli-Fin 1

48 FIG. 61 Typical Building Management System Diagram HIGH WATER TEMPERATURE LIMIT CONTROL FIG. 62 High Water Temperature Control A Manual Reset High Limit control is located on the left front side of the control panel, beside the Command Dis pla...

[Page 49] Intelli-Fin 1

49 HOT SURFACE IGNITION SYSTEM IGNITION CONTROL MODULE DIAGNOSTIC STATUS CODES FIG. 63 Hot Surface Ignition Control Module FIG. 64 Hot Surface Igniter This appliance uses a proven hot sur face ignition control system. The operation of the elect...

[Page 50] Intelli-Fin 1

50 Diagnostic Status Indication The ignition module has an LED that indicates the status of the ignition safety circuits. The flashing op er a tion of this LED indicates the di ag nos tic status of the ignition control module. The following listing g...

[Page 51] Intelli-Fin 1

51 OPERATION/DIAGNOSTIC LIGHTS, RESETS AND SWITCHES ADJ HI-LIMIT CIRCUIT BREAKER ALARM RESET SOUND ALARM POWER SILENCE AUTO RESET TEST MANUAL LOW WATER CUT-OFF ALARM BURNER FIG. 67 Burner Assembly FIG. 66 Exterior Control Panel The control pane...

[Page 52] Intelli-Fin 1

52 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/...

[Page 53] Intelli-Fin 1

53 FILTER ACCESS PLATE FIG. 70 Cleaning the Internal Combustion Air Blower Inlet Filter CONDENSATE MANAGEMENT SYSTEM (Optional) FIG. 71 Location and Connection of Neutralization Reservoir This high efficiency appliance may operate as a condensing...

[Page 54] Intelli-Fin 1

54 Many codes will require the acidic condensate to be neu tral ized before it can be placed in a drain system. The optional condensate management system consists of a neutralizer kit to control the pH of the liquid discharged to a drain system. Th...

[Page 55] Intelli-Fin 1

55  WARNING Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap. Failure to follow this warning could result in produc...

[Page 56] Intelli-Fin 1

56 LIGHTING INSTRUCTIONS 1. STOP! Read the safety information. 2. Set the Temperature Set Point func tion of the Command Display to the lowest setting. 3. Turn Off all electrical power to the appliance. 4. This appliance is equipped with an ignition...

[Page 57] Intelli-Fin 1

57 9. Excel 10 enables the Ignition Mod ule. 10. Ignition Module enables the Vari able Frequency Drive. 11. Excel 10 Controller drives the Variable Frequency Drive. 12. The Variable Frequency Drive sup plies the Combustion Air Blower with 230 VAC...

[Page 58] Intelli-Fin 1

58 CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. A. EXAMINE THE VENTING SYSTEM at least once a year. Check more often in the first year to determine inspection ...

[Page 59] Intelli-Fin 1

59 C. FLUE GAS PASSAGEWAYS CLEANING PROCEDURES: Any sign of soot around the inner jacket, outer jacket, flue pipe connections, burner or in the areas between the fins on the copper heat exchanger indicates a need for clean ing. The following cleaning...

[Page 60] Intelli-Fin 1

60 NOTE: When the combustion air blower is removed for any reason, the inlet to the burner must be covered to prevent foreign objects from falling into the burner. A foreign object such as a nut, bolt, wire or other metallic items will cause a rapid...

[Page 61] Intelli-Fin 1

61 NOTE: All gaskets/sealant on disassembled components or jacket panels must be replaced with new gaskets/ sealant on reassembly. Gasket and sealant kits are available from your distributor. F. PRIMARY HEAT EXCHANGER INSPECTION 1. Turn off all powe...

[Page 62] Intelli-Fin 1

62 9. Carefully reinstall the heat ex chang er if removed from the appliance. 10. Reinstall inner rear jacket panels, bypass piping and condensate hoses. Use new gasket material to ensure a proper air seal. 11. Reassemble all water piping. Test f...

[Page 63] Intelli-Fin 1

63 FREEZE PROTECTION CAUTION Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids. 4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of...

[Page 64] Intelli-Fin 1

64 (d) Drain the unit completely. Remove the caps from the two drains located on the rear of the appliance. Open the relief valve and manually open the bypass valve to allow air into the system so the water will drain out. Open the union fittin...

[Page 65] Intelli-Fin 1

65 PIPING LENGTHS The boiler’s integral circulator pro vides the water flow from the primary boiler piping, through the boiler and back to the primary system. Pipe di am e ter and length are critical to ensure proper flow through the boiler. A 3 in...

[Page 66] Intelli-Fin 1

66 PRIMARY/SECONDARY BOILER PIPING TO EXPANSION TANK AND MAKEUP WATER SYSTEM TO SYSTEM 12” MAX. FROM SYSTEM FIG. 80 Primary/Secondary Piping of a Single Boiler CAUTION At no time should the system pressure be less than 12 PSIG. MAKE-UP WATE...

[Page 67] Intelli-Fin 1

67 The automatic bypass system allows part of the boiler discharge water to be mixed with the inlet water to the pri ma ry heat exchanger to increase the boiler inlet temperature above 130°F (55°C). This will prevent the products of combustion from...

[Page 68] Intelli-Fin 1

68 TEMPERATURE/PRESSURE GAUGE This boiler is equipped with a dial type temperature/pressure gauge. This gauge is factory installed in the out let side of the boiler bypass piping. The gauge has one scale to read system pressure and a separate scale...

[Page 69] Intelli-Fin 1

69 Boiler Operation 28. Turn the run/stop switch to the “RUN” position to start boiler operation. 29. Push the resets for low water lev el, high water temperature and flame failure. 30. Observe the boiler synchronization process before start-u...

[Page 70] Intelli-Fin 1

70 DOMESTIC HOT WATER SUPPLY BOILER This section applies only to those appliance used to supply domestic hot water, installed with a storage tank(s). The integral circulating pump installed in the bypass piping assembly is used to control water ve l...

[Page 71] Intelli-Fin 1

71 TABLE - FF Maximum Flow Rate Btu/hr Input Maximum Flow 1,500,000 - 2,000,000 90 GPM If higher flow rates are required through the water heater, an optional Cupro-Nickel heat exchanger is avail able. Consult the factory for specific ...

[Page 72] Intelli-Fin 1

72 5. Be sure the pipes between the water heater or hot water supply boiler and storage tank are not less than 3 inch (76.2 mm) diameter for up to 70 equivalent feet (21.2 m) of pipe to and from the heater. If maximum equivalent length for the s...

[Page 73] Intelli-Fin 1

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

[Page 74] Intelli-Fin 1

74 TABLE - HH Common Water Manifold Size For Multiple Water Heater Hot Water Supply Boiler Installations Btu/hr Input Temperature Rise Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow. Commo...

[Page 75] Intelli-Fin 1

75 THERMOSTAT SETTINGS 1. The Excel 10 temperature con trol ler is adjusted to a low test setting when shipped from the factory. 2. Using the Command Display, adjust the temperature set point to the lowest settings which will satisfy hot water dem...

[Page 76] Intelli-Fin 1

76 NOTE: (1) This water heater, when set at the lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes. (2) Higher stored water tem per a ture increases the ability of the water heater to s...

[Page 77] Intelli-Fin 1

77 Ladder Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models J 3 5 4 6 1 2 3 O . C . J1 J 2 3 2 1 J 4 P RES E T R E SE T C HA S S I S G R O UN D G N D P U G PU BL Y 24 V A C LW C O PROB E T ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ O A SENSOR INLET SENSO R RE...

[Page 78] Intelli-Fin 1

78 Wiring Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models 888 8 P R O G V OL T S A MP S HE RT Z RUN F W D RE V VFD ENABLE J3 E G ND GND A1- 3 O H M G ND G N D 2 2VD C O U T E - BUS D I - 4 G N DDI - 3 D I - 2 GND 2 OU T 3 O U T 5 O U T 1 O U...

[Page 79] Intelli-Fin 1

79 Wiring Diagram (continued) 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models 50 Hz L i mit Res i s to r 1.2 K Oh m Y TO V F D TE R M I NAL NU M B E R 15 T O V FD TE R M I NAL NUMB E R 14 O P TIO NAL 50 H z LIM I T R ESI S ...

[Page 80] Intelli-Fin 1

80 8/09-Printed in U.S.A. Revision Notes: Rev. 4 (IFB/IFW-i&s-04) reflects additional text on Page 39, changes made to Figures 47 & 48, Table AA (Page 51), and LBLs on Pages 77-79. Revision 5 (ECO #C02870) reflects changes made to the scald s...