Installation & Operation Manual
Models: 502, 752, 1002, 1302,
1501, 1701, and 2001
Up To 5:1 Turndown
Beginning with
Serial #1707104971206
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual and the Power-fin Service Manual be
reviewed completely before proceeding with an
installation. Perform steps in the order given.
Failure to comply could result in severe personal
injury, death, or substantial property damage.
⚠WARNING:
Save this manual for future reference.
100280321_2000538685_Rev AG
2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
⚠ DANGER
⚠WARNING
⚠CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Contents
HAZARD DEFINITIONS .................................................. 2
PLEASE READ BEFORE PROCEEDING .................. 3-4
THE POWER-FIN -- HOW IT WORKS ........................ 5-7
RATINGS ....................................................................... 8-9
1. DETERMINE UNIT LOCATION
Outdoor Installation ........................................................... 10
Clearances ....................................................................... 11
Provide Air Openings to Room ........................................ 11
Flooring and Foundation ................................................. 12
Vent and Air Piping .......................................................... 12
Prevent Combustion Air Contamination ........................... 12
Using an Existing Vent System to Install a New Boiler ... 12
Corrosive Contaminants and Sources ............................. 13
Removing a Boiler from Existing Common Vent .............. 13
Remove Boiler from Wood Pallet ..................................... 14
Combustion and Ventilation Air Requirements ........... 14-15
Combustion Air Filter ......................................................... 16
2. GENERAL VENTING
Before You Begin ............................................................. 17
Venting Category Definitions ............................................ 17
Vent Materials ............................................................. 18
Condensing Vent Options ........................................... 19-22
Outdoor Venting ............................................................... 23
Non-Condensing Vent Options ................................... 24-25
Common Venting ............................................................. 26
GeneraI Venting .......................................................... 27-28
Vertical Air Inlet/Horizontal Air Inlet .............................29-30
Air Inlet Piping All Categories and Clearances ............31-36
3. WATER CONNECTIONS
Inlet and Outlet Connections ............................................ 37
Heat Exchanger ............................................................... 37
Heating Boiler Installations ............................................... 38
Boiler Piping Diagrams ................................................ 40-43
4. GAS CONNECTIONS
Gas Supply ....................................................................... 46
Gas Pressure Test ........................................................... 46
Gas Connection ............................................................... 46
Gas Piping ........................................................................ 47
Checking Gas Supply Pressure ....................................... 48
High and Low Gas Pressure Switches .................. 48-49
5. ELECTRICAL CONNECTIONS
Boiler Operating Control Module ...................................... 50
Line Voltage Connections ........................................... 50
Low Voltage Connections ........................................... 51
Wiring of the Cascade ...................................................... 52
Low Voltage Field Wiring Connections ............................ 53
6. CONDENSATE DISPOSAL
Condensate Trap Installation ........................................... 54
7. START-UP
Fill Water ........................................................................... 55
Freeze Protection ............................................................. 55
Oxygen Prevention ........................................................... 56
Boiler Water...................................................................... 56
Check for Gas Leaks ........................................................ 57
Placing the Boiler in Operation ......................................... 57
Final Checks Before Starting the Boiler ............................ 58
Set Space Heating Operation ........................................... 60
8. OPERATING INFORMATION
Set Hot Water Generator (HW) Operation ........................ 61
Configuration of the Cascade ...................................... 62
General ........................................................................ 63-65
Cascade ............................................................................ 66
Sequence of Operation ..................................................... 67
Smart Touch with Power-fin CON•X•US Interface ............ 68
9. DOMESTIC WATER HEATERS ............................. 69-77
10. MAINTENANCE
Maintenance and Annual Startup .................................78-83
11. DIAGRAMS
Wiring Diagram ........................................................ 84
Ladder Diagrams ...................................................... 85
Revision Notes .................................................. Back Cover
3
Please read before proceeding
3
Installation & Operation Manual
Installer – Read all instructions, including
this manual and the Power-fin Service
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
When servicing boiler –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this boiler 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.
• The installer must verify that at least one carbon
monoxide alarm has been installed within a residential
living space or home following the alarm manufacturer’s
instructions and applicable local codes before putting the
appliance into operation.
Boiler water –
• Thoroughly flush the system to remove debris. Use
an approved pre-commissioning cleaner (see Start-Up
Section), without the boiler connected, to clean the
system and remove sediment. The high efficiency heat
exchanger can be damaged by build-up or corrosion due
to sediment.
NOTE: Cleaners are designed for either new systems or
pre-existing systems. Choose accordingly.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals in
the system may be damaged. This can result in
substantial property damage.
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
and/or property may result.
• Continual fresh make-up water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the heat exchanger, and causes failure.
Addition of oxygen carried in by makeup water can cause
internal corrosion in system components. Leaks in boiler
or piping must be repaired at once to prevent the need for
makeup water.
Freeze protection fluids (Boiler Only) –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
When calling or writing about the boiler
– Please have the boiler model and serial
If the information in this manual is not
followed exactly, a fire or explosion may
⚠WARNING
NOTICE
⚠WARNING
⚠WARNING
⚠WARNING
DO NOT install units in rooms or
environments that contain corrosive
⚠WARNING
The California Safe Drinking Water and
Toxic Enforcement Act requires the
Manual, before installing. Perform steps in the order given.
User – This manual is for use only by a qualified heating
installer/service technician. Refer to the User’s Information
Manual for your reference.
Have this boiler serviced/inspected by a qualified service
technician, at least annually.
Failure to comply with the above could result in severe personal
injury, death or substantial property damage.
number from the boiler rating plate.
Consider piping and installation when determining boiler
location.
Any claims for damage or shortage in shipment must be
filed immediately against the transportation company by the
consignee.
Factory warranty (shipped with unit) does not apply to units
improperly installed or improperly operated.
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.
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 near by phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
• Installation and service must be performed by a qualified
installer, service agency, or the gas supplier.
Governor of California to publish a list of substances known
to the State of California to cause cancer, birth defects, or
other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
This product contains a chemical known to the State of
California to cause cancer, birth defects, or other reproductive
harm. This boiler can cause low level exposure to some of the
substances listed in the Act.
contaminants (see Table 1A on page 13). Failure to comply
could result in severe personal injury, death, or substantial
property damage.
Installation & Operation Manual
4
Please read before proceeding
⚠WARNING
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 or debris
near it, stand on it or in any way block
the flow of fresh air to your appliance.
3. UNDER NO CIRCUMSTANCES must
flammable materials such as gasoline or
paint thinner be used or stored in the
vicinity of this appliance, vent-air intake
system or any location from which fumes
could reach the appliance or vent-air
intake system.
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. Where required by the authority
having jurisdiction, the installation must conform to American
Society of Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Boilers, ASME CSD-1.
All boilers conform to the latest edition of the ASME Boiler
and Pressure Vessel Code, Section IV. Where required by the
authority having jurisdiction, the installation must comply with
the Canadian Gas Association Code, CAN/CGA-B149.1 and/
or B149.2 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 hot water boilers, ANSI Z21.13 and gas water heaters,
ANSI Z21.10.3.
The Power-fin - How it works...
1. Heat exchanger
The heat exchanger allows system water to flow through specially
designed tubes for maximum heat transfer. The glass lined
headers and copper finned tubing are encased in a jacket that
contains the combustion process.
2. Heat exchanger access cover
The heat exchanger access cover is a stainless steel door which
allows access for service, maintenance, and removal of the heat
exchanger from inside the combustion chamber.
3. Blower
The blower pulls in air and gas through the venturi (see item 5)
and injects the fuel/air mixture into the burner, where they burn
inside the combustion chamber.
4. Gas valve
The gas valve allows the proper amount of gas to pass into the
burner for combustion. The gas valve on the Power-fin works
under a negative pressure (M9 models only) so gas should only be
pulled through the valve when the blower is in operation.
5. Venturi
The venturi attaches to the inlet (or suction) side of the blower
and generates the negative pressure needed by the gas valve.
6. Flue sensor (not shown)
The flue sensor is mounted in the exhaust collar of the unit and
monitors the flue gas temperature. If the temperature in the stack
exceeds the maximum temperature the unit will shut down to
prevent a hazardous condition. In Category I models the
flue sensor helps to control the amount of modulation to prevent
condensation in the stack.
7. Outlet temperature sensor
This sensor monitors the outlet water temperature. If selected
as the controlling sensor, the appliance will maintain set point by
adjusting the firing rate of the unit according to this sensor.
8. Inlet temperature sensor
This sensor monitors inlet water temperature. If selected as the
controlling sensor, the appliance will maintain set point by
adjusting the firing rate of the unit according to this sensor.
9. Temperature and pressure gauge (boilers only)
The temperature and pressure gauge monitors the outlet
temperature of the appliance as well as the system water pressure.
10. Electronic display
Digital controls with SMART TOUCH screen technology, full
color display, and an 8” user interface screen.
11. Burner (not shown)
The burner is made of a woven fabric over steel screen construction.
The burner uses pre-mixed air and gas and provides a wide range
of firing rates.
12. Water outlet (system supply)
The water outlet is a 2 1/2" pipe connection that supplies water to
the system with connections for a flow switch (see #28), a relief
valve (see #24), and a temperature and pressure gauge (boilers
only) (see #9).
13. Water inlet (system return)
The water inlet is a 2 1/2" pipe connection that receives water from
the system and delivers it to the heat exchanger.
14. Gas connection pipe
The gas pipe connection on this appliance is 1", 1 1/4", or 1 1/2"
NPT. To deliver the correct amount of gas volume to the appliance
it may be necessary to have a larger gas line reduced at the
appliance. Please reference the National Fuel Gas Code charts for
more details.
15. SMART TOUCH Control Module
The SMART Touch Control Module is the main control for the
appliance. This module contains the programming that operates
the blower, gas valve, and pumps in addition to other programmable
features.
16. Air intake
The air intake pipe allows fresh air to flow directly to the
appliance. The air inlet is part of the filter box assembly where air
filtration is accomplished with a standard filter.
17. Line voltage terminal strip
The line voltage terminal strip provides a location to connect all of
the line voltage (120 VAC) contact points to the unit.
18. Low voltage connection board
The low voltage connection board provides a location to tie in
all of the low voltage contacts to the appliance. This is where most
of the external safety devices are connected to the unit such as the
louver proving switch.
19. Condensate trap
The condensate trap is designed to prevent flue gases from
escaping the appliance through the combustion chamber drain.
20. Access cover - front
The front access cover provides access to the gas train as well as the
blower and other key components for service and maintenance.
21. Hot surface igniter (HSI)
The hot surface igniter is a device that is used to ignite the air/
gas mixture as well as monitor the performance of the flame
during operation. This device acts as a flame sense electrode.
22. Flame inspection window (sight glass - not shown)
The flame inspection window is a quartz glass window that
allows a visual inspection of the burner and flame during
operation.
23. High limit sensor
Device that monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting (field
adjustable), it will break the control circuit, shutting the
appliance down.
24. Relief valve
The relief valve is a safety device that ensures the maximum
pressure of the appliance is not exceeded. Boilers operate on
pressure only and are shipped from the factory at a rating of
50 PSI. Water heaters operate on temperature and pressure and
are shipped standard as 150 PSI and 210°F (98.9°C).
25. Power switch
The power switch is used to engage and disengage power to the
appliance on the 120 VAC circuit.
26. Air pressure switch
The air pressure switch is a safety device which ensures proper
blower operation. The air pressure switch is wired in series with
the low voltage control circuit in such a way that if the fan does not
engage or shuts down prematurely the device will break the
control circuit and the unit will shut down.
27. Flow switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass and
should never be operated without flow. The flow switch makes
contact when flow is detected and allows the unit to operate. If
flow is discontinued during operation for any reason the flow
switch will break the control circuit and the unit will shut down.
5
Installation & Operation Manual
28. Drain port(s)
Location from which the heat exchanger can be drained.
29. Manual shutoff valve
Manual valve used to isolate the unit from the gas supply.
DIR #2000537294 00
10
20
Models 502 - 1302 Front View
DIR #2000537314 00
26
3
5
4
23
21
1
Models 502 - 1302 Left Side (inside unit) - F9
DIR #2000537322 00
8
4
15
2
7
25
Models 502 - 1302 Right Side (inside unit) - M9
Models 502 - 1302 Rear View
6
The Power-fin - How it works...
Installation & Operation Manual
2000619668 00
29
14
18
17
12
16
13
28
19
27
9
24
Installation & Operation Manual
7
10
20
DIR #2000538550 00
DIR #2000538553 00
3
5
21
23
1
Models 1501 - 2001 Left Side (inside unit)
DIR #2000538558 00
4
8
15
7
24
9
2
25
Models 1501 - 2001 Right Side (inside unit)
DIR #2000538552 00
17
14
29
18
13
24
12
19
27
9
16
28
Models 1501 - 2001 Rear View
Models 1501 - 2001 Front View
The Power-fin - How it works... (continued)
Installation & Operation Manual
Ratings
HLW
LOW LEAD CONTENT
Power-Fin
Water Heater Ratings
Model Number
Note: Change “N” to
“L” for L.P. gas models
.
Input
MBH
(Note 4)
Min Max
GPH
at 100°F
Rise
PFN0502-M9 100 500 515
PFN0752-M9 150 750 773
PFN1002-M9 200 999 1029
PFN1302-M9 260 1300 1339
PFN1501-M9 300 1500 1545
PFN1701-M9 340 1700 1752
PFN2001-M9 440 2000 2061
PFN0502-F9 N/A 500 515
PFN0752-F9 N/A 750 773
PFN1002-F9 N/A 999 1029
PFN1302-F9 N/A 1300 1339
PFN1501-F9 N/A 1500 1545
PFN1701-F9 N/A 1700 1752
PFN2001-F9 N/A 2000 2061
Other Specifications
Appliance
Water
Content
Gallons
Water
Connections
Gas
Connections
Air / Vent
Sizes
(Note 3)
3.6 2.5" 1" 5" - 4"
4.0 2.5" 1 1/4" 5" - 5"
4.3 2.5" 1 1/4" 6" - 6"
4.8 2.5" 1 1/4" 6" - 8"
5.5 2.5" 1 1/2" 6" - 6"
5.8 2.5" 1 1/2" 7" - 7"
6.2 2.5" 1 1/2" 8" - 8"
3.6 2.5" 1" 5" - 7"
4.0 2.5" 1 1/4" 5" - 9"
4.3 2.5" 1 1/4" 6" - 10"
4.8 2.5" 1 1/4" 6" - 12"
5.5 2.5" 1 1/2" 6" - 12"
5.8 2.5" 1 1/2" 7" - 14"
6.2 2.5" 1 1/2" 8" - 14"
8
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.
2. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and
pickup. Ratings are based on a piping and pickup
allowance of 1.15.
3. Power-fin boilers require special gas venting. Use only
the vent materials and methods specified in the Power-
fin Installation and Operation Manual.
4. Standard Power-fin boilers are equipped to operate from
sea level to 4,500 feet only. The boiler will de-rate by
4.5% for each 1,000 feet above sea level up to 4,500 feet.
5. High altitude Power-fin boilers are equipped to operate
from 3,000 to 5,500 feet only. e boiler will de-rate by
4.0% for each 1,000 feet above sea level up to 5,500 feet.
e operation given in this manual remains the same as
the standard boilers. A high altitude label (as shown in
FIG A.) is also axed to the unit.
HIGH ALTITUDE
ONLY
DIR #2000530350 00
Figure A High Altitude Label Location
De-rate values are based on proper combustion calibration and
CO
2
’s adjusted to the recommended levels.
6. For Power-n boiler installations above 5,500 feet contact the
factory.
7. Ratings have been conrmed by the Hydronics Section of
AHRI.
Power-Fin
AHRI Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models
.
Input
MBH
(Note 4)
Min Max
Gross
Output
MBH
(Note 1)
Net
AHRI
Ratings
Water,
MBH
(Note 2)
PBN0502-M9 100 500 425 370
PBN0752-M9 150 750 638 554
PBN1002-M9 199.8 999 849 739
PBN1302-M9 260 1300 1105 961
PBN1501-M9 300 1500 1275 1109
PBN1701-M9 340 1700 1445 1257
PBN2001-M9 440 2000 1700 1478
PBN0502-F9 N/A 500 425 370
PBN0752-F9 N/A 750 638 554
PBN1002-F9 N/A 999 849 739
PBN1302-F9 N/A 1300 1105 961
PBN1501-B9 750 1500 1260 1096
PBN1701-B9 850 1700 1428 1242
PBN2001-B9 1000 2000 1680 1461
Other Specifications
Appliance
Water
Content
Gallons
Water
Connections
Gas
Connections
Air / Vent
Sizes
(Note 3)
3.6 2.5" 1" 5" - 4"
4.0 2.5" 1 1/4" 5" - 5"
4.3 2.5" 1 1/4" 6" - 6"
4.8 2.5" 1 1/4" 6" - 8"
5.5 2.5" 1 1/2" 6" - 6"
5.8 2.5" 1 1/2" 7" - 7"
6.2 2.5" 1 1/2" 8" - 8"
3.6 2.5" 1 1/4" 5" - 7"
4.0 2.5" 1 1/4" 5" - 9"
4.3 2.5" 1 1/4" 6" - 10"
4.8 2.5" 1 1/4" 6" - 12"
5.5 2.5" 2" 6" - 12"
5.8 2.5" 2" 7" - 14"
6.2 2.5" 2" 8" - 14"
Installation & Operation Manual
Ratings (continued)
9
10
Installation & Operation Manual
1 Determine unit location
Installation must comply with:
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, NFPA 54 / ANSI Z223.1 –
latest edition.
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1 -
latest edition, when required.
• National Electrical Code, NFPA 70 - latest edition.
• For Canada only: CSA B149.1 Installation Code,
CSA C22.1 Canadian Electrical Code Part 1 and any
local codes.
The Power-fin gas manifold and
controls met safe lighting and other
performance criteria when the boiler
underwent tests specified in ANSI
Z21.13/CSA 4.9 – latest edition.
Before locating the appliance, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
2. 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 appliance. The
pan must not restrict combustion air flow. Under no
circumstances is the manufacturer to be held
responsible for water damage in connection with
this appliance, or any of its components.
3. Check area around the boiler. Remove any
combustible materials, gasoline and other
flammable liquids.
NOTICE
Failure to keep boiler area clear
and free of combustible materials,
gasoline, and other flammable
liquids and vapors can result in
severe personal injury, death, or
substantial property damage.
4. The Power-fin must be installed so that gas control
system components are protected from dripping or
spraying water or rain during operation or service.
5. If a new boiler will replace an existing boiler, check
for and correct system problems, such as:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing
system and boiler to freeze and leak.
• Debris left from existing piping, if not flushed and
cleaned with an appropriate cleaner.
⚠WARNING
Adequate hydronic system antifreeze must be used. A snow screen
should be installed to prevent snow and ice accumulation around
the unit or its venting system.
Outdoor installation
⚠WARNING
Do not install the appliance where the
appliance will be exposed to freezing
temperatures.
Do not install the appliance where
condensation may form on the inside
or outside of the appliance, or where
condensation may fall onto the appliance.
Failure to install the appliance properly could
result in severe personal injury, death, or
substantial property damage.
DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 13).
Failure to comply could result in severe
personal injury, death, or substantial property
damage.
⚠WARNING
This appliance requires a special venting
system. Use only the vent materials specified in
this manual. Failure to follow all instructions
can result in flue gas spillage and carbon
monoxide emissions, causing severe personal
injury or death.
⚠WARNING
7. If the optional neutralizing kit is to be used, elevate
the boiler at least 3” above the floor.
8. Check around the boiler for any potential air contaminants
that could risk corrosion to the boiler or the boiler combustion
air supply (see Table 1A on page 13). Prevent combustion
air contamination. Remove any of these contaminants from
the boiler area.
9. For outdoor models, you must install an optional outdoor kit.
Instructions for installing the outdoor kit are included in the
kit. Do not install outdoor models directly on the ground.
You must install the outdoor unit on a concrete, brick, block,
or other non-combustible pad. Outdoor models have
additional special location and clearance requirements. A
wind proof cabinet protects the unit from weather. Vent
materials are field supplied.
6. The appliance must be installed on a level floor,
both front to back and side to side, for proper
condensate drainage.
Installation & Operation Manual
11
1 Determine unit location (continued)
Provide clearances:
Clearances from combustible materials
- Hot water pipes ........................................................... 1/4"
- Sides .............................................................................. 0"
- Rear ............................................................................... 0"
- Front ............................................................................. 0"
- Top ................................................................................ 0"
- Floor ........................................................... Combustible
- Vent pipe - at least 1" from combustible material
Figure 1-1 Clearances
0"
RIGHT
SIDE
0"
FRONT
MIN
0"
LEFT
SIDE
0"
TOP
MIN
4" REAR
MIN FROM
PIPING
DIR #2000527453 00
Provide air openings to room:
The Power-fin alone in boiler room
1. No air ventilation openings into the boiler room are
needed when clearances around the Power-fin are at
least equal to the SERVICE clearances shown in FIG. 1-1.
For spaces that do NOT supply this clearance, provide
two openings as shown in FIG. 1-1. Each opening must
provide one square inch free area per 1,000 Btu/hr of
boiler input.
2. Combustion air openings are required when using the
Room Air Option on 24 of this manual.
The Power-fin in the same space with other gas or
oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1
(Canada) to size/verify size of the combustion/ventilation
air openings into the space.
The space must be provided with
combustion/ventilation air openings
correctly sized for all other appliances
located in the same space as the Power-fin.
Failure to comply with the above warnings
could result in severe personal injury,
death, or substantial property damage.
2. Size openings only on the basis of the other appliances in
the space. No additional air opening free area is needed
for the Power-fin when it takes its combustion air from
outside (direct vent installation).
⚠WARNING
Recommended clearances for service access
- Sides .............................................................................. 0"
- Rear ............................................................................... 24"
- Front ............................................................................. 24"
- Top ................................................................................ 24"
If you do not provide the recommended
service clearances shown, it may not be
possible to service the boiler without
removing it from the space.
NOTICE
Maintain minimum specified clearances for adequate
operation. All installations must allow sufficient space for
servicing the vent connections, water pipe connections, 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 this manual.
Multiple boilers may be installed side by side with no clearance
between adjacent boilers because this boiler is approved for
zero clearance from combustible surfaces; however, service
access will be limited from the sides.
Consult the Venting section of this manual for specific
installation instructions for the appropriate type of venting
system that you will be using.
Installation & Operation Manual
12
1 Determine unit location
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
⚠WARNING
When using an existing vent system to
install a new boiler:
Check the following venting components before installing:
• Material - For materials listed for use with this appliance,
see Section 2 - Venting.
• Size - To ensure proper pipe size is in place, see Table 2D.
Check to see that this size is used throughout the vent
system.
• Manufacturer - Only use the listed manufacturers and
their type product listed in Table 2B for CAT IV positive
pressure venting with flue producing condensate.
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. The supports
should adequately prevent sagging and vertical slippage,
by distributing the vent system weight. For additional
information, consult the vent manufacturer’s
instructions for installation.
• Terminations - Carefully review Section 2 to
ensure requirements for the location of the vent and air
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical
options listed in the General Venting Section. ?
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 13.
With stainless steel vent, seal and connect all pipe and
components as specified by the vent manufacturer used.
Do not install the boiler on carpeting even if
foundation is used. Fire can result, causing
severe personal injury, death, or substantial
property damage.
If flooding is possible, elevate the boiler sufficiently to prevent
water from reaching the boiler.
Flooring and foundation
Flooring
The Power-fin is approved for installation on combustible
flooring, but must never be installed on carpeting.
Vent and air piping
The Power-fin requires a special gas vent system, designed for
pressurized venting.
The boiler is to be used for either direct vent installation or
for installation using indoor combustion air. See page 14 of
this manual when considering room air. Note prevention of
combustion air contamination below when considering vent/
air termination.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall, unless
otherwise specified. You may use any of the vent/air piping
methods covered in this manual. Do not attempt to install
the Power-fin using any other means.
Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits given in this
manual.
Prevent combustion air contamination
Install air inlet piping for the Power-fin as described in this
manual. Do not terminate vent/air in locations that can allow
contamination of combustion air. Refer to Table 1A, page
13 for products and areas which may cause contaminated
combustion air.
Ensure that the combustion air will not
contain any of the contaminants in Table
1A, page 13. Contaminated combustion
air will damage the boiler, resulting in
possible severe personal injury, death
or substantial property damage. Do not
pipe combustion air near a swimming
pool, for example. Also, avoid areas
subject to exhaust fumes from laundry
facilities. These areas will always contain
contaminants.
⚠WARNING
⚠WARNING
Assure that the floor and structure is
sufficient to support the installed weight
of the boiler, including the water content
in the heat exchanger. If not, structural
building failure will result, causing severe
personal injury, death, or substantial
property damage.
⚠WARNING
Installation & Operation Manual
1 Determine unit location (continued)
13
When removing a boiler from existing
common vent system:
Do not install the Power-fin into a common
vent with any other appliance except as noted
in Section 2 on page 22 or 25. This will cause
flue gas spillage or appliance malfunction,
resulting in possible severe personal injury,
death, or substantial property damage.
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury or
death.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while the
other appliances remaining connected to the common venting
system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies, which
could cause an unsafe condition.
c. Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space in
which the appliances remaining connected to the common
venting system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust thermostat so appliance will
operate continuously.
e. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a match
or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined herein, return doors, windows,
exhaust fans, fireplace dampers, and any other gas-burning
appliance to their previous conditions of use.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CAN/CSA B149.1, Natural Gas and Propane Installation
Code. When re-sizing any portion of the common venting
system, the common venting system should be resized
to approach the minimum size as determined using the
appropriate tables in Part 11 of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code.
⚠ DANGER
⚠WARNING
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other similar
products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Table 1A Corrosive Contaminants and Sources
Installation & Operation Manual
14
1 Determine unit location
Remove boiler from wood pallet
1. To remove the boiler from the pallet:
a. Remove the four (4) shipping brackets securing the unit
to the right and left sides of the pallet.
b. The boiler can now be removed from the pallet
using a lift truck lifting from the front or rear of
the boiler. The lift truck forks must extend at
least half way under the boiler heat exchanger to
assure proper lifting technique with no damage to
the boiler.
Do not drop the boiler or bump the jacket
on the floor or pallet. Damage to the boiler
can result.
NOTICE
Combustion and ventilation air
requirements for appliances drawing air
from the equipment room
Provisions for combustion and ventilation air must be in
accordance with Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas Code, NFPA 54 / ANSI
Z223.1, in Canada, the latest edition of 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 and/or be of sufficient volume to assure adequate
combustion air and proper ventilation for all gas fired appliances
in the equipment room to assure adequate combustion air and
proper ventilation.
The requirements shown are for the appliance only; additional
gas fired appliances in the equipment room will require an
increase in the net free area and/or volume to supply adequate
combustion air for all appliances.
No combustion air openings are needed when the appliance is
installed in a space with a volume NO LESS than 50 cubic feet
per 1,000 Btu/hr of all installed gas fired appliances and the
building MUST NOT be of “Tight Construction”
3
.
A combination of indoor and outdoor combustion air may
be utilized by applying a ratio of available volume to required
volume times the required outdoor air opening(s) size(s). This
must be done in accordance with the National Fuel Gas Code,
NFPA 54 / ANSI Z223.1.
Figure 1-2_Combustion Air Direct from Outside
1. If air is taken directly from outside the building
with no duct, provide two permanent openings to
the equipment room each with a net free area of one square
inch per 4000 Btu/hr input (5.5 cm
2
per kW) (see FIG. 1-2).
DIR #2000528613 00
Figure 1-3_Combustion Air Through Ducts
2. If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the
equipment room, each of the two openings should be
sized based on a minimum free area of one square inch
per 2000 Btu/hr (11 cm
2
per kW) of input (see FIG. 1-3).
Figure 1-4_Combustion Air from Interior Space
DIR #2000528615 00
DIR #2000528618 00
Installation & Operation Manual
15
1 Determine unit location (continued)
3. If air is taken from another interior space combined with
the equipment room:
(a) Two spaces on same story: Each of the two openings
specified above should have a net free area of one square
inch for each 1000 Btu/hr (22 cm
2
per kW) of input, but
not less than 100 square inches (645 cm
2
) (see FIG. 1-4).
(b) Two spaces on different stories: One or more openings
should have a net free area of two square inches per 1000
Btu/hr (44 cm
2
per kW).
Figure 1-5_Combustion Air from Outside - Single Opening
DIR #2000528624 00
4. If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the
opening must be sized based on a minimum free area
of one square inch per 3000 Btu/hr (7 cm
2
per kW). This
opening must be located within 12” (30 cm) of the top of
the enclosure (see FIG. 1-5).
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.
Combustion air requirements are based on the latest edition
of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1; in
Canada refer to the latest edition of CGA Standard CAN/CSA
B149.1. Check all local code requirements for combustion air.
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 equipment room. Each opening must have a
net free area as specified in Table 1B. Single openings shall
commence within 12" (30 cm) of the ceiling. The minimum
dimension of air openings shall not be less than 3" (80 mm).
⚠CAUTION
Under no circumstances should the
equipment room ever be under 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.
The result is improper combustion and a non-warrantable,
premature appliance failure.
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. If a fan is used to supply combustion
air to the equipment room, the installer must make sure that it
does not cause drafts which could lead to nuisance operational
problems with the appliance.
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, headers, flue collectors, and
the vent system.
Installation & Operation Manual
16
1 Determine unit location
Figure 1-7_Filter Access
1. Locate the combustion air filter box mounted on the rear of
the appliance.
2. Locate the flat thumb bolt at the top of the air filter box and
turn it a 1/4 turn counterclockwise to align it with the slot
in the air filter box.
3. Lift and remove the air filter box cover to gain access to the
air filter.
4. Slide the air filter out the top of the air filter box.
5. Inspect the air filter for dirt and debris, replace if necessary.
6. Replace the air filter and the air filter box cover. Turn the
thumb bolt clockwise a 1/4 turn to secure the air filter box
cover to the air filter box.
CAUTION
During construction the air filter should be
checked more frequently to ensure it does
not become clogged with combustion dirt
and debris.
NOTICE
Sustained operation of an appliance with
a clogged burner may result in nuisance
operational problems, bad combustion, and
non-warrantable component failures.
TABLE - 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
Model
Number
*Outside Air from
2 Openings Directly from
Outdoors
*Outside Air from
1 Opening Directly
from Outdoors, in
2
Inside Air from
2 Ducts Delivered from
Outdoors
Inside Air from
2 Ducts Delivered from
Interior Space
Top
Opening, in
2
Bottom
Opening, in
2
Top
Opening, in
2
Bottom
Opening, in
2
Top
Opening, in
2
Bottom
Opening, in
2
502
125
(807 cm
2
)
125
(807 cm
2
)
167
(1077 cm
2
)
250
(1613 cm
2
)
250
(1613 cm
2
)
500
(3226 cm
2
)
500
(3226 cm
2
)
752
188
(1213 cm
2
)
188
(1213 cm
2
)
250
(1613 cm
2
)
375
(2420 cm
2
)
375
(2420 cm
2
)
750
(4839 cm
2
)
750
(4839 cm
2
)
1002
250
(1613 cm
2
)
250
(1613 cm
2
)
333
(2149 cm
2
)
500
(3226 cm
2
)
500
(3226 cm
2
)
1000
(6452 cm
2
)
1000
(6452 cm
2
)
1302
325
(2097 cm
2
)
325
(2097 cm
2
)
433
(2794 cm
2
)
650
(4194 cm
2
)
650
(4194 cm
2
)
1300
(8388 cm
2
)
1300
(8388 cm
2
)
1501
375
(2420 cm
2
)
375
(2420 cm
2
)
500
(3226 cm
2
)
750
(4839 cm
2
)
750
(4839 cm
2
)
1500
(9678 cm
2
)
1500
(9678 cm
2
)
1701
425
(2742 cm
2
)
425
(2742 cm
2
)
567
(3658 cm
2
)
850
(5484 cm
2
)
850
(5484 cm
2
)
1700
(10968 cm
2
)
1700
(10968 cm
2
)
2001
500
(3226 cm
2
)
500
(3226 cm
2
)
667
(4303 cm
2
)
1000
(6452 cm
2
)
1000
(6452 cm
2
)
2000
(12904 cm
2
)
2000
(12904 cm
2
)
The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase
in the net free area and/or volume to supply adequate combustion air for all appliances.
No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per
1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”
3
.
1
Outside air openings shall directly communicate with the outdoors.
2
Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.
3
”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour). For buildings of “Tight
Construction”, provide air openings into the building from outside.
Combustion air filter
This unit has a standard air filter located at the combustion air
inlet as shown above in FIG. 1-7. This air filter is provided to
help ensure clean air is used for the combustion process. Check
this filter every month and replace when it becomes dirty. The
filter size on Models 502 -1302 is 16” x 12” x 1” (40.6cm x
30.5cm x 2.5cm) and for Models 1501 - 2001 it is 16” x 16” x 1”
(40.6cm x 40.6cm x 2.5cm). You can find these commercially
available filters at any home center or HVAC supply store.
Follow the steps below when replacing the combustion air filter:
Installation & Operation Manual
2 Venting
BEFORE YOU BEGIN
Identify your appliance’s vent system:
This manual covers venting requirements for CAT II/IV and CAT I models. Be sure to correctly identify the type of vent
system your appliance requires before proceeding.
Category II/IV Models: See page 19
Water PFN0502PM-M9
Heaters PFN0752PM-M9
PFN1002PM-M9
PFN1302PM-M9
PFN1501PM-M9
PFN1701PM-M9
PFN2001PM-M9
Boilers PBN0502-M9
PBN0752-M9
PBN1002-M9
PBN1302-M9
PBN1501-M9
PBN1701-M9
PBN2001-M9
A
D
B C
E F
CAT II requires vent
increaser kit.
Venting options:
Category I (Fan Assisted) Models: See page 24
Water PFN0502PM-F9
Heaters PFN0752PM-F9
PFN1002PM-F9
PFN1302PM-F9
PFN1501PM-F9(*)
PFN1701PM-F9(*)
PFN2001PM-F9(*)
Boilers PBN0502-F9
PBN0752-F9
PBN1002-F9
PBN1302-F9
PBN1501-B9(*)
PBN1701-B9(*)
PBN2001-B9(*)
G H I
Venting options:
⚠ DANGER
Failure to use correct venting materials can result in loss of life from flue gas spillage into working or
living space.
Venting Category Definitions: (Reference National Fuel Gas Code ANSI Z223.1)
CAT IV: Positive pressure condensing
An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause excessive condensate
production in the vent.
CAT II: Negative pressure condensing
An appliance that operates with a non-positive vent static pressure with a vent gas temperature that may cause excessive
condensate production in the vent.
CAT I: Negative pressure non-condensing
An appliance that operates with a non-positive vent static pressure with a vent gas temperature that avoids excessive condensate
production in the vent.
*CAT I “B9” models require field supplied barometric dampers.
NOTICE
Category II venting is required when common
venting multiple M9 models .
17
NOTICE
PB/PF 0502 - 1302 - F9 Models (Only) with a CAT I
sized vent connection can be sidewall vented per the
requirements from the D, E, and F vent sections of
this manual.
Installation & Operation Manual
18
2 Venting
Vent Materials:
Category II/IV Vent Material
Suppliers:
Category II/IV flue pipe materials and vent adapters can be
obtained from the following manufacturers:
Or other listed Category IV vent systems suitable for a
condensing, positive pressure, gas fired appliance.
A Category IV flue MUST have all vent joints and seams sealed
gastight and have provisions for a drain to properly collect and
dispose of condensate that may occur in the venting system.
Category II Increaser Kit
“Must be purchased from manufacturer”
Figure 2-2_Category IV to II Conversion Chart
TABLE - 2B
FLUE ADAPTER SIZES
MODEL FLUE ADAPTER SIZE
PB/FN0502-M9 4"
PB/FN0752-M9 5"
PB/FN1002-M9 6"
PB/FN1302-M9 8"
PB/FN1501-M9 6"
PB/FN1701-M9 7"
PB/FN2001-M9 8"
TABLE - 2C
CATEGORY IV TO CATEGORY II CONVERSION
KITS
MODEL FLUE SIZE KIT NUMBERS
PB/FN0502-M9 4" to 7" 100338293
PB/FN0752-M9 5" to 9" 100338294
PB/FN1002-M9 6" to 10" 100338295
PB/FN1302-M9 8" to 12" 100338296
PB/FN1501-M9 6" to 8" 100338297
PB/FN1701-M9 7" to 9" 100338298
PB/FN2001-M9 8" to 10" 100338299
Category I Vent Material Suppliers:
Category I venting materials are readily available from your local plumbing/HVAC supply houses.
*Note: The manufacturer of the selected vent material can also provide a vent adapter to connect the vent material to the
Power-fin’s vent connection.
Figure 2-1_Flue vs. Rain Shield Connection
CAUTION
DO NOT attach vent pipe to rain shield.
Vent pipe should be connected directly to
the flue pipe (see FIG. 2-1).
The Power-Fin M9 models are supplied with an integral FasNSeal vent connector. The installer must use a
specific vent starter adapter supplied by the vent manufacturer to adapt to different vent systems.
NOTICE
Common venting CAT II:
Flues of multiple appliances may be combined by incorporating
a vent increaser to change the Category IV appliance to a
Category II vent system which can be common vented using
an engineered vent system. An increaser must be used and
the combined engineered vent system must be designed to
ensure that flue products will be properly exhausted from the
building at all times. Failure to use the correct vent increaser
or a properly sized vent system may result in a hazardous
condition where flue gases spill into an occupied living
space. Consult a vent designer to determine the diameter of
the common vent pipe required for combined vent installation.
It is recommended that all vent joints and seams are sealed
gastight. This vent system has specific vent material and
installation requirements. The negative draft in a conventional
vent installation must be within the range of 0.02 to 0.08 inches
w.c. to ensure proper operation. Make all draft readings while
the unit is in stable operation (approximately 2 to 5 minutes).
TABLE - 2A
APPROVED STAINLESS STEEL VENT
MANUFACTURERS
Make Model Standard
ProTech Systems FasNSeal Vent UL1738 / ULC-S636
Z-Flex Z-Vent UL1738 / ULC-S636
Heat Fab Saf-T CI Vent UL1738 / ULC-S636
Metal Fab Corr/Guard Vent UL1738 / ULC-S636
Flex-L International StaR 34 Vent UL1738 / ULC-S636
*with AL29-4C Stainless Steel
2000844747 00
FLUE CONNECTION
(RAW PIPE FOR F9/B9)
RAIN SHIELD
FLUE CONNECTION
(FEMALE NOMINAL
CONNECTION FOR M9)
Installation & Operation Manual
2 Venting (continued)
19
Condensing Vent Options: CAT II & IV
(CAT II vent options A, B, & C requires an adapter kit - see page 18)
A
CAT II
requires an
adapter kit.
See page 18.
Vertical vent with combustion air from
equipment room - see page 20.
CAT II/
IV
D
Sidewall termination with combustion air from
equipment room - see page 21.
CAT IV
B
CAT II
requires an
adapter kit.
See page 18.
Vertical Direct Vent installation with rooftop
combustion air inlet - see page 20.
CAT II/
IV
E
Horizontal Direct Vent installation with sidewall
combustion air inlet - see page 22.
CAT IV
C
CAT II
requires an
adapter kit.
See page 18.
Vertical DirectAire installation with sidewall
combustion air inlet - see page 21.
CAT II/
IV
F
Horizontal DirectAire installation with vertical
combustion air inlet - see page 22.
CAT IV
DIR #2000533996 00
D
IR
#
2
000533996
00
OUTDOOR
VENTING
see page 23
Installation & Operation Manual
20
2 Venting
A
CAT II
requires an
adapter kit.
See page 18.
CAT II/IV
Vertical vent with combustion air from equipment room - see page 19.
The flue outlet terminates on the rooftop.
The termination point for the flue products must follow the vertical vent termination clearance requirements
on pages 32 and 33. These units can be identified by the Category IV and the control number M9 as noted on
the unit’s rating plate.
The flue from this Category IV appliance must have all vent joints and seams sealed gastight. 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.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a vertical termination (see pages 27 and 28).
Condensing vent options: CAT II & IV
(CAT II vent options A, B, & C requires an adapter kit - see page 18)
TABLE - 2D
VENT TERMINATION SIZES
MODEL
CAT II
VENT SIZE
CAT IV
VENT SIZE
MODEL
CAT II
VENT SIZE
CAT IV
VENT SIZE
PB/FN0502-M9 7" 4" PB/FN1501-M9 8" 6"
PB/FN0752-M9 9" 5" PB/FN1701-M9 9" 7"
PB/FN1002-M9 10" 6" PB/FN2001-M9 10" 8"
PB/FN1302-M9 12" 8"
-- -- --
B
CAT II
requires an
adapter kit.
See page 18.
CAT II/IV
Vertical direct vent installation with rooftop combustion air inlet - see
page 19.
The Vertical Direct Vent system is installed with a Category IV flue and a separate combustion air pipe to the
outdoors. The flue outlet and combustion air intake must both terminate on the rooftop.
The termination point for the flue products must follow the vertical vent termination clearance requirements
on pages 32 and 33. These units can be identified by the Category IV and the control number M9 as noted on
the unit’s rating plate.
The optional Direct Vent system requires the installation of specific venting materials that are purchased
locally.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a vertical termination (see pages 27 and 28).
The Vertical Direct Vent system requires the installation of an additional pipe to supply combustion air from
outdoors directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages
30 and 31.
TABLE - 2E
AIR & VENT TERMINATION SIZES
MODEL
CAT II CAT IV
MODEL
CAT II CAT IV
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
PB/FN0502-M9 5" 7" 5" 4" PB/FN1501-M9 6" 8" 6" 6"
PB/FN0752-M9 5" 9" 5" 5" PB/FN1701-M9 7" 9" 7" 7"
PB/FN1002-M9 6" 10" 6" 6" PB/FN2001-M9 8" 10" 8" 8"
PB/FN1302-M9 6" 12" 6" 8"
-- -- -- -- --
Installation & Operation Manual
2 Venting (continued)
21
Condensing vent options: CAT II & IV
(CAT II vent options A, B, & C requires an adapter kit - see page 18)
C
CAT II
requires an
adapter kit.
See page 18.
CAT II/IV
DirectAire Vertical installation with sidewall combustion air inlet - see
page 19.
The DirectAire Vertical with a Sidewall Combustion Air Vent system terminates the flue at the rooftop and air inlet
at the sidewall. The flue outlet and combustion air intake terminate in different pressure zones.
The optional DirectAire vent system requires the installation of specific venting materials that are purchased locally.
The termination point for the flue products must follow the vertical vent termination clearance requirements on
pages 32 and 33. These units can be identified by the Category IV and the control number M9 as noted on the
unit’s rating plate.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a vertical termination (see pages 27 and 28).
The DirectAire Vertical system requires the installation of an additional pipe to supply combustion air from
outdoors directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages 30
and 31.
Sidewall combustion air inlet: 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 model. 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 - 2F
AIR INLET CAP TERMINATIONS
MODEL
CAT II CAT IV
CAT IV
KIT
NUMBER
MODEL
CAT II CAT IV
CAT
IV KIT
NUMBER
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
PB/FN0502-M9 5" 7" 5" 4" 100168088 PB/FN1501-M9 6" 8" 6" 6" 100168089
PB/FN0752-M9 5" 9" 5" 5" 100168088 PB/FN1701-M9 7" 9" 7" 7" 100168090
PB/FN1002-M9 6" 10" 6" 6" 100168089 PB/FN2001-M9 8" 10" 8" 8" 100168091
PB/FN1302-M9 6" 12" 6" 8" 100168089
-- -- -- -- -- --
Air Inlet Cap
D
CAT IV
Sidewall termination with combustion air from equipment room - see page
19.
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed Category IV
vent materials and accessories. The installer must supply suitable vent pipe material. The sidewall vent cap must
be purchased from the appliance manufacturer.
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.
The termination point for the flue products must follow the sidewall vent termination clearance requirements
on pages 33 - 36. These units can be identified by the Category IV and the control number M9 as noted on the
unit’s rating plate. Note: PB/FN0502 - 1302 - F9 models with Category I sized vent connection can be sidewall
vented with Category IV vent material using the vent decreaser included in the kit listed in Table 2G. This venting
technique with corresponding vent decreasers is not available on the larger PB/FN1501 - 2001 models.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a sidewall termination (see pages 27 and 28).
TABLE - 2G
FLUE VENT TERMINATION SIZES
MODEL
CAT IV
VENT SIZE
CAT IV
KIT
MODEL
CAT IV
VENT SIZE
CAT IV
KIT
MODEL
CAT IV
VENT SIZE
CAT IV
KIT
PB/FN0502-M9 4" 100169247 PB/FN0502-F9 4" 100169234 PB/FN1501-M9 6" 100169201
PB/FN0752-M9 5" 100169248 PB/FN0752-F9 5" 100169235 PB/FN1701-M9 7" 100169202
PB/FN1002-M9 6" 100169201 PB/FN1002-F9 6" 100169236 PB/FN2001-M9 8" 100169246
PB/FN1302-M9 8" 100169246 PB/FN1302-F9 8" 100169237
--
-- --
Vent Cap
22
2 Venting
E
CAT IV
Condensing vent options: CAT IV
Horizontal direct vent installation with sidewall combustion air inlet - see
page 19.
The horizontal direct vent system is installed with a Category IV flue and a separate combustion air pipe to the outdoors.
The flue outlet and combustion air intake must both terminate on the same sidewall.
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed Category IV vent
materials and accessories. The installer must supply suitable vent pipe material. The horizontal direct vent must be
purchased from the appliance manufacturer.
The termination point for the flue products must follow the sidewall vent termination clearance requirements on pages
33 - 36. These units can be identified by the Category IV and the control number M9 as noted on the unit’s rating plate.
Note: PB/FN0502 - 1302 - F9 models with Category I sized vent connection can be sidewall vented with Category IV
vent material using the vent decreaser included in the kit listed in Table 2H. This venting technique with corresponding
vent decreasers is not available on the larger PB/FN1501 - 2001 models.
The horizontal direct vent kit includes the wall penetration assembly and the discharge screen assembly for the flue and
a combustion air inlet cap. All required vent pipe and fittings must be purchased locally.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation and for
venting flue products to the outdoors with a sidewall termination (see pages 27 and 28).
The horizontal direct vent system requires the installation of an additional pipe to supply combustion air from outdoors
directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages 30 and 31.
TABLE - 2H
SIDEWALL AIR AND VENT TERMINATION SIZES
MODEL
CAT IV
CAT IV
KIT
MODEL
CAT IV
CAT IV
KIT
MODEL
CAT IV
CAT IV
KIT
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
PB/FN0502-M9 5" 4" 100147172 PB/FN0502-F9 5" 4" 100147161 PB/FN1501-M9 6" 6" 100147169
PB/FN0752-M9 5" 5" 100147173 PB/FN0752-F9 5" 5" 100147162 PB/FN1701-M9 7" 7" 100147170
PB/FN1002-M9 6" 6" 100147169 PB/FN1002-F9 6" 6" 100147163 PB/FN2001-M9 8" 8" 100147171
PB/FN1302-M9 6" 8" 100147174 PB/FN1302-F9 6" 8" 100147164
-- -- -- --
Vent Cap
Air Inlet Cap
F
CAT IV
Horizontal DirectAire installation with vertical or sidewall combustion air -
page 19.
The Horizontal DirectAire vent system terminates the flue at the sidewall and air inlet at either the rooftop or a sidewall
opposite the vent termination. The flue outlet and combustion air intake terminate in different pressure zones.
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed Category IV vent
materials and accessories. The installer must supply suitable vent pipe material. The Horizontal DirectAire vent cap must
be purchased from the appliance manufacturer.
The termination point for the flue products must follow the sidewall vent termination clearance requirements on pages
33 - 36. These units can be identified by the Category IV and the control number M9 as noted on the unit’s rating plate.
Note: PB/FN0502 - 1302 - F9 models with Category I sized vent connection can be sidewall vented with Category IV
vent material using the vent decreaser included in the kit listed in Table 2I. This venting technique with corresponding
vent decreasers is not available on the larger PB/FN1501 - 2001 models.
The Horizontal DirectAire vent system with a vertical air inlet requires a sidewall vent kit. The Horizontal DirectAire
vent system with a sidewall air inlet requires a horizontal direct vent kit. All required vent pipe and fittings must be
purchased locally.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation and for
venting flue products to the outdoors with a sidewall termination (see pages 27 and 28).
The Horizontal DirectAire vent system requires the installation of an additional pipe to supply combustion air from
outdoors directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages 29 and 30.
TABLE - 2I
SIDEWALL VENT TERMINATION SIZES
MODEL
CAT IV
CAT IV
KIT
MODEL
CAT IV
CAT IV
KIT
MODEL
CAT IV
CAT IV
KIT
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
PB/FN0502-M9
5"
4" 100169247 PB/FN0502-F9 5" 4" 100169234 PB/FN1501-M9 6" 6" 100169201
PB/FN0752-M9
5"
5" 100169248 PB/FN0752-F9 5" 5" 100169235 PB/FN1701-M9 7" 7" 100169202
PB/FN1002-M9
6"
6" 100169201 PB/FN1002-F9 6" 6" 100169236 PB/FN2001-M9 8" 8" 100169246
PB/FN1302-M9
6"
8" 100169246 PB/FN1302-F9 6" 8" 100169237
-- -- --
--
Vent Cap
Installation & Operation Manual
23
2 Venting (continued)
Installation & Operation Manual
Outdoor venting
• In order to properly vent the appliance in an outdoor
configuration the optional outdoor vent kit must be used
(see Table 2I).
• Vent materials for outdoor venting are to be field supplied.
• The vent must terminate at least 36 inches above the top of
the unit.
• All vent materials must be supported as recommended by
the vent manufacturer.
• The terminations in Table 2K must be used.
Model Outdoor Kit No. Description
502 - 1302 100280318 M/B Series
1501 - 2001 100280319 M Series
1501 - 2001 100280320 B Series
Table 2J Outdoor Vent Kits
Before installing a venting system, follow all
requirements found in the General Venting
section of this manual.
Outdoor vent / air inlet location
Keep venting areas free of obstructions. Keep area clean and free
of combustible and ammable materials. Maintain minimum
clearances to combustibles as stated in this manual.
Do not install outdoor models directly on the ground. You must
install the outdoor unit on a concrete, brick, block, or pressure-
treated wood platform.
NOTICE
Only install outdoor models outdoors,
and only use the vent caps specified in
this manual. Personal injury or product
damage may result if any other cap is used,
or if an outdoor model is used indoors.
Properly install all covers, doors, and jacket
panels to ensure proper operation and
prevent a hazardous condition.
Units are self-venting and can be used outdoors when installed
with the optional outdoor kit. All vent materials must be eld
supplied and supported per the vent manufacturer’s instructions.
Combustion air supply must be free of contaminants (see the
Combustion and Ventilation Air Requirements section of this
manual). To prevent recirculation of the ue products into the
combustion air inlet, follow all instructions in this section.
⚠WARNING
Model
Category IV (AL29-4C)
Diameter Heat Fab Z-Flex Metal-Fab
PB/PF 502
4 CCA04RC/5400CI 2SVSRCF04 4CGSWC
PB/PF 752
5 CCA05RC/5500CI 2SVSRC05 5CGSWC
PB/PF 1002
6 CCA06RC/5600CI 2SVSRC06 6FCSSWCB
PB/PF 1302
8 CCA08RC/5800CI 2SVSRC08 8FCSSWCB
PB/PF 1501
6 CCA06RC/5600CI 2SVSRC06 6FCSSWCB
PB/PF 1701
7 CCA07RC/5700CI 2SVSRC07 7FCSSWCB
PB/PF 2001
8 CCA08RC/5800CI 2SVSRC08 8FCSSWCB
Table 2K Approved Outdoor Terminations
Model
Category I
Diameter Heat Fab Z-Flex Metal-Fab
PB/PF 502
7 CCA07RC/5700CI 2SVDRC07 7MC
PB/PF 752
9 CCA09RC/5900CI 2SVDRC09 10MC*
PB/PF 1002
10 CCA10RC/51000CI 2SVDRC10 10MC
PB/PF 1302
12 CCA12RC/51200CI 2SVDRC12 12MC
PB/PF 1501
12 CCA12RC/51200CI 2SVDRC12 12MC
PB/PF 1701
14 CCA14RC/51400CI 2SVDRC14 14MC
PB/PF 2001
14 CCA14RC/51400CI 2SVDRC14 14MC
*Requires increaser for diameter of termination.
Note: e terminations listed above can be used on indoor installations, but are required on all outdoor installations.
Installation & Operation Manual
2 Venting
24
Non-Condensing Vent Options: CAT I
G
Vertical negative draft venting system - see
pages 25 and 26.
H
DirectAire vertical venting with vertical air inlet
- see pages 25 and 26.
I
DirectAire vertical venting with sidewall inlet -
see pages 25 and 26.
A required field supplied
barometric damper MUST BE
installed in location shown.
3'
12"
A required field supplied
barometric damper MUST BE
installed in location shown.
A required field supplied
barometric damper MUST BE
installed in location shown.
Vertical negative draft venting system -
see page 25.
CAT I - F9
CAT I - B9
DirectAire vertical venting with vertical
air inlet - see page 25.
CAT I - F9CAT I - B9
DirectAire vertical venting with sidewall
inlet - see page 25.
CAT I - F9
CAT I - B9
INCORRECT
INSTALLATIONS
Installation & Operation Manual
25
2 Venting (continued)
Non-Condensing vent options: CAT I
Vertical negative draft venting system - see page 24.
Units that may be vented with a Category I, Type “B” vent material operate with limited burner modulation.
These units can be identified by the Category I and the control number F9 or B9 as noted on the unit’s rating
plate. These are the only units that can be vented with standard double-wall vent material. See the General
Venting and the Negative Draft General Venting on pages 26 and 27. The flue must terminate at the rooftop and
follow the clearance requirements on pages 32 and 33. Combustion air is supplied from the equipment room.
The installation of the vent must conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1, in
Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.
The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c. to
ensure proper operation. Make all draft readings while the unit is in stable operation (approximately 2 to 5
minutes).
TABLE - 2L
FIELD PROVIDED TERMINATIONS
MODEL VENT SIZES MODEL VENT SIZES
PB/FN0502-F9 7" PB/FN1501-F9 12"
PB/FN0752-F9 9" PB/FN1701-F9 14"
PB/FN1002-F9 10" PB/FN2001-F9 14"
PB/FN1302-F9 12"
-- --
G
CAT I
TABLE - 2M
FIELD PROVIDED TERMINATIONS
MODEL AIR SIZES VENT SIZES MODEL AIR SIZES VENT SIZES
PB/FN0502-F9 5" 7" PB/FN1501-F9 6" 12"
PB/FN0752-F9 5" 9" PB/FN1701-F9 7" 14"
PB/FN1002-F9 6" 10" PB/FN2001-F9 8" 14"
PB/FN1302-F9 6" 12"
-- -- --
DirectAire vertical venting with vertical air inlet - see page 24.
Units that may be vented with a Category I, Type “B” vent material operate with limited burner modulation.
These units can be identified by the Category I and the control number F9 or B9 as noted on the unit’s rating
plate. These are the only units that can be vented with standard double-wall vent material. See the General
Venting and the Negative Draft General Venting sections on pages 26 and 27. The flue must terminate at the
rooftop and follow the clearance requirements on pages 32 and 33. Combustion air is supplied vertically
from the rooftop. The installation of the vent must conform to the latest edition of the National Fuel Gas
Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment. The negative draft in a conventional vent installation must be within the range of
0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation
(approximately 2 to 5 minutes).
TABLE - 2N
AIR INLET CAP
MODEL
AIR
SIZES
VENT
SIZES
KIT
NUMBER
MODEL
AIR
SIZES
VENT
SIZES
KIT
NUMBER
PB/FN0502-F9 5" 7" 100168088 PB/FN1501-F9 6" 12" 100168089
PB/FN0752-F9 5" 9" 100168088 PB/FN1701-F9 7" 14" 100168090
PB/FN1002-F9 6" 10" 100168089 PB/FN2001-F9 8" 14" 100168091
PB/FN1302-F9 6" 12" 100168089
--
--
-- --
DirectAire vertical with sidewall air inlet - see page 24.
Units that may be vented with a Category I, Type “B” vent material operate with limited burner modulation.
These units can be identified by the Category I and the control number F9 or B9 as noted on the unit’s rating
plate. These are the only units that can be vented with standard double-wall vent material. See the General
Venting and the Negative Draft General Venting sections on pages 26 and 27. The flue must terminate at the
rooftop and follow the clearance requirements on pages 32 and 33. Combustion air is supplied horizontally
from the outside. The installation of the vent must conform to the latest edition of the National Fuel Gas
Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment. The negative draft in a conventional vent installation must be within the range of
0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation
(approximately 2 to 5 minutes).
H
CAT I
I
CAT I
Air Inlet Cap
Installation & Operation Manual
2 Venting
26
Common Venting CAT II:
Flues of multiple Power-fins may be combined by incorporating a vent increaser to change the Category IV appliance to a
Category II vent system which can be common vented using an engineered vent system. The increaser kit must be provided by the
manufacturer and the combined engineered vent system must be designed to ensure that flue products will be properly exhausted
from the building at all times. Failure to use the correct vent increaser or a properly sized vent system may result in a hazardous
condition where flue gases spill into an occupied living space. Consult a vent designer to determine the diameter of the common
vent pipe required for combined vent installation. It is recommended that all vent joints and seams are sealed gastight. This vent
system has specific vent material and installation requirements. The negative draft in a conventional vent installation must be
within the range of 0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation
(approximately 2 to 5 minutes).
Common Venting CAT I - Venting options: G, H, & I (F9 / B9)
The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c. to ensure proper
operation. Make all draft readings while the unit is in stable operation (approximately 2 to 5 minutes).
As noted in the diagrams on page 24, F9 models do not require a barometric damper in a single stack installation as illustrated.
However, common venting of multiple negative draft appliances requires that you MUST install a barometric damper on each
unit to regulate draft. Install per the requirements of the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/
CGA-B149 Installation Code. A field supplied inline condensate collection section MUST BE installed above the vent connector
of each unit.
Common Venting systems may be too large when an existing unit is removed. At the time of removal of an existing appliance,
follow the steps below with each appliance remaining connected to the common venting system placed in operation, while other
appliances remaining connected to the common venting system are not in operation:
a. Seal any unused opening in the common venting system.
b. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction,
leakage, corrosion, and other unsafe condition.
c. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances
remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers
and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods
and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace
dampers.
d. Place in operation the appliance being inspected. Follow the lighting (operating) instructions in this manual (see page 59).
Adjust thermostat so appliance will operate continuously.
e. Test for spillage at the draft hood / relief opening after five (5) minutes of main burner operation. Use the
flame of a match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance remaining connected to the common venting system vents properly when
tested as above, return doors, windows, exhaust fans, fireplace dampers, and other gas burning appliances to their previous
conditions of use.
g. Any improper operation of the common venting system should be corrected so that the installation conforms to the latest
edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code
for Gas Burning Appliances and Equipment.
When resizing any portion of the common venting system, the common venting system should be resized to approach the
minimum size as determined using the appropriate tables in the latest edition of the National Fuel Gas Code, ANSI Z223.1,
in Canada, the edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.
B9 Barometric Damper CAT I - Venting options: G, H, & I (Required for B9)
Category I B9 units require a field supplied barometric damper to be installed at the rear of the unit. The damper should be
installed directly after the flue collar prior to going vertical with the flue pipe as shown in the figures on page 24. The damper
position indicator should be visible after its installation. The damper should be sized appropriately for the flue pipe. 1501 B9 models
require a 12" damper. 1701 and 2001 B9 models require a 14" damper. When using barometric dampers, make-up air must be
supplied to the room in order for them to function. This location is important and specifically required for the B9 appliance and
may not match suggested locations found in the damper manufacturer’s installation manual. Otherwise follow the manufacturer’s
recommendations on damper installation and operation. The negative draft in a conventional vent installation must be within
the range of 0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation
(approximately 2 to 5 minutes).
Note: Barometric dampers may also be required on 502, 752, 1002, and 1302 “F9” models for use in high draft areas and are
required when common venting multiple negative draft Category I appliances (see Common Venting CAT I section).
Installation & Operation Manual
27
2 Venting (continued)
CAT I, II, & IV General venting information - Vent options: All Categories
Vent installation for connection to gas vents or chimneys must be in accordance with “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 Code for Gas
Burning Appliances and Equipment or applicable provisions of the local building codes.
All venting applications where combustion air is drawn from the equipment room must have adequate combustion and ventilation
air supplied to the equipment room in accordance with 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 distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the
minimum clearances stated in this manual and 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.
The vent connection is made directly to the flue outlet opening on the rear of the unit. The connection from the appliance vent to
the stack must be made as direct as possible with no reduction in diameter.
Vent system must be supported horizontally to prevent sagging. Methods and intervals for support vary by vent manufacturer and
vent material. Vent support methods and intervals shall adhere to vent manufacturer’s instructions, where applicable. Vent piping
must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.
When CAT II/IV venting is used, the vent for this appliance shall not terminate:
1. over public walkways; or
2. near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or
cause property damage; or
3. where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or
other equipment.
A water heater shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.
CAT IV Specific venting information: Vent Options A, B, C, D, E, & F
A Category IV venting system operates with a positive pressure in the vent. This positive pressure is generated by the internal
combustion air blower which operates the combustion process and also exhausts the flue products from the building. The Category
IV flue from this appliance cannot be combined with the vent from any other appliance. The Category IV flue from this appliance
must be a dedicated stack, there is one exception however. The Category IV flues from multiple Power-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
Category IV vent installation may result in a hazardous condition where flue gases spill into an occupied living space. Consult
the induced draft fan manufacturer to size the induced draft fan and to determine the diameter of the common vent pipe required
for a combined vent installation. The flue from this Category IV appliance must have all vent joints and seams sealed gastight. 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 flue 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.
The connection from the appliance vent to the stack or vent termination outside the building must be made with listed Category IV
vent material and must be as direct as possible. The Category IV vent and accessories such as firestop spacers, thimbles, caps, etc.,
must be installed in accordance with the vent manufacturer’s 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.
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.
NOTICE
Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness. Also
check for corrosion or deterioration. Immediately correct any problems observed in the venting system.
Installation & Operation Manual
2 Venting
28
CAT IV Specific venting information (continued): Vent options A, B, C, D, E, & F
Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs should slope upwards not less
than a 1/4 inch per foot 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 manufacturer’s 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. Connection of a negative draft flue into the positive pressure stack from this appliance
may cause flue products to be discharged into an occupied living space causing serious health injury.
When a Category IV vent system is disconnected for any reason, the flue must be reassembled and resealed according to the vent
manufacturer’s instructions.
The flue may terminate either vertically at the rooftop or horizontally on a sidewall. Refer to the specific vent termination sections
for information about recommended vent termination location and clearances.
Length of flue pipe
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 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.5m) of equivalent length for each 90° elbow installed in the
vent. Subtract 2 1/2 feet (0.7m) of equivalent length for each 45° elbow installed in the vent.
CAT II/IV Drain Tee Requirements: Vent options A, B, C, D, E, & F
Drain tee installation
A drain tee must be installed in the Category II & 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 rooftop termination or as one of the first
fittings in a horizontal flue connector that will terminate on a sidewall. Ensure that horizontal portions of the vent are properly
sloped to allow condensate to be evacuated at the drain tee. Plastic drain tubing, sized per the vent manufacturer’s instructions,
shall be provided as a drain line from the tee. The drain tubing must have a trap provided by a 10” (25.4cm) 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 neutralization system or a
suitable drain for disposal of condensate that may occur in the Category IV vent system. Ensure that the drain from the condensate
tee is not exposed to freezing temperatures. See Section 7, Startup - Freeze Protection for more information.
Figure 2-3_Drain Tee Installation
CAT I Specific venting information:
Follow all requirements set forth in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of
the CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local
building codes.
Installation & Operation Manual
29
2 Venting (continued)
Vertical Air Inlet: Vent options B, F, & H
Vertical combustion air inlet
The air inlet cap for the vertical rooftop air inlet is assembled from components purchased locally. The air inlet cap consists of two
90° elbows installed at the point of termination for the air inlet pipe. The first 90° elbow is installed on the rooftop at the highest
vertical point of the air inlet pipe and turned horizontal, the second 90° elbow is installed on the horizontal outlet of the first elbow
and turned down.
A 90° elbow and a 90° street elbow may be used to make this assembly. If a straight piece of pipe is used between the two elbows,
it should not exceed 6 inches (152mm) in length. The termination elbow on the air inlet must be located a minimum of 12 inches
(0.30m) above the roof or above normal levels of snow accumulation.
Location of a vertical 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 point of termination for the combustion air inlet cap MUST be at least 3 feet (0.91m) below the point of flue gas termination
(vent cap) if it is located within a 10 foot (3.05m) 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 (3.05m) 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 (0.30m) above the rooftop and above
normal snow levels as shown in FIG. 2-4.
The combustion air cap assembly used MUST adequately protect the combustion air inlet from wind and weather.
Combustion air supplied from outdoors must be free of contaminants (see Combustion and Ventilation Air, page 14). To prevent
recirculation of flue products into the combustion air inlet, follow all instructions in this section.
The combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot (0.91m) clearance below the
closest vertical flue outlet if within 10 feet (3.05m).
Figure 2-4_Vertical Air Inlet Clearances
Installation & Operation Manual
2 Venting
30
Multiple horizontal or vertical direct vent installations
Horizontal Air Inlet: Vent options C, E, F, & I
Sidewall combustion air inlet
The sidewall termination caps for both the flue products and combustion air must be purchased from the appliance manufacturer.
The part numbers for the required sidewall termination kit are listed under each designated table. Each kit includes both the special
combustion air inlet cap and the sidewall flue cap for installation on an exterior sidewall. The sidewall air inlet cap supplied in the
kit is sized to provide combustion air for a single appliance only.
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 (0.30m) 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 (0.91m) vertically below
the point of flue gas termination (vent cap) if it is located within a 10 foot (3.05m) radius of the flue outlet as shown in FIG. 2-5.
Figure 2-5_Verticalal Air Inlet Clearances
The combustion air inlet cap must not be installed closer
than 10 feet (3.05m) from an inside corner of an L-shaped
structure.
The combustion air cap assembly used MUST adequately
protect the combustion air inlet from wind and weather.
Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air, page
14). To prevent recirculation of flue products into the
combustion air inlet, follow all instructions in this section.
12" MIN
GRADE OR
SNOW LINE
TO BOILER INTAKE
AIR CONNECTION
FROM BOILER VENT
PIPE CONNECTION
36" MIN
12" MIN
36"MIN
12"
12"
12"
AIR
VENT
DIR# 2000539531
Figure 2-6 Multiple Vent Terminations (must also comply
with Figure 2-6)
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 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
a 3 foot (0.91m) vertical radius and 12 inches (0.30m) between
the nearest flue outlet cap or air inlet cap must be maintained as
shown in FIG. 2-6. All clearance and installation requirements
in this section and the applicable portions of the Category
IV General Venting section must be maintained on multiple
appliance installations.
Installation & Operation Manual
31
2 Venting (continued)
Length of air inlet pipe for both vertical and horizontal - Vent options:
All Categories
The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 50 equivalent feet (15.2m) in length.
Subtract 5 feet (1.52m) of equivalent length for each 90° elbow installed in the air inlet pipe. Subtract 2 1/2 feet (0.7m) of equivalent
length for each 45° elbow installed in the air inlet pipe.
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:
PVC, CPVC or ABS
Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as specified in this section.
Type “B” double-wall vent with joints and seams sealed as specified in this section.
*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic
air inlet pipe.
⚠WARNING
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.
NOTICE
The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold
climates to prevent the condensation of airborne moisture in the incoming combustion air.
Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical
rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a
high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of horizontal runs.
c. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant
to all screws or rivets installed in the vent pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and
standard commercial pipe cement for the material used. Use only cleaners, primers, and solvents that are approved for the
materials which are joined. Horizontal runs shall have supports suitable for non-metallic vent piping that do not clamp tightly
onto vent, allowing for vent expansion or contraction. Supports shall be as close to joints and fittings as practical and no more
than 5 feet apart. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone 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 rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed
to ensure that combustion air will be free of contaminants and supplied in proper volume.
⚠ DANGER
Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation,
spillage of flue products and carbon monoxide emissions causing severe personal injury or death.
Combined combustion air inlet points - Category I, II, & IV
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" (20.3cm) air inlet pipes (50.3 in
2
(324.5cm
2
) area each) have a total area of 100.6 in
2
(645.2cm
2
) requires a 12 inch (30.5cm)
(113.1in
2
area) (729.7cm
2
) common air inlet pipe.] The air inlet point for multiple boiler air inlets must be provided with an exterior
opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet. This
exterior opening for combustion air must connect directly to the outdoors. The total length of the combined air inlet pipe must
not exceed a maximum of 50 equivalent feet (15.2m). You must deduct the restriction in area provided by any screens, grills, or
louvers installed in the common air inlet point. These (screens, grills, or louvers) 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.
Installation & Operation Manual
2 Venting
32
Vertical Vent Termination Clearances - Venting options: A, B, C, G, H & I
Figure 2-7_Vent Termination from Peaked Roof - 10 ft.
or Less From Ridge
Figure 2-8_Vent Termination from Peaked Roof - 10 ft.
or More From Ridge
Figure 2-9_Vent Termination from Flat Roof - 10 ft.
or Less From Parapet Wall
Figure 2-10_Vent Termination from Flat Roof - 10 ft. or
More From Parapet Wall
The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof
within a 10 foot (3.05m) radius of the termination.
The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.
A vertical termination less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet
wall.
The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot
(1.22m) horizontal distance is maintained from electric meters, gas meters, regulators, and relief equipment.
The venting system shall terminate at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m).
The venting system shall terminate at least 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above any door,
window, or gravity air inlet into any building.
Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent cannot terminate below
grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above the roof or above normal snow levels.
To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.
Vertical Vent Termination Clearances - Venting options: A, B, C, G, H & I
Flue gases from this appliance may contain large amounts of water vapor that will form a white plume in winter. Plume could
obstruct 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 dislodging of ice
from the vent system or vent termination.
Installation & Operation Manual
33
2 Venting (continued)
Vertical Vent Termination Clearances - Venting options: A, B, C, G, H & I
Masonry chimney installations
A masonry chimney must be properly sized for the installation of a high efficiency gas-fired appliance. Venting of a high
efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exterior masonry
chimneys, with one or more sides exposed to cold outdoor temperatures, are more likely to have venting problems. The temperature
of the flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney
to generate proper draft. This will result in condensing of flue products, damage to the masonry flue/tile, insufficient draft and
possible spillage of flue products into an occupied living space. Carefully inspect all chimney systems before installation.
A standard masonry chimney must NOT be used to vent the products of combustion from the flue of a Category IV, positive
pressure appliance. If a masonry chimney is to be used, the chimney MUST use a sealed, metallic, corrosion resistant liner system
to vent flue products from this high efficiency appliance. Sealed, metallic, corrosion resistant liner systems (single-wall, double-
wall, flexible or rigid metallic lines) 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 AL29-
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.
⚠ CAUTION
Venting of a high efficiency Category IV appliance into a masonry chimney without a sealed stainless steel
liner can result in operational and safety problems. Any breaks, leaks, or damage to the masonry flue/tile will
Location of a sidewall vent termination - Venting options: D, E, & F
The vent cap shall terminate at least 3 feet (0.91m) above any forced air inlet within 10 feet (3.05m).
The vent shall terminate at least 4 feet (1.22m) below, 4 feet (1.22m) horizontally from or 1 foot (0.30m) above and 2 feet (0.60m)
horizontally from any door, window, or gravity air inlet to the building.
The sidewall vent termination must be at least 8 feet (2.4m) horizontally from any combustion air intake located above the sidewall
termination cap.
Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent cap 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 (0.30m) above grade, above normal snow levels and at least 7 feet (2.13m) above
grade when located adjacent to public walkways.
The vent terminal shall not be installed closer than 3 feet (0.91m) from an inside corner of an L-shaped structure.
The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot
(1.22m) horizontal distance is maintained from electric meters, gas meters, regulators, and relief equipment.
Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked
flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be
protected with a rust resistant sheet metal plate.
The sidewall vent system MUST use the sidewall vent cap kit provided by the appliance manufacturer for installation on a sidewall
termination.
The sidewall vent cap MUST be purchased as a kit from the appliance manufacturer to ensure proper operation. Locally purchased
or fabricated sidewall vent caps should not be used.
allow spillage of the positive pressure flue products from the chimney. These flue products can easily escape into an
occupied living space causing a health hazard. If there is any doubt about the condition of a masonry chimney, or
its acceptability for use after insertion of a corrosion resistant liner system, consult with local code officials.
⚠WARNING
Do not vent this unit into a masonry chimney without a sealed stainless steel liner system. Any breaks, leaks or
damage to the masonry ue/tile will allow the ue products to leak from the chimney and into occupied living
spaces. is could cause serious injury or death due to carbon monoxide poisoning and other harmful ue products.
NOTICE
Check with local code ocials to determine code requirements or advisability of a masonry chimney with a
sealed corrosion-resistant liner system.
Inspection of a masonry chimney
A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products. A clay-tile-lined
chimney must be structurally sound, straight and free of misaligned tile, gaps between liner sections, missing sections of liner or any
signs of condensate drainage at the breaching or clean out. If there is any doubt about the condition of a masonry chimney, it must
be relined with a properly-sized and approved chimney liner system. An unlined masonry chimney must not be used to vent flue
products from this high-efficiency unit. An unlined chimney must be relined with an approved chimney liner system when a new
appliance is being attached to it. Metallic liner systems (Type-B double-wall or flexible or rigid metallic liners) are recommended.
Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney.
Installation & Operation Manual
2 Venting
34
Sidewall Vent Termination Clearances - Venting options: D, E, & F
Figure 2-11A Direct Vent Terminal Clearances
Canadian Installations¹ US Installations²
A =
Clearance above grade, veranda, porch,
deck, or balcony
12 in (30 cm) 12 in (30 cm)
B =
Clearance to window or door that may
be opened
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 9 in (23 cm) for appliances >
10,000 Btuh (3 kW) and < 50,000 Btuh (15
kW), 12 in (30 cm) for appliances > 50,000
Btuh (15 kW)
C =
Clearance to permanently closed
window
*
*
D =
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
*
*
E = Clearance to unventilated soffit
*
*
F = Clearance to outside corner
*
*
G = Clearance to inside corner
*
*
H =
Clearance to each side of center line
extended above meter / regulator
assembly
3 ft (91 cm) within a height 15 ft (4.6 m)
*
I =
Clearance to service regulator vent
outlet
3 ft (91 cm)
*
Table 2O Direct Vent Terminal Clearances
Installation & Operation Manual
2 Venting (continued)
35
K =
Clearance to a mechanical air supply
inlet
6 ft (1.83 m)
3 ft (91 cm) above if within 10 ft (3 m)
horizontally
L =
Clearance above paved sidewalk or
paved driveway located on public
property
7 ft (2.13 m)†
7 ft (2.13 m) for mechanical draft systems
(Category I appliances). Vents for
Category II and IV appliances cannot be
located above public walkways or other
areas where condensate or vapor can
cause a nuisance or hazard
M =
Clearance under veranda, porch, deck,
or balcony
12 in (30 cm)‡ *
* Clearance in accordance with local installation codes and the requirements of the gas supplier.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he oor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
Table 2O Direct Vent Terminal Clearances (continued)
Figure 2-11B Other than Direct Vent Terminal Clearances
J =
Clearance to nonmechanical air supply
inlet to building or the combustion air
inlet to any other appliance
6 in (15 cm) for appliances < 10,000 Btuh
(3kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh
(3kW), 9 in (23 cm) for appliances > 10,000
Btuh (3 kW) and < 50,000 Btuh (15 kW),
12 in (30 cm) for appliances > 50,000 Btuh
(15 kW)
Installation & Operation Manual
2 Venting
36
Canadian Installations¹ US Installations²
A =
Clearance above grade, veranda, porch,
deck, or balcony
12 in (30 cm) 12 in (30 cm)
B =
Clearance to window or door that may
be opened
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening; 1 ft
(300 mm) above opening
C =
Clearance to permanently closed
window
* *
D =
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
* *
E = Clearance to unventilated soffit
* *
F = Clearance to outside corner
* *
G = Clearance to inside corner
* *
H =
Clearance to each side of center line
extended above meter / regulator
assembly
3 ft (91 cm) within a height 15 ft (4.6 m)
*
I =
Clearance to service regulator vent
outlet
3 ft (91 cm)
*
J =
Clearance to nonmechanical air supply
inlet to building or the combustion air
inlet to any other appliance
6 in (15 cm) for appliances < 10,000 Btuh
(3kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening; 1 ft
(300 mm) above opening
K =
Clearance to a mechanical air supply
inlet
6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m)
horizontally
L =
Clearance above paved sidewalk or
paved driveway located on public
property
7 ft (2.13 m)† 7 ft (2.13 m) for mechanical draft systems
(Category I appliances). Vents for
Category II and IV appliances cannot be
located above public walkways or other
areas where condensate or vapor can
cause a nuisance or hazard
M =
Clearance under veranda, porch, deck,
or balcony
12 in (30 cm)‡ *
* Clearance in accordance with local installation codes and the requirements of the gas supplier.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he oor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
Table 2P Other than Direct Vent Terminal Clearances
DIR #2000537298 00
MANUAL
SHUTOFF
VALVE
GAS
CONNECTION
PIPE
WATER
INLET
WATER
OUTLET
Figure 3-1_Water Connections
Heat exchanger
This appliance uses a finned copper tube heat exchanger
to maximize the heat transfer process. The heat exchanger
is mounted in the inner jacket on the front side of the
appliance. The heat exchanger is composed of two circular,
glass lined, and cast iron headers with either 20 or 24
(depending on the model) vertical finned copper tubes
(FIG. 3-2). A series of “V” shaped baffles are installed
between the individual tubes to control the movement
of the flue products over the finned copper surface and
increase heat transfer. Water enters the heat exchanger
and makes four passes over the area exposed to direct heat
from the burner. A circulating pump MUST be installed
to ensure proper water flow over the heat transfer surfaces
during burner operation. Water temperatures in the heat
exchanger are determined by water flow.
Figure 3-2_Heat Exchanger(s)
Initial set-up of maximum water flow
On initial start-up of the Power-fin, the maximum water flow to
the heat exchanger must be checked and manually limited with
a valve or bypass before normal operation begins.
Minimum water temperatures
A minimum return water temperature of 140°F (60°C) has
been established to control condensate formation based on
the Btu/hr output at rated burner input. Maintaining inlet
water temperatures to the appliance equal to or higher than
the specified minimum temperature ensures proper operation
of the appliance and prevents condensate formation on the
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 temperature in the heat exchanger above
the 140°F (60°C) dew point of flue products. Operation of the
appliance 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 (see
the Low Temperature Bypass Requirements section on page 45
of this manual).
⚠ CAUTION
An appliance allowed to operate at return
temperatures below the specified minimum
setting may experience problems with
the operating controls, safety switches,
obstruction of the flue gas passages on the
heat exchanger, incomplete combustion and
possible flue gas spillage. Sustained operation
at lower than specified water temperatures
may cause hazardous conditions that may
result in personal injury or non-warrantable
damage to the appliance.
Inlet and outlet connections
For ease of service, install unions on the inlet and outlet
of the appliance. The connection to the appliance marked
“Water Inlet” on the header should be used for return from
the system. The connection on the header marked “Hot
Water Outlet” is to be connected to the supply side of the
system. Minimum water pipe connections to this appliance
are 2 1/2 inches (63.5mm) pipe. See the piping requirements
in the heating boiler or water heater section of this manual
for multiple appliance installations.
3 Water connections
37
Installation & Operation Manual
Water flow switch
A water flow switch is factory installed in the outlet piping on
all heating boilers and water heaters. The flow switch must
prove water flow before a trial for ignition can begin. The
flow switch requires a minimum flow of 26 GPM to make the
flow switch and start burner operation. A water flow switch
meets most code requirements for a low water cutoff device
on boilers requiring forced circulation for operation. A fault
message, Flow Sw/LWCO will be indicated in the Operator
Interface on a low water flow condition as sensed by the flow
switch.
Low water cutoff
If this boiler is installed above radiation level, a low water
cutoff device must be installed at the time of boiler installation.
An electronic low water cutoff is available as a factory supplied
option on all models. The low water cutoff should be inspected
every 6 months. A fault message, Flow Sw/LWCO will be
indicated in the Operator Interface on a low water condition
as sensed by the low water cutoff.
Relief valve
This unit is supplied with a relief valve(s) sized in accordance
with ASME Boiler and Pressure Vessel Code, Section IV
(“Heating Boilers”). The relief valve(s) is installed in the
vertical position and mounted in the hot water outlet. No
valve is to be placed between the relief valve and the unit.
To prevent water damage, the discharge from the relief valve
shall be piped to a suitable floor drain for disposal when relief
occurs. No reducing couplings or other restrictions shall be
installed in the discharge line. The discharge line shall allow
complete drainage of the valve and line. Relief valves should
be manually operated at least once a year.
⚠ CAUTION
Avoid contact with hot discharge water.
Heating boiler installations
Piping of the boiler system
The drawings in this section show typical boiler piping
installations, see FIG.’s 3-3 through 3-6. 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 to ensure
proper operation. A water meter to monitor makeup water
is recommended. Makeup water volume should not exceed
5% of total system per year. Install a Y-strainer or equivalent
multi-purpose strainer just before the boiler pump at the inlet
of the heat exchanger. This item is used to remove system
debris from older hydronic systems and to protect newer
systems.
⚠ CAUTION
The boiler system should not be operated
at less than 12 PSIG (Non-metallic system
piping must have an oxygen barrier to be
considered a closed loop).
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 on this page.
⚠ CAUTION
A leak in a boiler “system” will cause the
“system” to intake fresh water constantly,
which will cause the tubes to accumulate a
lime/scale build up. This will cause a non-
warrantable failure.
Water connections (heating boilers only)
All boilers have 2 1/2 inch copper pipe inlet and outlet
connections. Installed piping to and from the boiler must be a
minimum of 2 1/2 inch diameter.
⚠ CAUTION
Field installed reducing bushings must not
be used.
Any reduction in pipe size may decrease flow resulting in high
water temperatures, boiler noise, flashing to steam, and non-
warrantable heat exchanger damage.
The boiler may be installed with a primary/secondary piping
system provided to the boiler. It is important to guarantee that
adequate flow is provided to properly dissipate heat from the
boiler and also ensure that flow through the boiler does not
exceed the maximum recommended flow rate of 75 GPM for
Models 502 - 1302 and 90 GPM for Models 1501 - 2001 for a
boiler equipped with a copper heat exchanger.
Boiler circulator requirements
This is a low mass, high efficiency hot water boiler which
must have adequate flow for quiet, efficient operation. Pump
selection is critical to achieve proper operation. A pump should
be selected to achieve proper system design water temperature
rise. A separate pump may be installed in a secondary loop
to the boiler. Pipe diameter and length are critical to ensure
proper flow through the boiler. A System Temperature Rise
Chart (Table 3A on page 44) is provided to assist in proper
pump selection. This table provides GPM and boiler head-loss at
various temperature rises for each model based on Btu/hr input.
Temperature rise is the difference in boiler inlet temperature
and boiler outlet temperature while the boiler is firing at full
rate.
3 Water connections
Installation & Operation Manual
*Please note that these illustrations are
meant to show system piping concept only,
the installer is responsible for all equipment
and detailing required by local codes.
NOTICE
IMPORTANT
All boiler piping must contain an oxygen
barrier. This will help prevent any excess
oxygen from entering the system.
NOTICE
It is recommended to install an inlet water
strainer to prevent debris from entering the
heat exchanger or system.
38
The boiler primary piping system must have a circulator
installed in the main system loop to carry the heated boiler
water to the point of use in the main system.
Multiple boilers may also be installed with a primary/secondary
manifold system. Multiple boilers should be connected to the
common manifold in reverse return to assist in balancing flow
to multiple boilers.
The installer must ensure that the boiler has adequate flow
without 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 either increasing the size of the boiler pump or
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.
Circulator pump specifications
1. Maximum operating pressure for the pump must exceed
system operating pressure.
2. Maximum water temperature should not exceed the
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 must run when the boiler is firing. Separate
supply circuits can be provided or the two circuits (pump
and controls) can be combined for connection to one circuit,
properly sized for both.
⚠ CAUTION
At no time should the system pressure be less
than 12 PSIG.
Intermittent pump operation
An intermittent pump operation feature is provided. The
boiler’s 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 minimum
30 second period after the temperature set point is satisfied.
This timing is selectable from the Operator Interface. This
timing will remove any of the residual heat from the combustion
chamber before turning the pump off. See the wiring diagram
in Section 11 of this manual.
Pump Maintenance: Inspect the pump every six (6) months
and oil as necessary. Use SAE 30 non-detergent oil or lubricant
specified by the pump manufacturer.
The boiler is recommended for installation in a primary/
secondary piping system. This type of system uses a separate
boiler circulating pump to supply flow to and from the boiler
only. The secondary pump is sized based on the head loss of the
boiler and related pipe and fittings in the secondary loop only.
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 installed a maximum of 12 inches (0.30m) (or 4 pipe
diameters) apart to ensure connection at a point of zero pressure
drop in the primary system. There should be a minimum of
10 pipe diameters of straight pipe before and after the boiler
secondary loop connections to prevent turbulent flow at the
secondary loop connections. 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
fully ported having the same inside 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.
Low system water volume
System run time is very important to the overall operating
efficiency of the boiler. Short cycling of the boiler creates
problems with condensation in the vent stack, condensation on
the heat exchanger, system temperature spikes, and mechanical
component failures. To prevent short cycling of the boiler, it is
important to limit the boiler cycles to six or fewer per hour.
A buffer tank is an effective way to enhance a small system load
and increase heating system efficiency (see FIG. 3-6 on page 43
of this manual). Buffer tanks add water volume to the system
and act as a flywheel to absorb the additional Btu’s provided by
the boiler when only a single zone of a large system is calling
for heat.
To calculate the proper buffer tank size for a multiple zone
system:
(Run Cycle) (Output - Minimum System Load)
(Temp. Rise) (8.33) (60 Min.)
PBN2001-B9 ( 1.7:1 Turndown)
Min. Load = 100,000 Btu/Hr
Min. Boiler Output = 850,000 Btu/Hr
Cycle Time = 10 Min
Temp. Rise = 38
(10)(850,000 – 100,000) / (38)(8.33)(60) = 395 Gallons
3 Water connections (continued)
39
Installation & Operation Manual
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 in the Operator Interface on
the boiler’s front control panel.
Figure 3-3_Primary/Secondary Piping of a Single Boiler
Y-STRAINER
TO FLOOR DRAIN
12” MAX OR 4 PIPE DIAMETERS
SYSTEM CIRCULATOR
HEATING
RETURN
LOOP
EXPANSION TANK
PRESSURE REDUCING VALVE
BACK FLOW PREVENTER
WATER METER
MAKE UP WATE
R
AIR SEPARATOR
HEATING
SUPPLY
LOOP
DIR #2000570678_000
DIRT SEPARATOR
(RECOMMENDED)
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
1 75 2 1/2
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
1 90 2 1/2
40
3 Water connections
Installation & Operation Manual
*Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
Figure 3-4_Primary/Secondary Piping of Multiple Boilers
EXPANSION
TANK
AIR SEPARATOR
PRESSURE REDUCING
VALVE
BACK FLOW
PREVENTER
BALL VALVE
(TYPICAL)
BOILER 1
(LEADER)
TEMPERATURE /
PRESSURE GAUGE
PRESSURE GAUGE
DRAIN POINT
(TYPICAL)
BOILER CIRCULATOR
(TYPICAL)
SYSTEM SUPPLY SENSOR
(WHEN USED)
SYSTEM CIRCULATOR
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12” APART
BOILER 2
(MEMBER 1)
MAKE UP WATER
MAY SUBSTITUTE
LOW LOSS HEADER
FROM SYSTEM
FROM SYSTEM
DIRT SEPARATOR
(RECOMMENDED)
DIR #2000570679_000
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
2 150 3 1/2
3 225 4
4 300 5
5 375 6
6 450 6
7 525 6
8 600 8
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
2 180 4
3 270 5
4 360 6
5 450 6
6 540 6
7 630 8
8 720 8
3 Water connections (continued)
41
Installation & Operation Manual
*Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
Figure 3-5_Boiler with Low Temperature Bypass Piping - Using a Thermostatic Mixing Valve Required for Systems
Operating at less than 140°F (60°C) Return Water Temperatures from the Heating Return Loop
Y-STRAINER
TO FLOOR DRAIN
12" MAX OR 4 PIPE DIAMETERS
MIXING
VALVE
SYSTEM CIRCULATOR
HEATING
RETURN
LOOP
EXPANSION TANK
PRESSURE REDUCING VALVE
BACK FLOW PREVENTER
WATER METER
MAKE UP WATE
R
AIR SEPARATOR
HEATING
SUPPLY
LOOP
DIRT SEPARATOR
(RECOMMENDED)
DIR #2000570680_000
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
1 75 2 1/2
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
1 90 2 1/2
42
3 Water connections
Installation & Operation Manual
*Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
Figure 3-6_Primary/Secondary Piping with Buffer Tank
DIR #2000537578 00
BUFFER TANK
COMMON MANIFOLD MUST
BE SIZED TO ACCOMMODATE
COMBINED FLOW RATE FOR
ALL BOILERS
LOCHINVAR BOILERS
PUMP
Y-STRAINER
(TYPICAL)
DRAIN
NOTICE
The Inlet/Outlet System tappings are shown in the optional location on the side of the tank for pictorial
purposes. The standard location for the system tappings is 180° from the recirculation tappings.
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
2 150 3 1/2
3 225 4
4 300 5
5 375 6
6 450 6
7 525 6
8 600 8
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
2 180 4
3 270 5
4 360 6
5 450 6
6 540 6
7 630 8
8 720 8
3 Water connections (continued)
43
Installation & Operation Manual
*Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
44
Installation & Operation Manual
The installer must ensure that the boiler is supplied with
adequate flow without excessive temperature rise. It is
recommended that this boiler be installed with a bypass
in the piping if the maximum recommended flow rate is
exceeded. The bypass will help to ensure that the boiler can
be supplied with adequate water flow. Flow rates exceeding
the maximum recommended flow will result in erosion of the
boiler tubes. A typical bypass with a valve as shown in FIG.
3-5 will allow control of boiler flow.
TABLE - 3B
BOILER TEMPERATURE RISE AT MAXIMUM FLOW
Temperature Rise at Full Rate Fire, 75 and 90 GPM
Maximum Flow
Model Temperature Rise
502 11°F (6.1°C)
752 17°F (9.4°C)
1002 23°F (12.8°C)
1302 30°F (16.7°C)
1501 28°F (15.6°C)
1701 32°F (17.8°C)
2001 38°F (21.1°C)
Boiler bypass requirements
TABLE - 3A
SYSTEM TEMPERATURE RISE CHART
Temperature Rise and Head Loss Based on Boiler Output in Btu/hr
Btu/hr 30°F DT 35°F DT 40°F DT 45°F DT 50°F DT 55°F DT 60°F DT
Input Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd
500,000 425,000 29.0 0.9 24.9 0.7 21.8 0.5 19.3 0.4 17.4 0.3 15.8 0.2 14.5 0.1
750,000 638,000 43.5 2.1 37.3 1.8 32.6 1.3 29.0 1.0 26.1 0.8 23.7 0.7 21.8 0.6
1,000,000 849,000 58.0 4.8 49.7 3.3 43.5 2.4 38.7 2.0 34.8 1.6 31.6 1.2 29.0 1.1
1,300,000 1,105,000 75.4 9.8 64.7 6.9 56.6 4.6 50.3 3.6 45.3 2.9 41.1 2.2 37.7 1.9
1,500,000 1,275,000 87.9 9.8 75.3 7.7 65.9 6.3 58.6 5.2 52.9 4.2 47.9 3.3 43.9 2.7
1,700,000 1,445,000 99.6* 14.1 85.4 10.2 74.7 7.9 66.4 6.5 59.8 5.3 54.3 4.6 49.8 3.9
2,000,000 1,700,000 N/A 20.2 100.4* 14.9 87.9 11.9 78.1 9.2 70.3 7.2 63.9 6.4 58.6 5.2
*Cupro-Nickel Heat Exchanger Required at Flows Above 75 GPM on Models 502 - 1302 and above 90 GPM on Models 1501 - 2001.
Temperature / pressure gauge
This boiler is equipped with a dial type temperature / pressure
gauge. This gauge is factory installed in the outlet side of
the boiler piping. The gauge has one scale to read system
pressure and a separate scale to read water temperature in
degrees Fahrenheit. The temperature / pressure gauge is
provided to meet code requirements. Water temperatures
can be more accurately monitored from the data provided in
the digital display in the Operator Interface.
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.
Installation with a chilled water system
Pipe refrigeration systems in parallel. Install duct coil
downstream at 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.
3 Water connections
For Example: Night Setback of the system loop water
temperature, Night Shutdown and Weekend Shutdown of the
entire boiler / heating system, and Indoor / Outdoor Air Reset
of the system loop water temperature. If any of these Building
Management System control functions are being utilized on
the hydronic heating system, some type of low return water
protection MUST BE provided.
If the boiler heating system will be used on a Water Source Heat
Pump System, Radiant Floor Heating System, Snow Melting
Heating System, etc., some type of low return water protection
must be provided.
Condensation can cause operational problems, bad combustion,
sooting, flue gas spillage and reduced service life of the vent
system and related components.
To prevent the system return water temperature below 140°F
(60°C) from entering the boiler inlet, an electrically actuated
3-way mixing valve is available, consult manufacturer for kit
availability (see FIG. 3-5 on page 42). By using this valve, the
SMART TOUCH control will bypass outlet water back into the
inlet of the boiler to maintain the inlet temperature above 140°F
(60°C).
A fast acting, self contained mixing valve, set to 140°F (60°C),
may also be used. The installation of this valve must be done
as shown in FIG. 3-5. This arrangement will maintain the
required flow through the boiler.
When a mixing valve is used, an optional system return sensor
should be installed into the system return piping. This will allow
the display of the actual system return temperature, and will
also allow control of the system return temperature when the
SMART TOUCH control is programmed for inlet temperature
control. As always, installation of the system supply sensor is
strongly recommended as well. This will reduce the potential
for short cycling of the boiler, and provide more responsive
temperature regulation, even when the SMART TOUCH
control is programmed for inlet temperature control.
⚠ CAUTION
A boiler allowed to operate at set point
temperatures below the specified minimum
settings may experience operational
problems with the operating controls and
safety switches, obstruction of the flue gas
passages on the 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.
Three way valves in system
The installation of a three way valve on this boiler is not
generally recommended because most piping methods allow
the three way valve to vary flow to the boiler. This boiler is a
low mass, high efficiency appliance 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.
Radiant floor and snow melt heating
systems
This type of heating boiler application operates in a low
temperature range which requires a boiler bypass as described
under the Low Temperature Bypass Requirements section. A
non-metallic rubber or plastic tubing installed in a radiant (in
floor) system must have an oxygen barrier to prevent oxygen
from entering the system through the walls of the installed
tubing. Excessive oxygen absorption into the system will result
in an accelerated rate of corrosion causing a sludge buildup.
This excessive corrosion will also damage the boiler and system
components. Sludge formed as the result of excessive oxygen
in the system can restrict water flow resulting in a premature
boiler failure. Any boiler damage due to excessive oxygenation
is non-warrantable.
TABLE - 3C
MAXIMUM WATER FLOW
⚠ CAUTION: The maximum flow rate through Power-fin
models with a copper heat exchanger must be set to provide
and not exceed the following flow:
Model Maximum Flow
Maximum Flow for
CuNi Heat Exchanger
502, 752, 1002, and 1302 75 GPM 95 GPM
1501, 1701, and 2001 90 GPM 115 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.
Minimum boiler water temperatures
Inlet water temperatures below the specified minimum of
140°F (60°C) can excessively cool the products of combustion
resulting in condensation on the heat exchanger. Condensation
on the heat exchanger can cause operational problems, bad
combustion, sooting, flue gas spillage and reduced service life
of the related components. See the Low Temperature Bypass
Requirements section for boiler system applications below the
minimum specified temperature.
Low temperature bypass requirements
To prevent condensation problems, a boiler MUST NOT be
operated (other than for brief periods during initial system
startup) with an inlet water temperature of less than 140°F
(60°C). If normal system return temperatures are less than the
required 140°F (60°C) boiler inlet requirement, a method of
low return water temperature protection MUST BE provided
to protect the boiler.
45
3 Water connections (continued)
Installation & Operation Manual
46
Installation & Operation Manual
Gas supply
Verify that the appliance is supplied with the type of gas specified
on the rating plate. This appliance is configured for operation
up to 4000 feet altitude. Consult factory for installations above
4000 feet elevation.
Inlet gas pressure: Measured at the inlet pressure tap on the
appliance gas manifold. The pressure tap is located upstream of
the redundant gas valve and downstream of the field installed
gas cock.
TABLE 4A
INLET GAS PRESSURE
MODEL CODE
NATURAL LP
Max.
w.c.
Min.
w.c.
Max.
w.c.
Min.
w.c.
502 - 1302 F9 14.0 4.2 14.0 11.0
502 -1302 M9 14.0 4.0 14.0 11.0
1501 - 2001 B9/F9 14.0 4.0 14.0 8.0
1501 - 2001 M9 14.0 4.0 14.0 8.0
Gas pressure test
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 (3.5 kPa).
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 (3.5 kPa).
3. The appliance and its gas connection must be leak
tested before placing it in operation.
Checking manifold gas pressure
Reference the Power-fin Service Manual for information
regarding manifold gas pressure.
Gas connection
Safe operation of the appliance requires properly sized gas
supply piping. See gas line sizing data:
1. Gas pipe size may be larger than appliance connection.
2. Installation of a union at the appliance gas line
connection is required for ease of service and removal of
the gas train.
3. If an additional manual shutoff valve is required by local
codes, install the valve on the outside at the gas supply to the
appliance as shown in FIG. 3-1.
4. A sediment trap (drip leg) MUST be provided in the inlet of
the gas connection to the appliance, see FIG. 3-1.
5. Optional gas controls may require routing of bleeds and
vents to the atmosphere, outside the building when
required by local codes.
Maximum inlet gas pressure must not exceed the value specified.
Minimum value listed is for the purposes of input adjustment.
TABLE - 4B
FITTINGS TO EQUIVALENT STRAIGHT PIPE
Diameter Pipe
(inches)
1 1/2 2 3 4 5
Equivalent
length of
Straight Pipe
(feet)
4 5 10 14 20
NOTICE
If an inline high gas pressure regulator is
used, it MUST BE of the lockup type and
be located a minimum of 10 feet from the
appliance. Failure to do so may result in
insufficient gas volume supplied to the
appliance.
4 Gas connections
47
Installation & Operation Manual
Gas piping
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. Run pipe or tubing to the unit’s gas inlet. If tubing is used,
obtain a tube to pipe coupling in order to connect the
tubing to the unit’s gas inlet.
4. Install a sediment trap in the supply line to the unit’s gas
inlet (see FIG. 3-1).
5. Remove seal over gas inlet to the appliance.
6. Apply a moderate amount of good quality pipe compound
(DO NOT use Teflon tape) to pipe only, leaving two end
threads bare.
7. Connect gas pipe to inlet of appliance. Use a wrench to
support the gas manifold on the appliance.
8. For LP gas, consult your LP gas supplier for expert
installation.
DIR #2000538488 00
GAS LINE CONNECTION
SEDIMENT TRAP
MANUAL GAS
SHUTOFF VALVE
Figure 4-1_Gas Line Connection with Sediment Trap
(Drip Leg) and Manual Main Gas Shutoff 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 installations must comply with approved standards and
practices.
4 Gas connections (continued)
TABLE - 4C
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour
(based on .60 specific gravity, 0.30" w.c. pressure drop)
Pipe
Size
(Inches)
Length of Pipe in Straight Feet
10 20 30 40 50 60 70 80 90 100 125 150 175 200
1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A
3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A
1 514 353 284 243 215 195 179 167 157 148 131 119 109 102
1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209
1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313
2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602
2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960
3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700
4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460
48
Installation & Operation Manual
Figure 4-2_Gas Supply Pressure Measurement
14. Turn on the gas supply at the manual valve, turn on LP gas
at the tank if required.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the display of
the SMART TOUCH control module to the desired water
temperature so the appliance will call for heat.
17. Check burner performance by cycling the system while you
observe burner response. The burner should ignite
promptly. Flame pattern should be stable, see “Maintenance
- Normal Flame Pattern” in the Power-fin Service Manual.
Turn system off and allow burner to cool, then cycle burner
again to ensure proper ignition and flame characteristics.
Checking gas supply pressure
1. Turn the main power switch to the “OFF” position.
2. Shut off the gas supply at the manual gas cock in the gas
piping to the appliance. If fuel supply is LP gas, shut off gas
supply at the tank.
3. Remove the 1/8" hex plug from the gas pressure test port
located on the manual shutoff valve 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 inches water column or greater
to check inlet pressure.
4. Turn on gas supply at the field installed manual gas cock,
turn on LP gas at tank if required.
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the display to call for
heat.
7. Observe the gas supply pressure as the burner fires at 100%
of rated input. Percent of burner input will be shown on the
display of the SMART TOUCH control module.
8. Ensure inlet pressure is within specified range. Minimum
and maximum gas supply pressures are specified in the Gas
Supply section of this manual.
9. If gas pressure is out of range, contact the gas utility, gas
supplier, qualified installer or service agency to determine
necessary steps to provide proper gas pressure to the
control.
10. If gas supply pressure is within normal range, proceed to
remove gas manometer and replace pressure tap fittings in
the gas piping to the appliance.
11. Turn the power switch to the “OFF” position.
12. Shut off gas supply at the manual gas cock in the gas piping
to the appliance. If fuel supply is LP gas, shut off gas supply
at the tank.
13. Remove the manometer and related fittings from the gas
pressure test port at the inlet gas supply connection to the
appliance. Replace the 1/8" plug in the gas pressure test port
and tighten.
NOTICE
If a pressure drop of more than 2" w.c.
occurs between Standby (Static) Mode and
Operating (Dynamic) Mode, a gas volume
problem exists. Contact the gas utility, gas
supplier, qualified installer, or service agency
to determine the necessary steps to provide
the proper gas volume to the appliance.
High and low gas pressure switches
1. Manual reset high and low gas pressure switches are
supplied to meet M13 firing code for Factory Mutual, GE
GAP, and CSD-1.
2. In the Commonwealth of Massachusetts, gas appliances
over 1,000,000 BTU must be equipped with manual reset
high and low gas pressure switches when required to meet
the Massachusetts requirements.
NOTE: Massachusetts code requires a pressure regulator to be
installed upstream of the low gas pressure switch. Lochinvar
requires any inline regulator used MUST BE of the lockup
type and be located a minimum of 10 feet from the appliance.
Failure to do so may result in insufficient gas volume supplied
to the appliance. Massachusetts also requires a shutoff valve
be installed ahead of the regulator for replacement or service.
When required, both regulator and shutoff valve are to be “field
provided”.
3. Figures 4-3A, B, and C on page 49 show piping connections
for high and low gas pressure switches for respective Power-
fin models.
4 Gas connections
Installation & Operation Manual
High and low gas pressure switches (continued)
DIR #2000538217 00
VENTURI
COMBINATION VA LV E
DIAPHRAM VALVE
MANUAL
SHUTOFF
VALVE
Figure 4-4_Gas Train Assembly F9 - Models 502 - 1302
502 - 1302 F9 gas train
The combination gas valve on this appliance uses line (120
VAC) voltage for operation. These two valves satisfy the
requirement for the safety shutoff and operating valves
required on boilers and water heaters. The combination valve
also regulates the amount of gas mixed with the air delivered
to the burner for proper combustion. Both the combination
valve and diaphragm valve have threaded vents - see the
Venting of Gas Train Components section, this page.
There are no serviceable parts on the combination gas valve.
Venting of gas train components - F9/B9/M9
and optional gas train components
Local codes may require the routing component bleeds and
vents to the atmosphere outside the building. Components
(valves, pressure switches) having vents which would require
external vent lines are provided with threaded vent line
connections. These vent line connection points may be
accessed by removing the top jacket panels. Proper routing
of vent lines to the atmosphere from the factory supplied
termination points is the responsibility of the installing
contractor.
2000538251 00
2000
5
382
51
00
ALUMINUM
TUBING
.25 X .03
ROUTING MAY VARY
GAS
VALVE
TYPICAL PRESSURE REGULATOR
STYLE MAY VARY FROM SHOWN
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
TYPICAL SHUTOFF
VALVE
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
*SEE REGULATOR
INSTALLATION
NOTE IN THIS MANUAL
BALL VALVE
W/PRESSURE TAP
HIGH
GAS PRESSURE
SWITCH
LOW GAS
PRESSURE
SWITCH
REGULATING
GAS VALVE
DIR #2000538251 00
Figure 4-3A_PB/PF 502 - 1302 F9 High & Low Gas
Pressure Switches
2000538249 00
2000538249
00
DIR #2000538249 00
LOW
PRESSURE
SWITCH
HIGH
PRESSURE
SWITCH
ALUMINUM
TUBING
.25 X .03
ROUTING MAY VARY
GAS VALVE
BALL VALVE
W/PRESSURE TAP
TYPICAL PRESSURE REGULATOR
STYLE MAY VARY FROM SHOWN
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
TYPICAL SHUTOFF
VALVE
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
*SEE REGULATOR
INSTALLATION
NOTE IN THIS MANUAL
DIR #2000538246 00
ALUMINUM
TUBING
.25 X .03
ROUTING MAY VA RY
LOW PRESSURE
SWITCH
HIGH
PRESSURE
SWITCH
GAS VALVE
BALL VALVE
W/PRESSURE TAP
TYPICAL PRESSURE REGULATOR
STYLE MAY VA RY FROM SHOWN
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
TYPICAL SHUTOFF
VALVE
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
*SEE REGULATOR
INSTALLATION
NOTE IN THIS MANUAL
Figure 4-3B_PB/PF 502 - 1302 M9 High & Low Gas
Pressure Switches
Figure 4-3C_PB/PF 1501 - 2001 M9, B9, & F9 High &
Low Gas Pressure Switches
NOTICE
The gas train and controls assembly
provided on this unit have been tested under
the applicable American National Standard
to meet minimum safety and performance
criteria such as safe lighting, combustion,
and safety shutdown operation.
M9, B9, & 1501 - 2001 F9 gas train
The ratio gas valve on this appliance uses line (120 VAC)
voltage for operation. The valve contains the safety shutoff
and operating valves required on boilers and water heaters.
The ratio valve uses the negative pressure signal generated by
the venturi to modulate the amount of gas, so that the proper
mixture of air and gas is delivered to the burner throughout
the full range of burner operation. The ratio gas valve does not
require installation of a vent line - see the Venting of Gas Train
Components section below.
There are no serviceable parts on the combination gas valve.
DIR #2000538213 00
RATIO VA LV E
MANUAL SHUTOFF VALVE
VENTURI
Figure 4-5_Gas Train Assembly M9/B9 - Models 1501
- 2001
4 Gas connections (continued)
49
5 Electrical connections
Boiler operating control module
The operating temperature control for the appliance is the
SMART TOUCH control module. It is located on the inside
of the control panel, behind the front access door. Access
to adjust the temperature set point and other user adjustable
points is made through the Operator Interface located on the
right front access door. The outlet sensor is placed in a bulbwell
installed in the outlet side of the heat exchanger top header.
The inlet sensor is located in a bulbwell on the inlet side of the
heat exchanger top header.
The operating sensor, inlet or outlet, is selectable from the
screen in the Operator Interface.
The exact temperature set point is based on your system’s
requirements. Set the control set point(s) to the desired
operating water temperature.
The maximum temperature set point that can be programmed
into the standard control module from the Operator Interface
on a heating boiler is 215°F (101.7°C). The manual reset high
limit control for a heating boiler is adjustable up to a fixed
maximum setting of 230°F (110°C).
The maximum temperature set point for a water heater is 190°F
(88°C). The auto reset high limit is fixed at 200°F (93°C), and
the adjustable manual reset high limit has a maximum setting
of 230°F (110°C).
A 120 VAC, 15 Amp, 1 ph, 60 Hz circuit is required for
operation of the appliance controls.
The appliance, when installed, must be electrically grounded
in accordance with the requirements of the authority having
jurisdiction or in the absence of such requirements, with the
latest edition of the National Electrical Code ANSI/NFPA No.
70. When the unit is installed in Canada, it must conform to
the CAE C22.1, Canadian Electrical Code, Part I and/or local
Electrical Codes. Multiple units connected in a Cascade must
be grounded to the same ground connection.
1. All wiring between the appliance and field installed devices
shall be made with type T wire [63°F (35°C) rise].
2. All line voltage wire exterior to the appliance must be
enclosed in approved conduit or approved metal clad
cable.
3. The circulating pump must run continuously when the
appliance is being fired.
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 heat exchanger and 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 - 5A
AMP DRAW DATA
Model
Unit Blower &
Controls
Pump FLA*
Unit & Pump
FLA*
502 6.7 5.7 12.4
752 6.7 5.7 12.4
1002 6.7 5.7 12.4
1302 6.7 5.7 12.4
1501 8.3 8.8 17.1
1701 8.3 8.8 17.1
2001 8.3 8.8 17.1
*Standard Pump Supplied with Water Heaters Only
ELECTRICAL SHOCK HAZARD – For your
safety, turn off electrical power supply before
making any electrical connections to avoid
possible electric shock hazard. Failure to do
so can cause severe personal injury or death.
Wiring must be N.E.C. Class 1.
If original wiring as supplied with the boiler
must be replaced, use only type 105°C wire
or equivalent.
Boiler must be electrically grounded as
required by National Electrical Code ANSI/
NFPA 70 – latest edition.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
⚠WARNING
NOTICE
⚠ CAUTION
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, local codes, or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and
any local codes.
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 5-1.
2. Provide and install a fused disconnect or service switch
(15 AMP recommended) as required by the code (see
FIG. 5-1).
3. To activate a system pump, wire as shown in FIG. 5-1. If the
motor is larger than 1.5 AMP, you must install a contactor.
4. When connecting power to units which are to be cascaded,
each unit must be connected to the same ground connection.
50
Installation & Operation Manual
51
Installation & Operation Manual
5 Electrical connections (continued)
DIR #2000538495 00
DWG PUMP
DRY CONTACT
CONTACTOR
(FIELD SUPPLIED)
BOILER PUMP
DRY CONTACT
SYSTEM PUMP
DRY CONTACT
LINE 1 BK
SERVICE SWITCH
NEUTRAL W
Figure 5-1_Line Voltage Field Wiring Connections
EMS or remote thermostat connection
An EMS, remote thermostat or other remote temperature
control may be connected to the boiler (see FIG. 5-3). Follow
the manufacturer’s instructions supplied with the remote
temperature control for proper installation and adjustment.
Connection of a set of dry switching contacts or a remote on/off
thermostat to the low voltage connection board will allow the
unit to be switched on and off by making or breaking a 24 VAC
control circuit. Remove the factory jumper between the enable
terminals on the low voltage connection board and connect the
remote temperature control in its place, see FIG. 5-4 on page 53.
A
B
DETAIL A
DETAIL B
DIR #2000537609 00
REMOTE
ON/OFF WIRE
CONNECTION
Ensure that all wiring used to connect the switching contacts
of the remote temperature controller to the connection board
are a minimum of 18 gauge and have a maximum installed
length of 300 feet (91.4m). Set the SMART TOUCH control to
a set point temperature slightly higher than the setting of the
remote temperature control. This will ensure that the remote
temperature controller functions as the operating control for
the heater.
Figure 5-3_Remote ON/OFF Wire Connection
DIR #2000537609 00
LOW VOLTAGE
WIRING KNOCKOUTS
Figure 5-2_Routing Field Wiring
Low voltage connections
1. Route all low voltage wires through the knockouts in the
rear of the heater, as shown in FIG. 5-2.
2. Connect low voltage wiring to the low voltage connection
board as shown in FIG. 5-4 on page 53 of this manual and
the heater wiring diagram.
Installation & Operation Manual
5 Electrical connections
52
Louver proving switch
1. When the operation of a louver proving switch needs to be
verified before the boiler fires, remove the jumper wire from
these terminals and connect them to the normally open
contacts on its proving switch (FIG. 5-4).
System supply sensor
1. By installing the system supply sensor into the supply of the
primary loop, the temperature of the primary supply can
be controlled. The SMART TOUCH control automatically
detects the presence of this sensor, and controls the boiler
firing rate to maintain the system supply temperature to the
set point (if the outlet sensor control is currently selected).
2. Connect these terminals to the system supply sensor
(FIG. 5-4).
System return sensor
1. By installing the system return sensor into the return of the
primary loop, the temperature of the primary return can
be sensed when a 3-way valve or other device is installed
ahead of the heater inlet. The SMART TOUCH control
automatically senses the presence of this sensor. If the inlet
sensor is selected as the controlling sensor, the SMART
TOUCH control will adjust the firing rate to hold the
system return temperature to the set point. It is strongly
recommended that the system supply sensor be installed as
well.
2. Connect these terminals to the system return sensor (FIG.
5-4).
Boiler Management System (BMS)
1. An external control may be connected to control either the
firing rate or the set point of the appliance. Connect the 0 -
10 VDC terminals to the 0 - 10 VDC output of the external
control. The SMART TOUCH control can be programmed
to use the enable output of the Boiler Management System,
or use the voltage signal to enable the heater. Connect the
enable terminals to the enable output of the BMS, when
used.
2. Make sure the ground terminal is connected to the ground
output terminal of the external control, and the 0 - 10 VDC
terminal is connected to the 0 - 10 VDC terminal of the
external control.
Runtime contacts
The SMART TOUCH control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
Alarm contacts
The SMART TOUCH control closes another set of contacts
whenever the heater is locked out or the power is turned off.
This can be used to turn on an alarm, or signal a Building
Management System that the boiler is down.
Wiring of the cascade
When wiring the heaters for Cascade operation, select one
heater as the Leader heater. The remaining heaters will be
designated as Members. See page 62 Configuration of the
Cascade for a detailed explanation of this procedure.
On boilers, connect the system supply sensor and outdoor air
sensor (if used) to the Leader boiler. The location of the system
supply sensor should be downstream of the boiler connections
in the main system loop. The system supply sensor should be
wired to the low voltage connection board at the terminals
marked for the system supply sensor (see FIG. 5-4). The Leader
control will use the water temperature at the system supply
sensor to control the operation of the Cascade.
If outdoor air reset is desired, the outdoor air sensor should
be wired to the low voltage connection board at the terminals
marked for the outdoor air sensor (FIG. 5-4). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected, the
Leader control will maintain the space heating (SH) set point
that is programmed into the control.
If a Thermostat, Zone Control enable output, or Building
Management System enable output are available, it should be
wired to the low voltage connection board on the Leader boiler
at the enable terminals. If the boilers are to run continuously,
leave the jumper wire between the enable terminals. This will
initiate a call for heat on the Cascade. Also, leave the jumpers on
the enable terminals of all the Member heaters. This will allow
them to run independently should the Leader heater fail.
Communication between the Leader heater and the Member
heaters is accomplished by using shielded, 2-wire twisted pair
communication cable. Connect one of the twisted pair wires
to terminal A on each of the low voltage connection boards,
and the other wire of the twisted pair to terminal B on each of
the low voltage connection boards. Connect the shield wire to
the shield ground terminal on all of the heaters. If more than
two heaters are on the Cascade, daisy chain the wiring from
the Cascade terminals on the second heater to the Cascade
terminals on the third heater, then from the third to the forth,
and so on. The connections can be made in any order, regardless
of the addresses of the heaters. Try to keep each cable as short
as possible.
When the Member 1 boiler is programmed as a Redundant
Leader, it allows the Member 1 boiler to automatically assume
control of the Cascade should it lose communication with the
Leader boiler. When this option is selected, it is required that
the Member 1 boiler have duplicate connections to the installed
external sensors (such as the system supply sensor), control
voltages, and heat demand settings of the Leader boiler.
Figure 5-4_Low Voltage Field Wiring Connections
5 Electrical connections (continued)
53
Installation & Operation Manual
DIR #2000534157 00
3-
WAY
VA
LVE
(BOILER ON
LY )
CCW
CW
COM
54
6 Condensate disposal
Installation & Operation Manual
Condensate trap installation
1. Locate the condensate trap kit shipped loose with the
appliance. The kit includes a sheet metal mounting
base, two (2) nuts and the condensate trap.
2. Install the condensate trap mounting base on the rear
of the appliance in the lower left-hand corner as
depicted in FIG. 6-1. Use the pre-drilled holes on the
appliance to secure the mounting base to the appliance.
3. Secure the condensate trap to the base using the two (2)
nuts supplied with the kit. The trap should be oriented
so that the barb connections are pointing toward the
appliance (FIG. 6-1).
4. Use a level to ensure that the condensate trap is level on
its base. Failure to keep the condensate trap level can
result in the spillage of flue products from the
condensate trap.
5. Locate the two hoses exiting the back of the appliance.
Attach the larger hose on the appliance to the lower
barb connection on the condensate trap. Secure the
hose to the barb with a field supplied hose clamp
(FIG. 6-1).
6. Attach the smaller hose on the unit to the upper barb
connection on the condensate trap. Secure the hose to
the barb connection with a field supplied hose clamp
(FIG. 6-1).
7. Route the 3-pin wiring harness from the condensate
trap to the matching connector on the lower back of
the appliance as shown in FIG. 6-1. This is the blocked
drain safety switch. This switch will shut the appliance
off if the condensate trap becomes too full of liquid.
8. Remove the four (4) screws securing the top cover to
the condensate trap and remove the cover (FIG. 6-1).
9. Locate the plastic ball inside the float tube. Verify there
is nothing under the ball causing it to not seat properly
(FIG. 6-1).
10. Replace the cover.
11. Replace the four (4) screws removed in Step 8.
12. A 1/2" pipe connection is supplied on the condensate
trap. Connect a suitable pipe or tube to this connection
(see FIG. 6-1).
Figure 6-1_Install Condensate Trap
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.
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.
⚠WARNING
NOTICE
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.
NOTICE
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to
freeze in the line or if the line is obstructed in
any other manner, the blocked drain safety
switch will prevent the appliance from firing.
55
7 Start-up
Installation & Operation Manual
Boiler water
BOILER WATER CHEMISTRY
Specication Range
Dissolved Solids < 2000 ppm
pH Level 6.5 to 9.5
Chloride < 150 ppm
• Monitoring pH, chlorides, TDS, and hardness
levels can prolong the life of the appliance by reducing
lime scale buildup, corrosion, and erosion. Check for
leaks to ensure that fresh water is not entering the
system.
• Continual fresh makeup water will reduce boiler life.
• Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger,
and causes failure.
• The addition of oxygen carried in by makeup water
can cause internal corrosion in system components.
• Leaks in the boiler or piping must be repaired at
once to prevent excessive makeup water. For this
purpose, it is recommended to install a water meter
to easily check the amount of makeup water entering
the system. Makeup water volume should not exceed
5% of the total system volume per year. NOTE: When
makeup water is added, make sure the chemical
additives are added to maintain the correct level.
• An approved multi-metal corrosion inhibitor
(comparable to Sentinel X100 or Fernox F1) is
recommended at the correct concentration and in the
manner recommended by the manufacturer.
Check/control fill water chemistry
Conduct water quality testing prior to
installing the appliance. Various solutions
are available to adjust water quality.
Hardness between 5 and 15 grains per gallon
1. Consult local water treatment companies for hard water
areas (above 15 grains per gallon hardness).
2. Hardness levels that are above 15 grains/gallon can lead
to lime scale buildup throughout the boiler system. If the
fill water is below 5 grains/gallons, usually due to use of a
water softener, it is recommended to mix in some potable
water at the inlet to increase the hardness of the water to
above 5 grains/gallons.
pH between 6.5 and 8.5
1. pH levels below 6.5 can cause an increase in the rate of
corrosion. pH of 8.5 or higher can potentially cause lime
scale buildup.
Total Dissolved Solids (TDS) less than 350 ppm
1. Total dissolved solids are all minerals, salts, metals, and
charged particles that are dissolved in water.
2. The greater the amounts of TDS present, the higher the
corrosion potential due to increased conductivity in the
water.
Chloride concentration less than 150 ppm
1. Do not fill boiler or operate with water containing
chlorine in excess of 150 ppm.
2. Filling with fresh drinking water should be acceptable.
3. Do not use the boiler to directly heat swimming pool or
spa water.
Freeze protection
IMPORTANT
Fill water
The manufacturer recommends the following for properly
filling your boiler with the appropriate water chemistry for
closed loop boilers. Good fill water quality will help extend
the life of the appliance by reducing the effects of lime scale
buildup and corrosion in closed loop systems.
1. Use glycol only if needed for freeze protection.
2. Propylene glycol is the recommended freeze protection.
3. Make sure to flush the boiler system before adding glycol.
4. Determine the freeze protection fluid quantity using system
water content, following the fluid manufacturer's instructions.
Boiler water content is listed on page 3. Remember to include
expansion tank water content.
Ethylene glycol is toxic, DO NOT use as your
freeze protection. Ethylene glycol has a sweet
aroma which children and pets could mistake
as food and ingest; leading to death.
⚠WARNING
Pre-Commissioning Cleaning
1. Prior to fill and start-up, flush the entire heating system.
2. Clean the entire heating system with an approved pre-
commissioning cleaner (comparable to Sentinel X300
and Fernox F3) in accordance with the manufacturer’s
recommendation to remove debris and prolong the life of
the heat exchanger.
3. Clean all water filtering devices in the system.
4. Flush the cleaning solution out of the entire system and
refill.
CAUTION
Do not use petroleum based cleaning or
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
DO NOT use "homemade cures" or "boiler
patent medicines". Serious damage to boiler,
personnel, and/or property may result.
CAUTION
Table 7A Boiler Water Chemistry
7 Start-up
Installation & Operation Manual
Fill and test water system
1. Fill system only after ensuring the water meets the
requirements of this manual.
2. Close automatic and manual air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. The minimum cold water fill pressure for a system is
12 psi.
b. Pressure will rise when the boiler is turned ON and
system water temperature increases.
4. At initial fill and during boiler startup and testing, check
the system thoroughly for any leaks. Repair all leaks before
proceeding further.
Purge air from water system
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valve in the piping diagrams on pages 40 through 43).
Route the hose to an area where water can drain and be
seen.
b. Close the boiler or system isolation valve between the
purge valve and fill connection to the system.
c. Close zone isolation valves.
d. Open the quick-fill valve on the cold water makeup
line.
e. Open purge valve.
f. Open the isolation valves one zone at a time. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close
the zone isolation valves and proceed with the next
zone. Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch that
system pressure rises to correct cold-fill pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. If purge valves are not installed in the system, open the
manual air vents in the system one at a time, beginning
with the lowest floor. Close the vent when water
squirts out. Repeat with remaining vents.
2. Open the automatic air vent (diaphragm-type or bladder
type expansion tank systems only) one turn.
3. Open other vents:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refill to correct pressure.
56
Oxygen prevention
Dissolved oxygen can have a negative effect on the boiler
system. Oxygen can cause iron oxide to generate iron
deposits. Oxygen may also increase the rate of corrosion
on non-stainless steel parts of the system. A low pH level
combined with oxygen further enhances its corrosive effects.
After boiler installation, check for air leaks in the following
areas:
• Suction gasket
• Pump
• Air valve
• O-ring gaskets
Precautions include installing a water meter to evaluate the
fresh water volume entering the system (should be no more
than 5% system volume). Additional volumes of fresh water
could indicate that a leak is present.
CAUTION
Eliminate all system leaks. Continual
fresh makeup water will reduce boiler
life. Minerals can build up in the
heat exchanger, reducing heat transfer,
overheating the heat exchanger, and
causing heat exchanger failure.
5. Local codes may require a backflow preventer or actual
disconnect from city water supply.
6. When using freeze protection fluid with automatic fill,
it is suggested to install a water meter to monitor water
makeup. Freeze protection fluid may leak before the
water begins to leak, causing the concentration to drop,
which reduces the freeze protection level.
7. The freeze protection set points may be lowered when
freeze protection fluid is used (see the Power-Fin
Service Manual).
8. Consult the glycol manufacturer for details on the
suggested mix of glycol and water for the desired freeze
protection level and the de-rate effect it will have on the
boiler output.
Test / replace freeze protection fluid
1. For systems using freeze protection fluids, follow the
fluid manufacturer's instructions.
2. Freeze protection fluid must be replaced periodically
due to degradation of inhibitors over time.
3. It is recommended to test the glycol concentration
annually and adjust within the desired set points.
57
Check for gas leaks
Before starting the boiler, and during initial
operation, smell near the floor and around
the boiler for gas odorant or any unusual
odor. Remove the front access panel and
smell the interior of the boiler enclosure.
Do not proceed with startup if there is any
indication of a gas leak. Use an approved
leak detection solution. Repair any leaks at
once.
⚠WARNING
Figure 7-1_Condensate Trap
Propane boilers only – Your propane
supplier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade, and the gas
may no longer have an odor. Before startup
(and periodically thereafter), have the
propane supplier verify the correct odorant
level in the gas.
⚠WARNING
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fittings
and condensate trap.
Fill condensate trap with water
1. Remove the four (4) screws securing the top cover to the
condensate trap and remove the cover (FIG. 7-1).
2. Locate the plastic ball inside the float tube. Verify there is
nothing under the ball causing it to not seat properly.
3. Fill with fresh water until the water begins to pour out of the
drain.
4. Replace the cover.
5. Replace the four (4) screws removed in Step 1.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the enable
terminals on the connection board.
2. Connect a voltmeter across these two incoming wires.
Close each thermostat, zone valve, and relay in the external
circuit one at a time and check the voltmeter reading across
the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and
correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board. Allow the boiler to
cycle.
7 Start-up (continued)
Check vent and air piping
1. Inspect vent piping and air piping for signs of
deterioration from corrosion, physical damage or
sagging. Verify air piping and vent piping are intact
and correctly installed per this manual.
Placing the boiler in operation
Boiler operational checks
2. Turn the boiler main power switch to the “ON”
position.
3. Verify operation of the SMART TOUCH control
module and Operator Interface.
4. Program the adjustable points from the Operator
Interface.
5. Push the reset for the low water cutoff (if equipped).
6. Ensure that maximum flow to the boiler does not exceed
75 GPM on Models 502 - 1302 and 90 GPM on Models
1501- 2001. Verify by checking temperature rise while
burner is firing at 100% of rated input.
7. 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.
8. Verify operation of safeties as necessary (low water
cutoff, high limit, gas pressure, etc.,).
9. Verify that all adjustable points in the Operator
Interface are set as required.
Installation & Operation Manual
58
7 Start-up
Installation & Operation Manual
Final checks before starting the boiler
q Read the Power-fin Service Manual to familiarize yourself
with SMART TOUCH control module operation. Read
this manual, page 59 for proper steps to start boiler.
q Verify the boiler and system are full of water and all
system components are correctly set for operation.
q Verify the preparation procedures of Section 7, pages 55
and 56 have been completed.
q Verify electrical connections are correct and securely
attached.
q Inspect vent piping and air piping for signs of deterioration
from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed
per this manual.
Start the boiler
1. Read and follow the Operating instructions in FIG. 7-2,
page 59.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is external limit control (if used) open? Is boiler water
temperature above 200°F (93°C)?
3. Is the boiler receiving a call for heat?
4. Is gas turned on at meter and boiler?
5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Power-fin Service Manual.
Check system and boiler
q Check water piping
1. Check system piping for leaks. If found, shut down
the boiler and repair immediately. (See WARNINGS
on pages 56 and 57 (startup) regarding failure to repair
leaks.)
2. Vent any remaining air from the system using manual
vents. Air in the system will interfere with circulation
and cause heat distribution problems and noise.
q Check vent piping and air piping
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
Venting system must be sealed gastight
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
q Check gas piping
1. Check around the boiler for gas odor following the
procedure on page 46 of this manual (connecting gas
supply piping).
If you discover evidence of any gas leak,
shut down the boiler at once. Find the
leak source with a bubble test and repair
immediately. Do not start the boiler again
until corrected. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Check flame and combustion
1. Turn the main power off to the boiler by placing the “On/
Off ” switch in the OFF position.
2. Remove the flue temperature sensor from the flue
collector. Note: Combustion measurements will be
made at this point.
3. Insert the probe from a combustion analyzer into the
hole left by the removal of the flue temperature sensor.
4. Turn the main power on to the boiler by placing the “On/
Off ” switch in the ON position.
5. Navigate to the Setup Screen from the Home Screen
by pressing the SETUP button along the left side of the
screen. Enter the installer password.
6. Select the Service Maintenance Screen. The tabs will
scroll (up and down) to reveal more options. See the
Power-Fin Service Manual for more detailed information.
7. Once the heat exchanger has modulated up to rate,
measure the combustion. The values should be in the
range listed in Table 9A of the Power-fin Service Manual.
CO levels should be less than 200 ppm for a properly
installed unit. If the combustion is not within range
reference the Troubleshooting Section in the Power-
fin Service Manual for possible causes and corrective
actions.
8. Once the heater analysis is complete, test the safety
shutoff device by turning the manual shutoff valve to the
OFF position and ensuring that the heater shuts down
and registers an alarm. Open the manual shutoff valve
and reset the control.
⚠WARNING
⚠WARNING
Figure 7-2_Operating Instructions
59
7 Start-up (continued)
Installation & Operation Manual
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instru ctions 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 call y lights th e burner. Do not try
to light the burner by hand.
B. BEFOR E OPER ATING smell all ar ound
the appliance area for ga s. Be sure to
smell next to the floor because some gas
is heavier than air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS
• Do not tr y to light any ap pl iance.
• Do not to uch any electric switch; do
not use any phon e in your buildi ng.
• Im mediately call your gas supplier from a
neighbor’s ph on e. Follow the gas supp lier’s
instructions.
• If you cannot reach your gas supplier , call
th e fire department.
C. Use only your hand to tu rn the gas control knob.
Never use tools. If the handle will not turn by
hand, don’t try to re
pair it, call a qualified service
te chnician. Force or attempted repair may
result in a fire or expl osion.
D. Do not use this appliance if any part has been
under water. Immediately call a qual ified
service technician to inspect th e applianc e an d
to replace any part of the control system and
any gas control which has been under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information
above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electr ic po wer to the
applianc e.
4. This appliance is equi pped with an
ignition device which automatically lights
the burner . Do not try to light th e burner
by hand.
5. Remove front door.
6. Turn gas shutoff valve counterclockwise
to “OFF”. Handle will be perpendicular to
pipe. Do not force.
7. Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B”
in the safety information above this label.
If you don’t smell gas, go to next step.
8. Turn gas shutoff valve clockwise to “ON”.
Handle wi ll be parallel to pi pe.
9. In stal l front door.
10. Turn on al l electric power to applianc e.
11. Se t ther mo
stat to desired setting.
12. If the appl iance will not operate, follow the
instructions “T o Turn Off Gas To Appliance” and
call yo ur service technician or gas supplier .
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electr ic po wer to the appl iance
if service is to be perfor med.
3. Remove front door.
4. Turn gas shut off valve counterclockwise to
“OFF”. Handle will be perpendi cular to pipe.
Do not force.
5. In stal l front door.
LBL2 0053 REV B
60
7 Start-up
Installation & Operation Manual
Set space heating set point temperature
During normal operation, set point temperatures can be
adjusted from the Home Screen by pressing the DETAILS
button on the bottom of the screen (see FIG. 7-3).
1. To change a set point, use the set point slider feature
or the PLUS (+) and MINUS (-) buttons
to adjust the set points as shown in FIG. 7-3.
2. Once the set point has been adjusted to the desired
setting, press the Door Menu slider (top left) or the
Setup button.
3. Press the APPLY CHANGES button on the top of the
screen.
NOTE: The APPLY CHANGES button must be pressed to
complete programming of the controls. Failure to press the
APPLY CHANGES button will result in an unprogrammed
control. The Door Menu button will become highlighted
when there are changes that can be applied.
Set space heating operation
Verify space heat circulator mode
The system pump output can be programmed to never run
(OFF), run only when a space heating demand is present
(ON), or run continuously except during warm weather
shutdown (WWSD). If the boiler is not heating an indirect
HW (Hot Water Generator) tank, it also turns on the boiler
pump. After the space heating call for heat ends, and the
system pump is programmed as ON, the system pump
continues to run for a short period of time. If the boiler
pump was running, it continues to run for a short period
of time as well. These pump delays are factory set to 30
seconds. If different delays are desired, the appropriate
parameters in the control must be changed. See the
Power-fin Service Manual for a detailed explanation of this
procedure.
Figure 7-3 User Set Point Screen
61
8 Operating information
Installation & Operation Manual
Set Hot Water Generator (HW) operation
Note: For more detailed instructions, please refer to the
Power-fin Service Manual.
Verify HW mode
There are two (2) modes of operation for HW. In Normal
Mode, when a HW demand begins, the control will start the
HW pump, turn off the boiler pump (if running), and modulate
to bring the outlet temperature to the HW boiler set point. The
maximum firing rate may be limited in this mode if desired.
In Zone Mode it is assumed that the indirect HW tank is piped
as a zone on the primary loop. When a HW demand begins, the
control will turn on the HW pump output, and raise the system
temperature set point to the HW boiler set point (if higher).
The boiler pump will be turned on. The system pump may be
forced on, forced off, or not changed, depending on the System
Pump Mode selected (reference the Power-fin Service Manual
for details). In this mode, any low temperature zones (such as
radiant heating) may need additional controls to limit the water
temperature sent to those zones.
Set HW boiler target temperature
When in the HW Mode, the control will modulate to maintain
the boiler outlet temperature or system supply temperature to
a set point. This set point is set at the factory to 180°F. If a
different set point is desired, the appropriate parameter in the
control must be changed. See the Power-fin Service Manual for
a detailed explanation of this procedure.
Set maximum HW fan speed
If the rated input of the indirect tank is less than the maximum
output of the boiler, change the maximum HW fan speed setting
to limit the boiler output accordingly, see the Power-fin Service
Manual for a detailed explanation of this procedure.
Set clock
The SMART TOUCH control has a built-in clock that it uses for
its night setback feature and for logging events. This clock must
be set when the appliance is installed and anytime the appliance
has been powered off for more than one day. Use the following
procedure to set the clock:
1. Press the SETTINGS button under the Lochinvar logo (see
FIG. 8-1).
2. Press the SET button across from the date and time.
3. Proceed to set the date, time, and time zone.
NOTE: Automatic Time Zone will not work.
4. Temperature units and WiFi may also be set here. These
items may be used to automatically sync the time.
5. Press the Home, View, or Back button to exit.
Figure 8-1 Rapid Setup Screen
62
8 Operating information
Installation & Operation Manual
DOOR
MENU
Figure 8-2 Cascade Screen
Configuration of the cascade
NOTE: For more detailed instructions, please refer to the
Power-Fin Service Manual.
When installing a Cascade system, all units must be
programmed for Cascade to operate. Access the Cascade
Setup options as follows:
1. Press the SETUP button on the left side of the display
screen.
2. Enter the installer password.
3. Select the Cascade option as shown in FIG. 8-2.
4. Each unit must have a unique address set. The leader has
more options which are described in the Power-Fin
Service Manual.
5. Once all the updates are complete, press the Door Menu
slider (top left) or the Setup button.
6. Press the APPLY CHANGES button on the top of the
screen.
NOTE: The APPLY CHANGES button must be pressed to
complete programming of the controls. Failure to press the
APPLY CHANGES button will result in an unprogrammed
control. The Door Menu button will become highlighted when
there are changes that can be applied.
63
8 Operating information (continued)
Installation & Operation Manual
General
How the appliance operates
The Power-fin uses a copper finned tube heat exchanger
to transfer heat from the flue products to the water. An
electronic control module monitors various inputs to initiate
a call for heat. The blower provides air to the burner and
forces the flue products out of the combustion chamber
and into the vent system. The control module regulates
the blower speed to control the firing rate of the unit. The
modulating gas valve monitors the amount of combustion air
being pulled into the blower and regulates the amount of gas
supplied, which then mixes with the combustion air and is
supplied to the burner.
How the control modules operate
The Power-fin boiler is equipped with a SMART TOUCH
control module. The SMART TOUCH control module
receives inputs from boiler sensors and external devices.
The control module activates and controls the blowers and
gas valves to regulate heat input and switches the boiler,
Hot Water Generator (HW), and system pumps on and
off as needed. The user programs the control module to
meet system needs by adjusting control parameters. These
parameters set operating temperatures and boiler operating
modes.
Control inputs and outputs
Enable
This input tells the boiler to provide water for space heating.
Hot Water Generator (HW) tank thermostat
This input tells the boiler to provide water for heating an
indirect HW tank.
0 - 10V BMS input (set point or power)
The Power-fin can be controlled by a Building Management
System (BMS) using a 0 - 10 VDC signal. The control can be
configured by the installer to use this signal to either control
set point or firing rate.
0 - 10V System Pump speed input
When a variable speed system pump is used, and there is a
0 - 10V signal available from the pump speed control, this
signal may be connected to the boiler. Doing so will allow
the boiler to anticipate changes in the BTU’s needed by the
system as the system flow changes, and therefore, help the
boiler to maintain the desired system temperature. Connect
the - input terminal to the COM or - output terminal on the
pump speed control, and the + input terminal to the 0 - 10V
or + output terminal on the pump speed control. Note that
the voltage on these inputs must never go below ground.
HW priority
The SMART TOUCH control allows the connection of a HW
thermostat or tank sensor to the low voltage connection board.
When a tank sensor is connected, the HW thermostat input is
ignored. When a boiler is programmed for HW Normal Mode,
the maximum firing rate can be limited to match the input rating
of the indirect tank coil.
HW / space heating (SH) cycling
If a HW call for heat is received while a space heating call is in
progress, and the HW is in Normal Mode, the control will start
the HW pump and shut the boiler pump off. The system pump
will remain on. For stand-alone boilers, if the space heating call is
still active while the HW call is in operation, the control will wait
for 30 minutes (time adjustable by installer) then it will switch
back to the space heating demand. There is a timer to switch from
space heating to HW and a timer to switch from HW to space
heating. The control will switch back and forth until one of the heat
demands end. This function does not apply to cascade systems.
Controlling sensor
The control module is programmed to use the outlet sensor as the
control sensor by default. If a system supply sensor is connected,
the control automatically uses it as the control sensor. The control
module may be programmed to use the inlet sensor as the control
sensor instead. In this case, the control will use the system return
sensor if it is connected.
Anti-cycling
After a space heating demand has been satisfied, the control will
delay the next space heating call for a set time period (time is
adjustable by the installer). The time delay will be bypassed if the
inlet water temperature drops too far during the delay.
Boiler, system, and HW pump control
When a space heating call for heat starts and no HW call is on, the
boiler pump is turned on. The system pump will turn on also if it is
programmed to do so. If a HW call for heat is on, the boiler pump
will wait to turn on until just before the HW pump turns off. After
the space heating call for heat ends, the boiler pump will run for an
additional period of time.
When a HW call for heat starts, the HW pump is turned on. If a
space heating call for heat is on, the boiler pump will turn off a few
seconds after the HW pump turns on.
Louver
When the boiler needs to control combustion air louvers, connect
a 24 VAC louver relay to the two (2) Louver Relay terminals.
Connect the Louver End Switch to the Louver Proving Switch
input on the Low Voltage Connection Board.
Temperature control
Modulation
The Power-fin is capable of modulating its firing rate from a
minimum of 20% to a maximum of 100%. The firing rate is
dictated by the call for heat (i.e., space heating or hot water
generation), the heating load, ramp delay (if enabled), and various
other temperature limitations.
8 Operating information
Installation & Operation Manual
64
Gradient limiting
If during operation of the boiler the outlet water temperature
is rising too quickly, the control will reduce the firing rate to
its lowest setting.
Outdoor air reset
If an outdoor air sensor is connected, the control module
will calculate the set point based on the programmed reset
curve. The installer can change the slope of the reset curve
by several adjustable parameters. The user can limit the
maximum set point for the system using the space heating
set point.
Boost function
If outdoor air reset is active, the boost temperature is not
0, a space heating demand has been active continuously for
a set period of time (time adjustable by installer) and there
has been no HW demands, the control will increase the set
point by a fixed number of degrees (adjustable by installer).
This process will continue until the space heating demand
ends, the set point reaches the programmed set point or a
maximum of 20 increases has occurred. Once the system
heat demand is satisfied, the set point will revert to the value
determined by the reset curve.
Night setback
The controller may be programmed to reduce the space
heating set point and/or Hot Water Generator set point for
each demand during a certain time each day. A start and
stop time for each demand can be programmed for each day
of the week. The controller can be programmed to reduce
the tank set point as well. A different set of start and stop
times can be programmed each day of the week.
Flame current support
To prevent nuisance shutdowns when the boiler is firing at
minimum rates, the control will increase the firing rate when
the flame signal drops too low.
ModBus
The Power-fin boiler can be connected to and controlled by a
Building Automation System through the ModBus interface.
Connect the A and B wires to the A and B terminals. If
connecting another cable (in a daisy chain), connect the
shield wire of the first cable to one of the shield terminals,
and the shield wire of the second cable to the other shield
terminal. If it is desired to ground the cable shield at the
heater, connect the shield wire to one of the shield terminals,
and install a jumper across the two (2) terminals in connector
X5 on the ModBus interface board.
0-10V Rate output
A 0-10V signal which indicates the firing rate of the heater
is available. This output may be connected to a Building
Management System (BMS) to allow it to monitor the actual
firing rate. Connect the - terminal to the COM or - terminal
on the BMS, and connect the + terminal to the 0 - 10V or +
terminal on the BMS.
Ramp Delay
For systems with lower flow, the SMART TOUCH can limit
the firing rate (when enabled) when a space heating call for
heat starts, or when switching from a DHW call for heat to a
space heating call for heat. There are six (6) limits that can be
programmed, as well as six (6) time intervals corresponding to
each limit. The sixth limit will also limit the firing rate for the
rest of the call for heat.
Protection features
Outlet temperature, flue temperature, and temperature
rise limiting
The outlet water temperature is monitored by the boiler outlet
temperature sensor. When the outlet temperature exceeds
215°F (102°C), the unit will reduce the fan speed. If the outlet
water temperature exceeds 220°F (104.4°C) the control will
shut the unit down until the minimum off time has expired and
the outlet drops 10°F (5.5°C).
The control module monitors the flue temperature by a
sensor located in the flue exhaust. If the flue temperature
exceeds 400°F (204.4°C) the control will reduce the maximum
fan speed. If the flue temperature exceeds 450°F (232.2°C)
the control will shut the unit down. The unit will restart
automatically once the flue temperature drops 50°F (10°C) and
the minimum off time has expired.
The control monitors the temperature difference between
the inlet and the outlet sensor. If this difference exceeds
55°F (12.8°C) the control will reduce the fan speed. If the
temperature difference exceeds 65°F (18.3°C) the control will
shut the unit down. The unit will restart automatically once
the temperature difference has dropped below 50°F (10°C) and
the minimum off time has expired.
Freeze protection
DO NOT install the boiler in a room likely to freeze.
The following integral feature of the SMART TOUCH control
module provides some protection for the boiler only -- not for
the system.
• The SMART TOUCH control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F (7°C):
• Below 45°F (7°C), the boiler and system pumps (if
enabled) operate constantly.
• Below 37°F (3°C), the boiler turns on.
• Boiler and pumps turn off if boiler water
temperature rises above 43°F (6°C).
This feature of the SMART TOUCH control
module does not eliminate the possibility
of freezing. The installation must still
use recognized design, installation and
maintenance practice to prevent freeze
potential for the boiler and system.
⚠ CAUTION
65
8 Operating information (continued)
Installation & Operation Manual
Monitor external limits
Connections are provided on the connection board for
external limits such as an additional high limit. The
SMART TOUCH control will shut off the burner and
inhibit relighting whenever any of these external limits
open.
Run-time and alarm outputs
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
Run-time and cycle counting
The control uses four timers to monitor the total hours of
burner operation:
75 - 100% 50 - 75%
25 - 50% <25%
The control uses four (4) ignition counters to monitor
the amount of boiler cycles. The first counter counts all
ignitions of the control. The second counter counts only
ignition attempts that have failed. The third and fourth
counters are the same as the first and second respectively,
but can be reset by the installer.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when
either a set amount of time has expired, or a set amount of
running hours or cycles has expired (all adjustable by the
installer). The service reminder notification can be reset
by the installer. The service company’s name and phone
number can be programmed to display when service is due.
Error logging
The control will hold in memory the last 10 blocking faults
as well as the last 10 lockout faults. The date and time of
the occurrence will be recorded as well. Only the 10 most
recent occurrences will be held in memory.
Boiler temperature regulation
Operating temperature (target)
The SMART TOUCH control module senses water
temperature and regulates boiler firing and firing rate to
achieve a target temperature. The target temperature can
be set between 32°F (0°C) and 215°F (101.7°C).
• Target temperature is fixed when the outdoor
sensor is not installed.
• Target temperature is calculated as described
under “Outdoor Reset Operation” and “Target
Temperature Boost” when the outdoor sensor is
connected.
High limit operations
The Power-fin SMART TOUCH control has two (2) integral
limits, one auto reset and one manual reset. The Power-fin
also has one auxiliary manual reset high limit. The integral and
auxiliary high limits are UL353 certified.
When the outlet temperature exceeds 225°F (107.2°C) (Installer
Adjustable Parameter), integral auto reset high limit action
occurs. The boiler will shut down until the outlet water cools
down and the timer expires.
If the outlet temperature exceeds 230°F (110°C) (User Adjustable
Dial), auxiliary manual reset high limit action occurs. The
boiler will shut down until the outlet water cools down and the
boiler is reset through the user interface.
If the outlet temperature exceeds 230°F (110°C) (Installer
Adjustable Parameter), integral manual reset high limit action
occurs. The boiler will shut down until the outlet water cools
down and the boiler is reset through the user interface.
Low water cutoff protection
A low water cutoff device with test and reset functionality is
provided in the boiler as standard equipment.
Flow sensing device
The SMART TOUCH control module uses temperature sensing
of both supply and return temperatures of the heat exchanger.
If the flow rate is too low or the outlet temperatures too high,
the control module modulates down and will shut the boiler
off. This ensures boiler shutdown in the event of low flow
conditions.
Outdoor reset operation, if used
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
See the Power-fin Service Manual to change the settings.
Reset curve
The reset curve looks at outdoor air temperature and adjusts
the set point.
NOTICE
If a mechanical flow switch is required to
meet local code requirements the Power-fin
boiler can be equipped with a field supplied
outlet flow switch. Please wire to the Louver
Proving Switch terminals.
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8 Operating information
Installation & Operation Manual
Cascade
When multiple boilers are installed, they can be wired together
in a cascade sequence. A maximum of eight boilers can be
controlled from a single control. In this application one boiler
would be designated as the Leader control and all others
would be designated as Member controls.
Once the Leader boiler receives a call for heat from the Enable
input, the 0 - 10 VDC input, or ModBus, the control will
determine what the set point will be. If outdoor air reset is
desired, connect the outdoor air sensor to the terminals on the
Low Voltage Connection Board on the Leader boiler. The set
point will be calculated based on the programmed reset curve
parameters. See the Power-fin Service Manual to program the
reset curve. If outdoor air reset is not desired, do not connect
the outdoor air sensor. A fixed temperature set point can
be programmed into the control, or provided through the
ModBus interface.
If the water temperature at the controlling sensor is less than
the set point + the turn-off offset - the off-on differential, the
control will initiate a call for heat on the Cascade (see the
Power-fin Service Manual for an explanation of the offset and
differential). The Leader will energize the lead boiler on the
Cascade. For a new startup this will be the Leader boiler.
The two (2) types of Cascade control are listed below:
Efficiency optimization
Efficiency optimization is chosen when the application is such
that overall heating efficiency is most important. The Cascade
will fire the boilers in a way that is the most efficient. This
allows more boilers to fire at one time, at a lower rate, thus
more efficient.
Lead/Lag
The Lead/Lag method is chosen when the application requires
firing as few boilers at a time as possible. This method will not
bring on another boiler until the current number of boilers
cannot meet the demand.
The parameters for both types of Cascade are adjustable.
Reference the Power-fin Service Manual for a more detailed
description of these adjustments.
Sequence of the cascade
To equalize the run time of all boilers on the Cascade, the
firing sequence will automatically be changed at set intervals.
For the first 24 hours after initializing the Cascade, the
sequence will be changed every hour. After that the sequence
will be changed once every 24 hours.
HW operation with cascade
For normal mode HW operation any boiler(s) in the Cascade
can be selected to provide heat for a HW call. Select a boiler to
be designated as the HW boiler. Connect the HW thermostat
or sensor to the terminals on the Low Voltage Connection
Board marked for the corresponding device. When the boiler
receives a HW call, the Leader control will take that boiler
out of the Cascade sequence. If another boiler is available, the
Leader will start it up to take its place.
The HW boiler will adjust its set point to the programmed
HW boiler set point and will adjust its firing rate to maintain
this. Once the HW call has been satisfied, the Leader control
will place that boiler back into the Cascade sequence.
Switching of the boiler between HW operation and SH
operation when there is a call for both does not occur in
Cascade Mode.
When HW is programmed for Zone Mode, connect the HW
thermostat or tank sensor to the Leader boiler. When a HW
call is received, the Leader will modulate the entire Cascade
to bring the system supply temperature up to the HW boiler
set point (if higher).
Night Setback and Ramp Delay operations with
cascade
Night Setback and Ramp Delay operation of the boilers within
the Cascade are available. Programming will be done through
the Leader boiler. Refer to the Power-fin Service Manual for
information regarding Night Setback and Ramp Delay.
67
8 Operating information (continued)
Installation & Operation Manual
Sequence of operation
1.
Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call,
HW pump for a hot water generator call).
2.
The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional).
3.
The control confirms that the gas pressure switch, blocked drain switch, limits, louver proving switch (optional) and
contacts close. The Pre-Purge cycle begins.
4.
The control confirms the blower comes up to the desired speed, and the air pressure switch is closed.
5.
Once the Pre-Purge cycle is complete, the control lowers the blower speeds, initiates sparking of the ignition
electrode, and opens the gas valve.
6.
After a short wait, the control stops sparking and checks for the presence of flame current through the flame sense
electrode.
7.
If the control does not detect flame current, the control will lockout indefinitely, until the RESET button on the touch
screen LCD is pressed.
8.
If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the
flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set
point temperature.
9.
If the current call for heat is for space heating and a HW call for heat becomes active, the control will turn on the HW
pump relay output, then turn off the boiler pump. It will then modulate the blower speed in order to maintain the
outlet temperature to the desired HW outlet set point temperature.
10.
Once both the space heating and HW calls for heat are satisfied, the control will turn off the gas valve(s) and begin
the Post-Purge cycle. Any pumps that are running will begin their respective Pump Delay cycles.
11.
At the end of the Post-Purge cycle, the louver relay contacts will de-energize.
12.
At the end of the Pump Delay cycle(s), the pump(s) will be turned off.
8 Operating information
Installation & Operation Manual
68
Figure 8-3 Home Screen
The Home Screen displays the available basic system information. It is divided into the following sections: Status, Demand,
Modulation, Sensors, and Navigation.
HOME
VIEW
SETUP
INFORMA
TION
SETTINGS
w/Power-fin CON•X•US Interface
• The Status Section is located on the top left of the screen
and displays how the unit is currently running (i.e. Off,
Stand-by, Blocking, and Lockout) including: current
driving demand, the next Hot Water Setback scheduled,
the reason for any blocking or lockout, and a power button.
• The Demand Section is located on the bottom left of the
screen and displays information about the targets and
limits of the current demand being serviced.
• The Modulation Section is located on the top right of the
screen and displays the target modulation of the unit. This
section also includes target and actual fan speeds.
• The Sensor Section is located on the bottom right of the
screen and displays both factory installed and field installed
sensor including: Outdoor Air, Hot Water Temperature,
System Supply, System Return, Inlet Water, Delta T, Outlet
Water, Flue Temperature, and Flame Current.
• The Navigation Section is located down the left side of the
screen. There are five (5) sections located below the
Lochinvar icon: Home, View, Setup, Information
(About), and Settings. The Home Section is the screen
shown above. The View Section provides more detailed
information including subsections for: History, Cascade,
Graphing, and a complete list of current Sensor Values.
The Setup Section has several screens to aid in setting
up the appliance. The Setup Section includes screens for
adjusting: Set Points, Pump Settings, Cascade, BMS, Ramp
Delay, and Night Setback. The Information Section
provides information about the hardware and software
including the current software version of the interface, the
version of the boiler control, and the CON·X·US device
serial number. The Setting Section enables several interface
setup features including: Time Setup, Temperature Unit
Select, Loch’n Link, System Update, and WiFi Setup.
69
This section applies only to those appliances used to supply
domestic hot water, installed with a storage tank(s). A
circulating pump MUST be installed in the piping assembly
to the storage tank and valves used to control water velocity
through the appliance. Proper water velocity is important for
correct operation of your water heater.
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 operation
sections apply to these instructions. Water heaters are designed
for installation with a storage tank. The operation of the
circulating pump, proper sizing of the piping between the tank
and heater and the control of water velocity, as explained in
this section, are important for correct operation of your water
heater.
NOTICE
NOTICE
To ensure proper velocity through the heat
exchanger, 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 exchanger 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.
Excessive lime/scale build-up in the heat
exchanger tubes is a result of restricted flow
and too little velocity in the tubes. Excessive
pitting or erosion in the tube is caused by
high water flow and too much velocity
through the tubes. Care should be taken
to measure temperature rise and maintain
velocity as follows:
When connecting the unit to piping made of
a different material, use of a dielectric fitting
or a dielectric union conforming to ASSE
1079 is recommended to prevent corrosion
and potential subsequent water leaks at or
near the connection. Dielectric fittings may
be required by local plumbing codes.
Initial set-up of maximum water flow
On initial start-up of the Power-fin the maximum water flow
through the heat exchanger must be manually set before normal
operation begins.
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 rate through the
water heater must be adjusted. Maximum flow on Models 502 -
1302 is 75 GPM and 90 GPM on Models 1501 - 2001. Flow rate
can be determined by measuring the temperature rise through
the water heater when it is firing at full rate input.
1. The pump must run continuously when the burner is
firing.
2. With the pump running and the burner in the water heater
in the off cycle, the inlet water temperature and outlet water
temperature readings on the Operator Interface should read
approximately the same temperatures. Water Temperature
Rise on the Operator Interface should read near zero.
3. Turn the water heater on and allow time for the temperature
to stabilize. The Service Mode can be used to force the water
heater to run at full fire. See the Power-fin Service Manual
for a detailed explanation of the Service Mode. Check the
water temperature rise in the Operator Interface when the
burner is firing at 100% of rated input.
4. Compare the water temperature rise in the Operator
Interface with the required temperature rise. Should
adjustment be needed, proceed as follows.
TABLE - 9B
TEMPERATURE RISE AT FULL RATE FIRE
75 AND 90 GPM FLOW
Model Temperature Rise
502 11°F (6.1°C)
752 17°F (9.4°C)
1002 23°F (12.8°C)
1302 30°F (16.7°C)
1501 28°F (15.6°C)
1701 32°F (17.8°C)
2001 38°F (21.1°C)
9 Domestic water heaters
Installation & Operation Manual
TABLE - 9A
MAXIMUM WATER FLOW
⚠ CAUTION: The maximum flow rate through Power-fin
models with a copper heat exchanger must be set to provide
and not exceed the following flow:
Model Maximum Flow
Maximum Flow for
CuNi Heat Exchanger
502, 752, 1002, and 1302 75 GPM 95 GPM
1501, 1701, and 2001 90 GPM 115 GPM
70
If the temperature rise is too low, the water velocity is too
high, adjust as follows:
1. Temperature rise can be increased by slowly closing the
field-installed ball valve in the outlet piping from the
water heater to the storage tank to achieve the proper
temperature rise.
2. Sustained high water velocity and low temperature rise
may result in pitting or erosion of the copper tubes in
the heat exchanger. This is a non-warrantable failure.
Temperature rise must be properly adjusted to achieve
the specified flow rate.
3. Once temperature rise has been properly set, return to
normal operation.
⚠ CAUTION
Temperature rise cannot be adjusted
when the burner is firing at less than
100% of rated input.
Water chemistry
NOTICE
Water temperature rise and maximum flow
data is based on heating potable water with
a hardness of 5 to 20 grains per gallon and
total dissolved solids not exceeding 350
ppm.
The required temperature rise and the standard circulating
pump are sized based on the heating of potable water with
a hardness of 5 to 20 grains per gallon and a total dissolved
solids not exceeding 350 ppm. Consult the manufacturer when
heating potable water exceeding these specifications. Heating
of high hardness and/or high total dissolved solids water may
require a larger circulating pump, an optional Cupro Nickel
heat exchanger and a revised temperature rise specification
based on the water chemistry of the water to be heated. Water
with a hardness of less than 5 grains per gallon will usually
have a 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.
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.
2. Be sure all valves are open between the water heater and
the storage tank. Ensure that all ball valves are fully
ported.
3. Check the pump to be sure it is running properly and
that the pump motor is running in the proper
direction.
4. Check diameter and length of the piping between the
storage tank and water heater against the head capacity
of the circulating pump.
5. Be sure the pipes between the water heater and storage
tank are not less than 2 1/2 inch (63.5mm) diameter.
To increase flow and decrease temperature rise, increase
the piping to 3 inch (76.2mm) diameter to decrease
head loss in the piping to the storage tank.
6. Common manifold piping for multiple unit
installations will require larger minimum pipe sizes
and tank circulating tappings to ensure proper flow.
9 Domestic water heaters
Installation & Operation Manual
NOTICE
1. Do not use the appliance to directly
heat swimming pool or spa water.
2. At initial fill and during water heater
start-up and testing, check system
thoroughly for any leaks. Repair all leaks
before proceeding further.
3. When water hardness levels are less
than 5 gpg or 85.5 mg/l, the following is
recommended:
a. Flush and clean existing water heating
system prior to installation.
b. Inspect and, if necessary, replace the
anodes in any existing tanks.
c. Install a Y-strainer on the inlet of each
water heater as detailed in this section.
d. Limit the run time of the hot water
recirculation loop.
e. Filter the hot water recirculation loop
to a level of 10 microns. CAUTION:
Check recirculation pump size to verify
it is sized for filter addition and upsize if
necessary.
4. When water softener is required, a
Template Assisted Crystallization system
is recommended.
71
Figure 9-1_Typical Water Heater Piping with Storage Tank
RELIEF VALVE
POWER-FIN WATER HEATER
INLET
OUTLET
BUILDING RETUR
N
BUILDING HO
T
WA
TER SUPPLY
MIXING VALVE
RELIEF VALVE
LOCK-TEMP
STORAGE TANK
DRAIN
COLD WATER SUPPLY
Y-STRAINER
DIR #2000570681_000
BUILDING RECIRCULATION
FILTER (IF REQUIRED SEE
SECTION 9)
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
1 75 2 1/2
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
1 90 2 1/2
9 Domestic water heaters (continued)
Installation & Operation Manual
72
Figure 9-2_Single Water Heater Piping with Two Storage Tanks
POWER-FIN WATER HEATER
BUILDING RETURN
BUILDING HOT
WATER SUPPLY
MIXING VALVE
RELIEF VALVE
DRAIN
COLD WATER SUPPLY
Y-STRAINER
DIR #2000570682_000
BUILDING RECIRCULATION
FILTER (IF REQUIRED SEE
SECTION 9)
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
1 75 2 1/2
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
1 90 2 1/2
9 Domestic water heaters
Installation & Operation Manual
73
Figure 9-3_Multiple Water Heater Piping with a Single Storage Tank
MIN. 4” COMMON
MANIFOLD SIZE
COLD WATER SUPPLY
MIXING VALVE
BUILDING HOT
WA
TER SUPPLY
RELIEF VALVE
LOCK-TEMP
STORAGE TANK
DRAIN
Y-STRAINER
(TYPICAL)
BUILDING RETURN
DIR #2000570683_000
BUILDING RECIRCULATION
FILTER (IF REQUIRED SEE
SECTION 9)
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
2 150 3 1/2
3 225 4
4 300 5
5 375 6
6 450 6
7 525 6
8 600 8
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
2 180 4
3 270 5
4 360 6
5 450 6
6 540 6
7 630 8
8 720 8
9 Domestic water heaters (continued)
Installation & Operation Manual
74
Installation & Operation Manual
Figure 9-4_Multiple Water Heater Piping with Multiple Storage Tanks
COLD WATER SUPPLY
POWER-FIN WATER HEATER
MIN. 4" COMMON
MANIFOLD SIZE
BUILDING RETURN
RELIEF VALVE
BUILDING HOT
WA
TER SUPPLY
MIXING
VALVE
DRAIN
Y-STRAINER
(TYPICAL)
DIR #2000570684_000
BUILDING RECIRCULATION
FILTER (IF REQUIRED SEE
SECTION 9)
COMMON MANIFOLD SIZE (Min.)
Models: 502, 752, 1002, & 1302
Number of Units GPM
Diameter
(in.)
2 150 3 1/2
3 225 4
4 300 5
5 375 6
6 450 6
7 525 6
8 600 8
COMMON MANIFOLD SIZE (Min.)
Models: 1501, 1701, & 2001
Number of Units GPM
Diameter
(in.)
2 180 4
3 270 5
4 360 6
5 450 6
6 540 6
7 630 8
8 720 8
9 Domestic water heaters
Installation & Operation Manual
Pump operation
1. The water heater must have a properly sized circulating
pump. This pump is sized to circulate water between
the heater and the storage tank only.
2. The pump is sized to the heater input and water
chemistry specifications noted in the Water Chemistry
section on page 70.
3. The diameter and length of the piping installed between
the storage tank(s) and water heater must be properly
sized based on the capacity of the circulating pump.
4. The pump must run continuously when the water
heater is energized. This is the standard operating
system for a water heater.
An intermittent pump control function with an all bronze
pump is installed as standard equipment on all water heater
systems. The pump will operate only while there is a “Call
for Heat” and for a timed period after the water temperature
set point is satisfied to remove any residual heat from the
combustion chamber.
5. Lubricate pump to manufacturer’s recommendations.
Pump damage due to inadequate lubrication is
non-warrantable.
The tank 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 tank sensor is in the literature
package shipped with the unit. Placing the sensor in the tapping
provided on the storage tank will improve temperature response
and prevent short cycles of operation.
When installing multiple water heaters and/or multiple storage
tanks, the diameter of the inter-connecting pipe and all fittings
must be increased. An increase in pipe diameter will decrease
head loss in the system piping and ensure proper flow. Proper
pipe size between the heater and storage tank MUST be
maintained to ensure that the standard pump supplied on the
water heater will maintain desired flow.
Heat exchanger
On all models, header inspection plugs in the heat exchanger
can be removed for field inspection and cleaning of copper
tubes. The heat exchanger may be removed from the unit.
TABLE 9C
COMMON WATER MANIFOLD SIZE FOR
MULTIPLE WATER HEATER INSTALLATIONS
Pipe sizing chart provides minimum pipe size for common
manifold piping to ensure adequate flow.
Number of Water Heaters
Common Manifold Size (Min.)
Models
502 - 1302 1501 - 2001
1 2 1/2" 2 1/2"
2 3 1/2" 4"
3 4" 5"
4 5" 6"
5 6" 6"
6 6" 6"
7
6" 8"
8
8" 8"
The standard circulating 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.
500,001 - 1,300,000 Btu/hr Models
1/2 HP, 120 VAC, 9.8 Amps
1,500,000 - 2,000,000 Btu/hr Models
3/4 HP, 120 VAC, 8.8 Amp
The standard pump selection is based on the following pipe and
fittings from the water heater to the storage tank:
6 - 90° elbows 2 - ball valves
2 - unions 1 - cold water tee
Not more than 45 feet of straight pipe.
For every elbow and tee in excess of those shown above,
DEDUCT 6.5 FEET from the maximum allowable straight pipe
in the heater to tank circulating loop.
9 Domestic water heaters (continued)
75
TABLE 9D
WATER HEATER PUMP APPLICATIONS
Model
Pipe
Size
Water
Hardness
Pump
Flow
Rate
(GPM)
Head
Loss
(FT)
Temp.
Rise
502 2-1/2"
5 to 15 gpg Armstrong 114109-957 75 15 11°F
15 to 20 gpg Grundfos TP 50-160/2B 95 15 9°F
752 2-1/2"
5 to 15 gpg Armstrong 114109-957 75 15 17°F
15 to 20 gpg Grundfos TP 50-160/2B 95 15 14°F
1002 2-1/2"
5 to 15 gpg Armstrong 114109-957 75 15 23°F
15 to 20 gpg Grundfos TP 50-160/2B 95 15 18°F
1302 2-1/2"
5 to 15 gpg Armstrong 114109-957 75 15 30°F
15 to 20 gpg Grundfos TP 50-160/2B 95 15 24°F
1501 2-1/2"
5 to 15 gpg Grundfos TP77PAB 90 15 28°F
15 to 20 gpg Grundfos TP 50-160/2B 115 15 22°F
1701
2-1/2"
5 to 15 gpg Grundfos - TP77PAB 90 15 32°F
15 to 20 gpg Grundfos TP 50-160/2B 115 15 25°F
2001
2-1/2"
5 to 15 gpg Grundfos TP77PAB 90 15 38°F
15 to 20 gpg Grundfos TP 50-160/2B 115 15 29°F
76
Minimum water temperatures (domestic
hot water use)
Domestic water temperatures:
This high efficiency water heater should be operated at a
temperature setting high enough to prevent condensing of
the products of combustion on the unit’s heat exchanger or
in the attached venting system. Use extreme caution when
storing water at elevated temperatures. A water temperature
setting maintained above the dew point of the products of
gas combustion should prevent condensate formation and
ensure proper performance of the venting system. The
manufacturer recommends the use of a properly sized
thermostatic mixing valve to supply domestic hot water at
temperatures less than 140°F (60°C). Storing the water at a
higher temperature and thermostatically mixing the water
will increase the available quantity of mixed hot water,
greatly reducing the possibility of condensate formation
on the heat exchanger or in the venting system and help
prevent the growth of water borne bacteria.
NOTICE
Adequate care MUST be taken to
prevent a potential scald injury when
storing water at elevated temperatures
for domestic use.
⚠ CAUTION
An appliance allowed to operate at return
temperatures below the specified minimum
setting may experience problems with
the operating controls, safety switches,
obstruction of the flue gas passages on the
heat exchanger, incomplete combustion,
and possible flue gas spillage. Sustained
operation at lower than specified water
temperatures may cause hazardous
conditions that may result in personal
injury or non-warrantable damage to the
appliance.
The maximum temperature set point that can be programmed
into the control module from the Operator Interface for water
heater operation is 190°F (88°C). The control is factory pre-set
at approximately 120°F (49°C). Facilities with small children
or invalids may require 120°F (49°C) or a 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.
NOTICE
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 --
⚠ CAUTION
Hotter water increases the risk of scald injury.
Thermostat adjustment procedure
During normal operation, set point temperatures can be
adjusted from the Home Screen by pressing the DETAILS
button on the bottom of the screen (see FIG. 7-3 on page
60).
1. To change a set point, use the set point slider feature
or the PLUS (+) and MINUS (-) buttons
to adjust the set points as shown in FIG. 7-3.
2. Once the set point has been adjusted to the desired
setting, press the SAVE button to save changes to the set
point and return to the Home Screen.
Note: The SAVE button must be pressed to ensure proper
programming of the controls. Failure to press the SAVE
button will require all changes to be reprogrammed.
Inlet water temperatures below the specified minimum
recommendations can excessively cool the products
of combustion resulting in condensation on the heat
exchanger. Condensation on the heat exchanger can cause
operational problems, bad combustion, sooting, flue gas
spillage and reduced service life of the related components.
9 Domestic water heaters
Figure 9-5_Danger Warning
Installation & Operation Manual
77
Location of Cold Water Supply Piping Connections
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
in this manual for correct piping (FIG.’s 9-1 thru 9-4). Higher
water temperatures reduce the volume of condensate formed.
⚠ CAUTION
Setting the temperature selector to higher
settings provides hotter water, which
increases the risk of scald injury.
⚠WARNING
Should overheating occur or the gas supply
fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead,
shut off the gas supply at a location external
to the appliance.
Adjustable high water temperature limit control
Figure 9-6_Adjustable High Water Temperature Limit Control
A high limit control is located on the inside of the left front
panel, as shown in FIG. 9-6. The setting of this control knob
limits maximum discharge water temperature. The water heater
temperature limit control is adjustable up to a maximum
setting of 210°F (99°C). This water heater also includes a fixed
high water temperature limit control set to 200° (93.3°C).
The RESET key on the display must be pushed whenever
water temperature has exceeded the set point of the 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 high limit
control before the reset function can be activated. A high limit
message will be shown in the Operator Interface when water
temperature exceeds the high water temperature limit control
set point.
Optional relief valve
This water heater 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 is equipped with this optional relief
valve and 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 installed in a
closed system, such as one with a backflow preventer or check
valve installed in the cold water supply, shall be provided with
means to control expansion. Contact the water supplier or local
plumbing inspector on how to correct this situation. Do not
plug or cap the relief valve discharge.
Cathodic protection
Hydrogen gas can be produced in a hot water system that has
not been used for a long period of time (generally two weeks
or more). Hydrogen gas is extremely flammable. To prevent
the possibility of injury under these conditions, we recommend
the hot water faucet be open for several minutes at the kitchen
sink before you use any electrical appliance which is connected
to the hot water system. If hydrogen is present, there will be
an unusual sound such as air escaping through the pipe as the
hot water begins to flow. There should be no smoking or open
flames near the faucet at the time it is open.
NOTICE
The high limit control will not reset until the
water temperature has dropped below the set
point of the high limit.
9 Domestic water heaters (continued)
Installation & Operation Manual
The following chart (Table 9E) 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 9E
APPROXIMATE TIME / TEMPERATURE
RELATIONSHIPS IN SCALDS
120°F More than 5 minutes
125°F 1 1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1 1/2 seconds
155°F About 1 second
78
10 Maintenance
Maintenance and annual start-up
Table 10A_Service and Maintenance Schedules
Installation & Operation Manual
Service technician
(see the following pages for instructions)
General:
• Address reported problems, if any
• Inspect interior; clean and vacuum if
necessary;
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check system water pressure/system
piping/expansion tank
• Check fill water meter
• Test boiler water. When test indicates,
clean system water with approved
system restorer following manufacturer’s
information.
• Check control settings
• Check the ignition and both flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 7.
• Flame inspection (stable, uniform)
• Check both flame signals (at least 10
microamps at high fire)
• Clean the heat exchanger
• Test low water cutoff (reference the
Power-fin Service Manual).
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheels
ANNUAL START-UP
Owner maintenance
(see the Power-fin User’s Information Manual for
instructions)
Daily
• Check boiler area
• Check pressure/temperature
gauge
Monthly
• Check vent piping
• Check air piping
• Check air and vent termination
screens
• Check relief valve
• Check condensate drain system
• Check building recirculation filter
(if filter required)
Every
6 months
• Test low water cutoff
• Reset button (low water
cutoff)
• Check boiler piping (gas and
water) for leaks
• Operate relief valve
End
of season
months
• Shut boiler down (unless boiler
used for domestic hot water)
79
10 Maintenance (continued)
Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the appliance. Failure to perform the service and maintenance could result in damage to the
appliance or system. Failure to follow the directions in this manual and component literature could result in
severe personal injury, death, or substantial property damage.
The appliance should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the appliance designated in Table 10A and explained on the following pages must be performed to
assure maximum appliance efficiency and reliability. Failure to service and maintain the appliance and system
could result in equipment failure.
Electrical shock hazard – Turn off power to the appliance before any service operation on the appliance except
as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical
shock, causing severe personal injury or death.
⚠WARNING
⚠WARNING
⚠WARNING
Installation & Operation Manual
Address reported problems
1. Inspect any problems reported by the owner and correct
before proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants
listed in Section 1 of this manual. If any of these are
present in the boiler intake air vicinity, they must be
removed. If they cannot be removed, reinstall the air and
vent lines per this manual.
Inspect boiler interior
1. Remove the front access covers and inspect the interior of
the boiler.
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Clean condensate trap
1. Inspect the condensate drain line, vent line, condensate
PVC fittings, and condensate trap.
Flush condensate trap with water
1. Remove the four (4) screws securing the top cover to the
condensate trap and remove the cover (FIG. 10-1).
2. Locate the plastic ball inside the float tube. Verify there
is nothing under the ball causing it to not seat properly.
3. Replace the top cover and the screws removed in Step 1.
Eliminate all system or boiler leaks.
Continual fresh makeup water will
reduce boiler life. Minerals can build up,
reducing heat transfer, overheating heat
exchanger, and causing heat exchanger
failure. Leaking water may also cause
severe property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using the procedure found in Section 4
- Gas Connections.
Check all piping for leaks
⚠WARNING
Figure 10-1 Condensate Trap
Flue vent system and air piping
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that air inlet pipe
is connected and properly sealed.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
⚠WARNING
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing
or performance problem.
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
80
10 Maintenance
Installation & Operation Manual
Check expansion tank
1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed or diaphragm or bladder type.
See Section 3 - Water Connections for suggested best
location of expansion tanks and air eliminators.
Check fill water meter
1. Check fill water meter for water usage. If the amount
exceeds 5% of your system volume, you could have a
leak. Have the system checked for leaks and fixed by a
qualified service technician.
Test boiler water
1. Test boiler water. Reference the Power-Fin Installation
and Operation Manual for guidelines. When test
indicates, clean system water with approved system
restorer following the manufacturer’s information.
Check boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 3 - Water Connections before
proceeding further.
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE
YEARS, by a licensed plumbing contractor
or authorized inspection agency, to ensure
that the product has not been affected
by corrosive water conditions and to
ensure that the valve and discharge line
have not been altered or tampered with
illegally. Certain naturally occurring
conditions may corrode the valve or its
components over time, rendering the
valve inoperative. Such conditions are
not detectable unless the valve and its
components are physically removed and
inspected. This inspection must only
be conducted by a plumbing contractor
or authorized inspection agency – not
by the owner. Failure to re-inspect the
boiler relief valve as directed could result
in unsafe pressure buildup, which can
result in severe personal injury, death, or
substantial property damage.
Following installation, the valve lever
must be operated AT LEAST ONCE A
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve
and not over-pressurization of the system due to expansion
tank waterlogging or undersizing.
⚠WARNING
⚠WARNING
Inspect ignition and flame sense
electrode
1. Remove the ignition and flame sense electrode from the
burner plate.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrode cannot be
cleaned satisfactorily, replace with a new one.
3. Replace ignition/flame sense electrode, making sure the
gasket(s) is in good condition and correctly positioned.
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger access
cover to ground terminal strip.
2. Verify all wiring is in good condition and securely attached.
3. Check ground continuity of wiring using continuity meter.
4. Replace ground wires if ground continuity is not satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
Check control settings
1. Navigate to the Setup Screen and check all settings. See
Section 1 of the Power-fin Service Manual. Adjust settings
if necessary. See Section 1 of the Power-fin Service Manual
for adjustment procedures.
2. Check settings of external limit controls (if any) and adjust
if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 7 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
YEAR to ensure that waterways are clear. Certain naturally
occurring mineral deposits may adhere to the valve, rendering
it inoperative. When manually operating the lever, water will
discharge and precautions must be taken to avoid contact with
hot water and to avoid water damage. Before operating lever,
check to see that a discharge line is connected to this valve
directing the flow of hot water from the valve to a proper place
of disposal. Otherwise severe personal injury may result. If no
water flows, valve is inoperative. Shut down the boiler until a
new relief valve has been installed.
81
10 Maintenance (continued)
Installation & Operation Manual
Check burner flame
Visually check main burner flames at each start-up after long
shutdown periods or at least every six months. A burner
viewport is located on the burner mounting flange.
Perform start-up and checks
1. Start appliance and perform checks and tests specified in
Section 7 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
The area around the burner viewport is hot
and direct contact could result in burns.
⚠WARNING
Figure 10-2_Flame Pattern Illustration
Normal Flame: A normal flame at 100% of burner input is blue,
with slight yellow tips, a well defined flame and no flame lifting.
Yellow Tip: Yellow tipping can be caused by blockage or partial
obstruction of air flow to the burner.
Yellow Flames: Yellow flames can be caused by blockage of
primary air flow to the burner or excessive gas input. This
condition MUST be corrected immediately.
Lifting Flames: Lifting flames can be caused by over firing the
burner, excessive primary air or high draft.
If improper flame is observed, examine the venting system,
ensure proper gas supply and adequate supply of combustion
and ventilation air.
Check all wiring
1. Inspect all wiring, making sure wires are in good condition
and securely attached.
Check control settings
1. Set the SMART TOUCH control module display to
Parameter Mode and check all settings. See Section 1 of the
Power-fin Service Manual. Adjust settings if necessary. See
Section 1 of the Power-fin Service Manual for adjustment
procedures.
2. Check settings of external limit controls (if any) and adjust
if necessary.
Check flue gas passageways
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.
All gaskets/sealants on disassembled
components or jacket panels must be
replaced with new gaskets/sealants on
reassembly. Gasket and sealant kits are
available from your distributor.
NOTICE
⚠ CAUTION
When a Category IV vent system is
disconnected for any reason, the flue must
be reassembled and resealed according to the
vent manufacturer’s instructions.
82
10 Maintenance
Installation & Operation Manual
Access to the burner will require the following steps:
1. Turn off main electrical power to the appliance.
2. Turn off main manual gas shutoff to the appliance.
3. Remove the front outer control panel covers. Slide out the
inner control panel to increase service clearances and
carefully remove the multi-pin wiring connectors on the
back of the control panel. Remove the screws along the
front and rear edge of the top outer jacket panel to remove
top. Remove the control panel to allow access to
the components in the top of the appliance.
4. Remove the sensing tubes from the low air pressure switch
to the combustion air blower.
5. Disconnect the wiring connections on the top of the
combustion air blower.
6. Remove the six (6) hex head bolts attaching the gas/air
venturi to the inlet of the combustion air blower.
7. Remove the four (4) nuts holding the combustion air
blower to the top of the burner and remove the combustion
air blower assembly.
8. Use care when removing the combustion air blower
assembly to prevent damage to the venturi and burner
gaskets.
9. Disconnect the power wires to the hot surface igniter.
10. Remove the hot surface igniter. The hot surface igniter is
fragile. Use care to prevent impact damage to the silicone
carbide igniter surface when removing the igniter.
Inspect and clean burner
The burner should be removed for inspection and cleaned
on an annual basis. An appliance installed in a dust or dirt
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 drywall dust can be drawn into the
burner with the combustion air and block the burner port area.
External combustion air filters are provided with the appliance.
These filters help ensure clean air is used for the combustion
process. Check filters every month and replace when necessary.
The burner of an appliance used for temporary heat without
combustion air filters installed will probably require a thorough
cleaning before the unit is placed into normal service.
11. Remove the eight (8) nuts holding the burner to the
heat exchanger.
12. The burner can now be lifted vertically out of the heat
exchanger chamber.
13. Use care when removing the burner to prevent damage
to the woven burner port surface or gaskets on removal.
14. 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.
15. Reassemble in reverse order.
Inspect and clean the heat exchanger
1. Turn off all power to the appliance.
2. Turn off main gas to appliance.
3. Remove the front outer jacket panel.
4. Remove the front inner jacket panel (see FIG. 10-3).
5. Check the heat exchanger surface for soot. If soot is
present, the heat exchanger must be cleaned and the
problem corrected.
6. Remove the burner as described in the Inspect and
Clean Burner section of this manual.
7. Check the “V” baffles on the heat exchanger. Remove
and clean if necessary.
8. Remove soot from the heat exchanger with a stiff bristle
brush. Use a vacuum to remove loose soot from
surfaces and inner chamber.
9. The heat exchanger can be removed by disconnecting
all water piping to the heat exchanger, removing the
screws holding the heat exchanger to the top of the
inner jacket and sliding the heat exchanger towards the
front of the appliance. Once the heat exchanger is
removed, a garden hose can be used to wash the tubes
to ensure that all soot is removed from the heat
exchanger surfaces. Note: Do not wet the insulation
blankets on the inside of the outer jacket panels.
10. Ensure that any soot present on the burner is removed.
See Inspect and Clean Burner section, this page.
83
10 Maintenance (continued)
Installation & Operation Manual
DIR #2000537314 00
HEAT EXCHANGER
Upon completion of any testing on the
gas system, leak test all gas connections
with a soap and water solution while main
burners are operating. Do not spray soap
and water solution on the SMART TOUCH
control module housing. The use of an
excessive amount of soap and water solution
can damage the control. 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
piping.
NOTICE
14. Reassemble outer jacket panels.
15. Cycle unit and check for proper operation.
Review with owner
1. Review the Power-fin User’s Information Manual with the
owner.
2. Emphasize the need to perform the maintenance schedule
specified in the Power-fin User’s Information Manual (and
in this manual as well).
3. Remind the owner of the need to call a licensed contractor
should the appliance or system exhibit any unusual behavior.
4. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up at the beginning of the
next heating season.
Oiled bearing circulators
Inspect the pump every six (6) months and oil as necessary. Use
SAE 30 non-detergent oil or lubricant specified by the pump
manufacturer.
Figure 10-3_Location of the Heat Exchanger Inside
Jacket
11. Carefully reinstall the heat exchanger and “V” baffles if
removed from the appliance.
12. Reinstall the inner jacket panel, burner, manifolds,
wires, and hoses. Use new gasket material to ensure a
proper air seal.
13. Reassemble all gas and water piping. Test for gas leaks.
84
-T
-T
-T
-T
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a
minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and shielded cables must be purchased from the factory. Use of a non-approved spark lead
or shielded cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
17
CN3-6
CN6-2
CN3-14
CN6-1
CN3-13
CN3-12
CN3-11
CN3-10
CN3-9
CN3-8
CN6-3
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
CN3-1
CN3-2
CN3-5
CN3-3
X7-8
X8-14
X8-13
X8-12
X8-11
X8-15
X8-5
X8-6
X8-16
X8-7
X8-17
X8-18
X8-1
SHIELD
SHIELD
A
B
BAS
OPTION
+
-
RATE
OUT
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
0-10V
TANK
SENSOR
OUTDOOR
SENSOR
+
+
-
-
0-10V
0-10V
BMS
IN
SYSTEM
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
X6-1
X6-2
X6-3
G
R
BL
YG
RO
W
LB
PK
RP
R
BL/W
GY
Y
R/W
BL
J3-5
J3-4
J3-6
LWCO
BOARD
J3-3
J3-2
J2-1
J2-2
X6-3
O
TEST
SWITCH
LWCO
PROBE
PR
LWCO RESET
X6-5
GPS1 GPS2
RP
PR
X6-12
AIR PROOVE
O
X6-6
BLOCKED DRAIN
SWITCH
RB
X8-3
X8-8
X8-2
X8-4
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
X4-1
X4-2
X4-3
X8-10
X8-20
X5-8
X5-7
X5-3
X5-9
X5-2
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
X5-1
"X5"
BLOCK WIRING
IS MODEL
DEPENDANT
PK
BR
PR
R
X10-1
X1-3
X10-4
X1-1
X1-12
X1-2
X1-4
X10-2
X10-5
X1-6
ON/OFF
SWITCH
GND
GAS VALVE
BK
W
RB
PR
RO
OR/W
W
X6-18
X6-8
X1-8
G
X6-9
X6-17
BLOWER
R
KB
PR
T
G
X1-7
X1-10
X1-5
FLAME SENSE
HSI
24V
TRANSFORMER
GY
PK
BL
Y
BK
X1-2
X1-3
X1-1
INTEGRATED CONTROL
LARGE CONNECTION BOARD
SMALL CONNECTION BOARD
JUNCTION
BOX
X11
X4
USB
INTERFACE
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
DHW PUMP
CONTACTOR
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
1.5A EACH MAX
C1
L1
120V 10
N
231
1
2
4
5
3
WIRING DIAGRAM
REV B
CN3-4
OPTIONAL
ETHERNET CABLE
E
GND
SW1
J2
8
43
J9
J17
J23
J12
J11
J8
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
LCD
DISPLAY
24V
J6
J7
COMMUNICATION
CONTROL BOARD
LG CON BRD
R
PR
GY
CN6-3
CN6-1
CN6-2
BAS
WIFI
DONGLE
G
4
PR
PK
Y
W
X6-4
HIGH LIMIT
SWITCH
R
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CN1-12
CN1-5
CN1-10
CN1-11
CN1-6
CN1-9
CN1-8
CN1-7
CN1-1
CN1-2
CN1-3
CN1-4
X3-1
X3-4
X6-1
X6-11
X3-2
X6-2
X6-14
X6-13
X6-10
X3-3
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
GROUND
OPEN SWITCH 1
CLOSE SWITCH
24 VAC
OR
OR
BK
BK
LB
T
R
T/BK
BR
Y
ENABLE
R
W
Y
BL
3 WAY
VALVE
X6-7
X6-16
RP
RB
BK
C1
GY
SWITCH
J2-3
GND
T
T
PR
O
O/BK
FLOW
SWITCH
PR
100279790
BAS
BOARD
(AS APPLICABLE)
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
Installation & Operation Manual
11 Diagrams
Figure 11-1 Wiring Diagram
85
Installation & Operation Manual
11 Diagrams (continued)
Figure 11-2 Ladder Diagram
JUNCTION BOX
TERMINAL STRIP
TERMINAL STRIP
NEUTRAL
INTEGRATED CONTROL
ON/OFF
SWITCH
F2
3.15 A
F4
5.0 A
SYSTEM PUMP
RELAY
BOILER PUMP
RELAY
DHW PUMP
RELAY
X1-1
X1-2
X1-4
X1-8
BLOWER
CONTACTOR
GAS
VALVE RELAY
X1-6
X10-1 X10-2
GAS
VALVE RELAY
X10-5
X10-4
GAS
VALVE
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOLIER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
BLOWER
BLOWER
X6-10X6-1
4
24V
TRANSFORMER
X6-3
X1-12
X1-3
LWCO
BOARD
TEST
SWITCH
LWCO
PROBE
LWCO RESET
J3-4
J3-3
J2-1
J2-2
J3-5
J3-2
X6-5
X6-12
X6-6
X3-3
X3-4
X3-2
X3-1
X6-11
X6-2
X6-14
INTEGRATED
CONTROL
GPS1 GPS2
AIR PROOVE
SWITCH
FLOW
SWITCH
BLOCKED DRAIN
SWITCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
ENABLE
R
W
SMALL
CONNECTION BOARD
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
X6-13
CN1-11
CN1-9
CN1-8
CN1-7
CN1-1
X1-5
X1-7
X1-10
FLAME
SENSE 1
HSI
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
SHIELD
SHIELD
A
B
BAS
OPTION
+
-
RATE
OUT
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
0-10V
TANK
SENSOR
OUTDOOR
SENSOR
+
+
-
-
0-10V
0-10V
BMS
IN
SYSTEM
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
LARGE
CONNECTION BOARD
CN6-1
CN3-6
CN3-14
CN3-13
CN3-11
CN3-9
CN3-8
CN3-1
CN3-2
CN3-3
CN3-5
CN6-2
CN6-3
CN3-10
CN3-12
X4-1
X4-2
X4-3
X6-3
X6-1
X6-2
X8-10
X8-20
X7-8
X8-13
X8-14
X8-12
INTEGRATED
CONTROL
X8-5
X8-15
X8-11
X8-6
X8-16
X8-7
X8-17
X8-18
-T
-T
-T
-T
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
X8-3
X8-8
X8-2
X8-4
GROUND
X6-18
X6-9
X6-17
X6-8
1
5
1.5A EACH MAX
X11
X4
X5-1
X5-7
X5-2
X5-8
X5-3
X5-9
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
USB
INTERFACE
"X5"
BLOCK WIRING
IS MODEL
DEPENDANT
L1
LADDER DIAGRAM
X8-1
CN3-4
OPTIONAL
ETHERNET CABLE
1
4
2
5
BLOWER
E
GND
WIFI
DONGLE
SW1
J2
8
43
J6
J9
J17
J23
J12
J11
LG CON BRD
J8
LCD
DISPLAY
USB CABLE
LCD
DISPLAY
J10
J7
BAS
CN6-1
CN6-3
24V
CN6-2
OPTIONAL USB/WIFI
EXTENSION CABLE
LCD
DISPLAY
3 WAY
VALVE
GROUND
OPEN SWITCH 1
CLOSE SWITCH
24 VAC
X6-4
HIGH LIMIT
SWITCH
CN1-2
X6-7
X6-16
CN1-3
J2-3
CHASSIS
GROUND
J3-6
CONTACTOR
1
120 V 1
O
SUPPLY
120V SUPPLY "N"
REV C 100279789
2-1X1-1X
X1-3
BAS
(AS APPLICABLE)
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requireements per either N.E.C.
in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same
wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and shielded cables
must be purchased from the factory. Use of
a non-approved spark lead or shielded cables can lead to operational problems
which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper
connector block locations when using diagrams to troubleshoot unit.
BAS
BOARD
(AS APPLICABLE)
Installation & Operation Manual
Notes
86
Installation & Operation Manual
Notes
87
Revision Notes: Revision A (PCP #3000005813 / CN #500005966)
initial release.
Revision B (PCP# 3000006581 / CN# 500006679) reflects an update
to venting category information on pages 34-36.
Revision C (PCP# 3000008544 / CN# 500008642) reflects an update
to the PF 502 input to 500,001 on page 75 along with edits made to the
piping diagrams on pages 71 - 74.
Revision D (PCP# 3000009248 / CN# 500009030) reflects limit
changes on pages 64-65 of the Operating Information section.
Revision E (PCP# 3000010217 / CN# 500009885) reflects an update
to the pump motor size in number 3 under “Line Voltage Connections.”
Revision F (PCP # 3000022655 / CN # 500012544) reflects an update
to the water chemistry and pump information on pages 3, 10, 38, 40-45,
55-56, 69-75, 78, and 80 along with the addition of the flue vs rain
shield image and caution on page 18.
Revision G (PCP # 3000021634 / CN # 500011858) reflects an update
to the piping diagrams on pages 40-43 and 71-74.
Revision H (PCP #3000024224 / CN #500014583) reflects an update to
the ratings chart on page 8 as well as all of the piping diagrams.
Revision J (PCP #3000028200 / CN #500017830) reflects an update to
the user interface display screens as well as updates to the ladder and
wiring diagrams.
Revision K (TLA #3000029494 / CN #500018868) reflects the addition of
the FasNSeal Notice on page 18.
Revision L (TLA #3000030320 / CN #500019614) reflects an update to
the text in Tables 3C and 9A.
Revision M (TLA #3000030852 / CN #500020656) reflects an update
to all of the piping diagrams, Table 10A, and the addition of the second
Notice on page 70.
Revision N (TLA #3000031557 / CN #500020650) reflects an update to
Figure 5-4.
Revision P (TLA #3000033465 / CN # 500022172) reflects edits made to
the CAT II increaser and Amp Draw table.
Revision R (TLA #3000034032 / CN #500022819) reflects an update to
the ratings table and Table 3A.
Revision T (TLA #3000034853 / CN #500023423) reflects the addition
of the Notice on page 17.
Revision U (TLA #300035559 / CN #500024192) reflects an update to
the Ratings Table.
Revision V (TLA #3000039487 / CN #500027540) reflects an update to
the water connections in the ratings table.
Revision W (TLA #3000041765 / CN #500029717) reflects an update to
FIG. 2-2 and Table 2B.
Revision X (TLA #3000041734 / CN #500029765) reflects an update
to the “Wiring of the Cascade” section, Figure 2-5, and the addition of
Figure 2-6.
Revision Y (TLA #3000044691 / CN #500032481) reflects a general
update to 2021 water heater standards.
Revision AA (PCP #3000047308 / CN #500035365) reflects the addition
of Cat I masonry chimney language to Venting on page 33.
Revision AB (PCP #3000053436 / CN #500040055) reflects an image
update on page 6.
Revision AC (PCP #3000054410 / CN #500041125) reflects an update
to the warnings on page 10.
Revision AD (PCP #3000055885 / CN #500042300) reflects an updated
ladder diagram on page 85.
Revision AE (PCP #3000057800 / CN #500043939) reflects an added
carbon monoxide warning on page 3.
Revision AF (PCP #3000060820 / CN #500046810) reflects the addition
of a dielectric notice on page 69.
Revision AG (PCP #3000065586 / CN #500051347) reflects venting
updates throughout and table 5A.
100280321_2000538685_Rev AG
04/25
