Lochinvar PBN2500, PBN3000, PBN3500, PBN4000, PBN5000 Installation Manual

100275648_2000534387_Rev H

Installation & Operation Manual

Models: 2500 - 5000

 WARNING:

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.

Save this manual for future reference.

Contents

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE POWER-FIN -- HOW IT WORKS ........................... 4-5

RATINGS ........................................................................... 6

1. DETERMINE BOILER LOCATION

Outdoor Boiler Installation ...................................................7

Clearances ......................................................................... 8

Provide Air Openings to Room .......................................... 8

Flooring and Foundation ................................................... 9

Vent and Air Piping ............................................................ 9

Prevent Combustion Air Contamination ............................. 9

Using an Existing Vent System to Install a New Boiler ..... 9

Corrosive Contaminants and Sources ............................. 10

Removing a Boiler from Existing Common Vent .............. 10

Remove Boiler from Wood Pallet ..................................... 11

Combustion and Ventilation Air Requirements ........... 11-13

Combustion Air Filter .........................................................13

2. GENERAL VENTING

Venting Options ................................................................ 14

Install Vent and Combustion Air Piping ........................... 15

Air Inlet Pipe Materials ................................................ 15

Vent and Air Piping .......................................................... 16

Air Intake / Vent Connections .......................................... 16

Min./Max. Combustion Air & Vent Piping Lengths ........... 17

Vent and Air Piping .......................................................... 18

Common Venting CAT II .................................................. 18

Outdoor Venting ................................................................19

3. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical ......................................... 20

Determine Location ..................................................... 20

Prepare Roof Penetrations ......................................... 20

Termination and Fittings ........................................ 20-21

Multiple Vent/Air Terminations .................................... 21

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 22-24

Determine Location ................................................ 22-24

Prepare Wall Penetrations .......................................... 23

Termination and Fittings ............................................. 23

Multiple Vent/Air Terminations ............................... 23-24

Room Air ..................................................................... 24

5. WATER CONNECTIONS

Inlet and Outlet Connections ............................................ 25

Heat Exchanger ............................................................... 25

Minimum Water Temperatures ......................................... 25

Water Flow Switch ........................................................... 26

Low Water Cutoff ............................................................. 26

Relief Valve ...................................................................... 26

Heating Boiler Installations .......................................... 26-34

6. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 35

Natural Gas ...................................................................... 35

Pipe Sizing for Natural Gas ........................................ 35

Natural Gas Supply Pressure Requirements ............. 35

Propane Gas .................................................................... 36

Pipe Sizing for Propane Gas ...................................... 36

Propane Supply Pressure Requirements ................... 36

Check Inlet Gas Supply ................................................... 36

Gas Pressure ................................................................... 37

Gas Valve Replacement .................................................. 37

7. FIELD WIRING

Boiler Operating Control Module .......................................38

Line Voltage Connections ................................................ 38

Low Voltage Connections ................................................ 39

Wiring of the Cascade ...................................................... 40

8. CONDENSATE DISPOSAL

Condensate Trap Installation ........................................... 42

9. START-UP .............................................................. 43-48

10. OPERATING INFORMATION

Set Hot Water Generator (HW) Operation ........................49

Configuration of the Cascade ..................................... 50

General .........................................................................51-53

Cascade ........................................................................... 54

Sequence of Operation .................................................... 55

Home Screen ................................................................... 56

11. MAINTENANCE

Maintenance & Annual Start-up ............................. 57-62

12. DIAGRAMS

Wiring Diagrams ................................................. 63-65

Ladder Diagrams ................................................. 66-68

Revision Notes .................................................. Back Cover

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.

Please read before proceeding

 WARNING

NOTICE

 WARNING

Installer – Read all instructions, including this manual and the Power-fin Service 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.

When calling or writing about the boiler – Please have the boiler model and serial 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.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

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.

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 10). Failure to comply could result in severe personal injury, death, or substantial property damage.

When servicing boiler –

Boiler operation –

Boiler water –

Freeze protection fluids –

Installation & Operation Manual

 WARNING

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

• 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.

• 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 build-up 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.

• 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.

The California Safe Drinking Water and Toxic Enforcement Act requires the 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.

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 headers and copper finned tubing are encased in a jacket that contains the combustion process.

2. Heat exchanger access cover (not shown)

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 / whirlwind (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 so gas should only be pulled through the valve when the blower is in operation.

5. Venturi / whirlwind

The venturi (models 2.5 - 3.0 only) and whirlwind (models

3.5 - 5.0 only) attaches to the inlet (or suction) side of the blower and generates the negative pressure needed by the gas valve.

6. Flue sensor

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.

7. Outlet temperature sensor (not shown)

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 (not shown)

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

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 metal fabric over stainless 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 4" ANSI flange connection that supplies water to the system with connections for a flow switch (see #28), a relief valve (see #25), and a temperature and pressure gauge (see #9).

13. Water inlet (system return)

The water inlet is a 4" ANSI flange connection that receives water from the system and delivers it to the heat exchanger.

14. Gas connection pipe

The gas connection pipe is a threaded black iron pipe connection (see Gas Connections Section for specific model pipe size requirements). This pipe should be connected to the incoming gas supply to deliver gas to the boiler.

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 contact points to the unit.

18. Low voltage connection boards

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.

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. Ignition electrode An electrical spark across the electrodes will ignite the burner.

22. Flame inspection window (sight glass) The flame inspection window is a quartz glass window that

allows a visual inspection of the burner and flame during operation.

23. Flame rod

The flame rod is used to verify the presence of a flame. If no flame is present, the gas valves will close, preventing gas to the main burners.

24. 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.

25. 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.

26. Power switch

The power switch is used to engage and disengage power to the appliance on the line voltage circuit.

27. Air pressure switch

This pressure switch monitors the pressure at the outlet of the blower to prevent over pressurization due to a blockage in either the heat exchanger or the vent.

28. 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.

29. Drain port(s)

Location from which the heat exchanger can be drained.

30. Manual shutoff valve (not shown)

Manual valve used to isolate the unit from the gas supply.

Installation & Operation Manual

The Power-fin - How it works... (continued)

Installation & Operation Manual

Front View

DIR #2000528576 00

DIR #2000528577 00

Rear View

415

Right Side (inside unit)

DIR #2000528590 00

DIR #2000528582 00

Left Side (inside unit)

Ratings

Installation & Operation Manual

Power-fin

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Min Max PBN2500 500 2500 2175 1870.5 PBN3000 600 3000 2610 2244.6 PBN3500 700 3500 3045 2618.7 PBN4000 800 4000 3480 2992.8 PBN5000 1000 5000 4350 3741.0

NOTICE

Maximum allowed working pressure is located on the rating plate.

Input MBH

(Notes 4 - 6)

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 Powerfin 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

2.0% 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 a xed to the unit.

De-rate values are based on proper combustion

calibration and

CO2’s adjusted to the recommended

levels.

Gross

Output

MBH

(Note 1)

Other Specifications

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Appliance

Water Content Gallons

8.4 4" 4" 2" 9" 9" 1,205

9.3 4" 4" 2" 9" 10" 1,262

10.2 4" 4" 2" 10" 10" 1,406

11.2 4" 4" 2 1/2" 10" 12" 1,441

13.0 4" 4" 2 1/2" 12" 14" 2,260

Pipe Size

Outlet

Pipe Size Inlet

Gas Inlet

Size

6. For Power- n boiler installations above 5,500 feet contact the factory.

7. Ratings have been con rmed by the Hydronics Section of AHRI.

HIGH ALTITUDE

DIR #2000530350 00

Air

Size

ONLY

Vent Size

(Note 3)

Weight

w/Water

(lbs.)

Figure A High Altitude Label Location

1 Determine boiler 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.

NOTICE

Before locating the boiler, 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.

 WARNING

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.

6. The appliance must be installed on a level floor, both front to back and side to side, for proper condensate drainage.

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.

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.

Installation & Operation Manual

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 10). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.

9. For outdoor models, you must install an optional vent kit. Instructions for installing the vent 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.

Outdoor boiler installation

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.

 WARNING

Do not install the appliance where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F (37.8°C).

Do not install the appliance where the relative humidity may exceed 93%. 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.

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.

1 Determine boiler location

Installation & Operation Manual

Provide clearances:

Clearances from combustible materials

- Hot water pipes ........................................................... 1/4"

- Sides .............................................................................. 0"

- Rear ............................................................................... 4"

- Front ............................................................................. 0"

- Top ................................................................................ 0"

- Floor ........................................................... Combustible

- Vent pipe - Follow special vent system manufacturer’s

instructions

Figure 1-1 Clearances

TOP

MIN

4" REAR

MIN FROM

PIPING

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.

 WARNING

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.

FRONT

MIN

NOTICE

RIGHT

SIDE

If you do not provide the recommended service clearances shown, it may not be

LEFT

SIDE

DIR #2000527453 00

possible to service the boiler without removing it from the space.

Recommended clearances for service access

- Sides .............................................................................. 0"

- Rear ............................................................................... 24"

- Front ............................................................................. 24"

- Top ................................................................................ 24"

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.

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).

Consult the Venting section of this manual for specific installation instructions for the appropriate type of venting system that you will be using.

1 Determine boiler location (continued)

Installation & Operation Manual

Flooring and foundation

Flooring

The Power-fin is approved for installation on combustible flooring, but must never be installed on carpeting.

 WARNING

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

 WARNING

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

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.

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. When room air is considered, see page 24 of this manual. 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.

When using an existing vent system to install a new boiler:

 WARNING

Check the following venting components before installing:

• Material - For materials listed for use with this appliance, see Section 2 - General Venting, Table 2A-1.

• Size - To ensure proper pipe size is in place, see Table 2C. 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 2A-1 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 Sections 2 through 4 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 10.

With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

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 10 for products and areas which may cause contaminated combustion air.

 WARNING

Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. 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.

1 Determine boiler location

Table 1A Corrosive Contaminants and Sources

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

Installation & Operation Manual

When removing a boiler from existing common vent system:

 DANGER

 WARNING

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.

Do not install the Power-fin into a common vent with any other appliance except as noted in Section 2 on page 18. 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.

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

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.

1 Determine boiler location (continued)

Remove boiler from wood pallet

1. To remove the boiler from the pallet: a. Remove the eight (8) shipping brackets securing the unit

to the right and left sides of the pallet (FIG. 1-2). 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.

NOTICE

Figure 1-2 Boiler Mounted on Shipping Pallet

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

Figure 1-3_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 cm2 per kW) (see FIG. 1-3).

Installation & Operation Manual

DIR #2000528613 00

BRACKETS (4X) ON BOTH

DIR #2000530041 00

THE LEFT AND RIGHT SIDES OF THE UNIT

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 1-4_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 cm2 per kW) of input (see FIG. 1-4).

DIR #2000528615 00

DIR #2000528618 00

Figure 1-5_Combustion Air from Interior Space

1 Determine boiler location

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 not less than 100 square inches (645 cm (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

per kW).

Figure 1-6_Combustion Air from Outside - Single Opening

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 cm2 per kW). This opening must be located within 12” (30 cm) of the top of the enclosure (see FIG. 1-6).

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.

All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers.

Where two openings are provided, one must be within 12" (30 cm) of the ceiling and one must be within 12" (30 cm) of the floor of the 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).

per kW) of input, but

) (see FIG. 1-5).

DIR #2000528624 00

Installation & Operation Manual

 CAUTION

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, perchloroethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the heat exchanger, headers, flue collectors, and the vent system.

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 corrected immediately.

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.

1 Determine boiler location (continued)

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

FIG. 1-3 FIG. 1-4 FIG. 1-5 FIG. 1-6

Model

Number

2500

3000

3500

4000

5000

*Outside Air from

2 Openings Directly from

Bottom

Opening, in

(cm2)

625

(4033)

750

(4839)

875

(5646)

1000

(6450)

1250

(8062)

Outdoors

Top

Opening, in

(cm2)

625

(4033)

750

(4839)

875

(5646)

1000

(6450)

1250

(8062)

*Outside Air from

2 Ducts Delivered from

Bottom

Opening, in

(cm2)

1250

(8065)

1500

(9678)

1750

(11291)

2000

(12900)

2500

(16129)

Outdoors

Top

Opening, in

(cm2)

1250

(8065)

1500

(9678)

1750

(11291)

2000

(12900)

2500

(16129)

2 Ducts Delivered from Interior Space

Opening, in

(16129)

(19355)

(22581)

(25800)

(32250)

Installation & Operation Manual

Same Story

Top

(cm2)

2500

3000

3500

4000

5000

Inside Air from

Bottom

Opening, in

(cm2)

2500

(16129)

3000

(19355)

3500

(22581)

4000

(25800)

5000

(32250)

Different

Opening, in

Stories

Total

(cm2)

5000

(32258)

6000

(38710)

7000

(45162)

8000

(51600)

10000

(64500)

*Outside Air from 1 Opening Directly from Outdoors, in

(cm2)

833

(5381)

1000

(6452)

1167

(7530)

1333

(8600)

1667

(10750)

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.

Outside air openings shall directly communicate with the outdoors.

Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.

”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.

Follow the steps below when replacing the combustion air filter:

AIR FILTERS

LIFT AND SLIDE OUT BOTH FILTER COVER PLATES TO GAIN ACCESS TO THE AIR FILTERS

1. Locate the combustion air filter box mounted on the rear of the appliance.

2. Remove four (4) #10 hex head fasteners from the filter cover plates (see FIG. 1-8).

3. Lift and slide out both filter cover plates to gain access to the air filters.

DIR #2000529297 00

Figure 1-8_Filter Access

4. Slide each air filter out the back slot openings of the air filter box.

5. Inspect the air filters for dirt and debris, replace

Combustion air filter

This unit has two (2) standard air filters located at the combustion air inlet as shown above in FIG. 1-8. These air filters are provided to help ensure clean air is used for the combustion process. Check filters every month and replace when necessary. The filter size for Models 2.5 - 3.5 is 20” x 14” x 1” (50.8 cm x

35.5 cm x 2.5 cm) and for Models 4.0 - 5.0 it is 25” x 16” x 1” (63.5 cm x 40.6 cm x 2.5 cm). You can find these commercially available filters at any home center or HVAC supply store.

NOTICE

if necessary.

6. Replace the air filters and the filter box cover plates. Replace the four (4) #10 hex head fasteners to secure the filter cover plates to the air filter box.

During construction the air filter should be checked more frequently to ensure it does not become clogged with combustion dirt and debris.

Sustained operation of an appliance with

NOTICE

Replace filters with a MERV rating no greater than 4.0.

CAUTION

a clogged burner may result in nuisance operational problems, bad combustion, and non-warrantable component failures.

2 General venting

000533996

Installation & Operation Manual

Direct venting

12"

Sidewall

DIR #2000527722 00

Vertical Vent, Sidewall Air

Optional room air

DIR #2000527724 00

DIR #2000527727 00

Vertical

Outdoor venting

DIR #2000533996 00DIR #2

Sidewall

DIR #2000527728 00

DIR #2000527723 00

Vertical

2 General venting (continued)

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

The Power-fin must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

ABS, PVC, or CPVC 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. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.

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. The ABS, PVC, CPVC, 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.

*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

NOTICE

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.

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.

2 General venting

Installation & Operation Manual

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.

Vent and air piping

The Power-fin is certified as a Category II/IV boiler. This product has been approved for use with stainless steel vent systems. All venting systems used with a Power-fin boiler

must be suitable for Category IV operation except for factory approved common vent systems operating as allowed in the Common Venting Section on page 18.

 WARNING

NOTICE

Use only the materials, vent systems, and terminations listed in Tables 2A-1 and 2A-2. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 2-1) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided with the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

2. Vent Connector - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 2-1 Combustion Air Adapter

COMBUSTION

AIR INTAKE

CONNECTOR

DIR #2000529298 00

The Power-fin uses model specific combustion air intake and vent piping sizes as detailed in Tables 2B and 2C on page 17.

NOTICE

Table 2A-1 Approved Stainless Steel Vent Manufacturers

The Power-fin is 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

Increasing or decreasing combustion air or vent piping to sizes not specified in this manual is not authorized.

Approved Stainless Steel Vent Manufacturers

Make Model

ProTech Systems (Dura-Vent Co.) FasNSeal Vent Z-Flex (Nova Flex Group) Z-Vent Heat Fab (Selkirk Corporation) Saf-T Vent Metal Fab Corr/Guard Securities Chimneys International Secure Seal SS Schebler Chimney Systems eVent

Installation & Operation Manual

2 General venting (continued)

Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV

Model

2500

3000 - 3500

4000 5000

Model

2500

3000 - 3500

4000

5000

Model

ProTech Z Flex Heat Fab

Adapter Intake Adapter Intake Adapter Flue Intake

810003982

810003984

810003987

810003990

810003397 810003409

810003435 810003447

810003476 810003488

810003516 810003528

2SVDSA09 2SVEE990 9901MAD CCK09TM

2SVDSA10 2SVEE1090 91001MAD CCK10TM

2SVDSA12 2SVEE1290 91201MAD CCK12TM

2SVDSA14 2SVEE1490 91401MAD CCK14TM

9890 9992

91090 91092

91290 91292

91490 91492

Metal-Fab Security Chimney ICC

Adapter Flue Intake Adapter Flue Intake Adapter Flue Intake

SSE9E9OU

SDOST90AUK

4" - 10"

SSE10E9OU

SDOST90AUK

4" - 10"

SSE12E9OU HE-12DSA-F

SSE14E9OU HE-14DSA-F

HE-9DSA-F

HE-10DSA-F

HE-9SCR-F

HE-9MC-F

HE-10SCR-F

HE-10MC-F

HE-12SCR-F

HE-12MC-F

HE-14SCR-F

HE-14MC-F

HE-8E90-F

HE-9SCR-F

HE-10E90-F

HE-10SCR-F

HE-12E90-F

HE-12SCR-F

HE-14E90-F

HE-14SCR-F

8FCGLCA

10FCGLCA

12FCGLCA

14FCGLCA

6-36"

8FCGSW90 SS9CRESTU

10FCGSW90 SS10CRESTU

12FCGSW90 SS12CRESTU

14FCGSW90 SS14CRESTU

SS0MCU

4" - 24"

SS0MCU

4" - 24"

SS0MCU

4" - 24"

SS0MCU

4" - 24"

Jeremias

Adapter Flue Intake

2500

3000 - 3500

4000 5000

SWKL9-KLC SWKL9-WRC SWKL9-90ET SWKL10-KLC SWKL10-WRC SWKL10-90ET SWKL12-KLC SWKL12-WRC SWKL12-90ET SWKL14-KLC SWKL14-WRC SWKL14-90ET

Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths

AIR INLET VENT

Model

2500 9" 12' 100' 9" 18' 100' 2.5% 3000 9" 12' 100' 10" 18' 100' 2.5% 3500 10" 12' 100' 10" 18' 100' 2.5% 4000 10" 12' 100' 12" 18' 100' 2.5% 5000 12" 12' 100' 14" 18' 100' 2.5%

Air Intake

Diameter

Air Intake

Min. Length

Air Intake

Max. Length

Vent

Diameter

Vent

Min. Length

(CAT IV only)

Vent

Max. Length

(CAT IV only)

De-Rate per

25 feet of Vent

Table 2C Room Air Minimum / Maximum Allowable Air / Vent Lengths

Model

2500 9" 18' 100' 1% 3000 9" 18' 100' 1% 3500 10" 18' 100' 1% 4000 12" 18' 100' 0% 5000 14" 18' 100' 0%

Vent

Diameter

Vent

Min. Length

(CAT IV only)

Vent

Max. Length

(CAT IV only)

Input De-Rate per

25 feet of Vent

Input

2 General venting

When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.

EXAMPLE: 20 feet (6 m) of pipe + (4) 90° elbows + (3) 45° elbows = 49 equivalent feet (15 m) of piping.

Removing from existing vent

Follow the instructions in Section 1, page 10 of this manual when removing a boiler from an existing vent system.

Installation & Operation Manual

 WARNING

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping. If contaminants are found, you MUST:

• Remove products permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

Common venting CAT II:

Vent and air piping

Vent and air system:

NOTICE

You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion).

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.

 WARNING

Vent, air piping and termination:

The Power-fin vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

 WARNING

Installation must comply with local requirements and with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only approved stainless steel pipe and fittings.

If the boiler combustion air inlet is located

in a laundry room or pool facility, for

example, these areas will always contain

hazardous contaminants.

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 2D Category IV to Category II Conversion Chart

Model

2500 9" 10" 3000 10" 12" 3500 10" 12" 4000 12" 14" 5000 14" 16"

Category IV

Standard Vent Size

Category II

Increaser Size

2 General 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 2E).

• 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 2F must be used.

Table 2E Outdoor Vent Kits

Model Outdoor Kit

2500 - 3000 100274941

3500 100274942 4000 100274943 5000 100274944

NOTICE

Before installing a venting system, follow all requirements found in the General Venting section of this manual.

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.

 WARNING

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.

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.

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 pressuretreated wood platform.

Table 2F_Approved Adapters and Flue Terminations

Model

2500

3000 - 3500

4000 5000

ProTech Z-Flex Heat Fab Metal Fab Security Chimney

Adapter Flue Adapter Flue Adapter Flue Adapter Flue Adapter Flue

810003982 FSCN0907 2SVDSA09 2SVSXITC09 9901MAD CCA09EX07 8FCGLCA 9FCSEC-C60 SS9CRESTU SS9ECU 810003984 FSCN1008 2SVDSA10 2SVSXITC10 91001MAD CCA10EX08 10FCGLCA 10FCSEC-C60 SS9CRESTU SS10ECU 810003987 FSCN1210 2SVDSA12 2SVSXITC12 91201MAD CCA12EX10 12FCGLCA 12FCSEC-C60 SS12CRESTU SS12ECU 810003990 FSCN1412 2SVDSA14 2SVSXITC14 91401MAD CCA14EX12 14FCGLCA 14FCSEC-C60 SS14CRESTU SS14ECU

3 Vertical direct venting

Vent/air termination – vertical

Installation & Operation Manual

 WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

 WARNING

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe except as noted in Section 2 on page 18. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 - latest edition for U.S. installations or CSA B149.1 Installation Code for Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 17 of this manual.

2. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

3. The air piping must terminate in a down-turned 180° return pipe no further than 2 feet (.6 m) from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an up-turned coupling as shown in FIG. 3-1. The top of the coupling or the rain cap must be at least 36" (914 mm) above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 36" (914 mm) above the air intake.

 WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting - Vertical Vent, Sidewall Air Section.

Figure 3-2 Vertical Termination of Air and Vent w/Rain Cap

BIRD SCREEN [TYPICAL]

VENT OUTLET 36" [914 MM] MINIMUM

BOVE AIR INLET

12" [305 MM] MINIMUM ABOVE ROOF / SNOW LINE

5. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to build-up of leaves or sediment.

Prepare roof penetrations

1. Air pipe penetration:

a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

2. Vent pipe penetration:

a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole per the vent manufacturer’s instructions. b. Insert a galvanized metal thimble in the vent pipe hole (when required by local codes).

3. Space the air and vent holes to provide the minimum spacing shown in FIG. 3-1.

4. Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent pipe and air pipe.

Termination and fittings

Figure 3-1 Vertical Termination of Air and Vent

1. Prepare the vent termination coupling and the air

termination elbow (FIG. 3-1) by inserting bird screens.

BIRD SCREEN [TYPICAL]

2. The air piping must terminate in a down-turned 180° return bend as shown in FIG. 3-1. Locate the air inlet pipe no further than 2 feet (.6 m) from the center of the

VENT OUTLET

36" MINIMUM

BOVE AIR INLET

VENT

COMBUSTION AIR

12" [305 MM] MINIMUM ABOVE ROOF / SNOW LINE

vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

3 Vertical direct venting (continued)

Installation & Operation Manual

3. The vent piping must terminate in an up-turned coupling as shown in FIG. 3-1. The top of the coupling or the rain cap must be at least 36" (914 mm) above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 36" (914 mm) above the air intake.

4. Maintain the required dimensions of the finished termination piping as shown in FIG. 3-1.

5. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

Multiple vent/air terminations

1. When terminating multiple Power-fin boilers, terminate

each vent/air connection as described in this manual (FIG. 3-3).

 WARNING

Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of flue products and the possibility of severe personal injury, death, or substantial property damage.

Figure 3-4 Alternate Vertical Terminations with Multiple Boilers

12” (305 MM)

DIR# 2000539526

2. Place roof penetrations to obtain minimum clearance of 12 inches (305 mm) between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 3-3). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Power-fin boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 3-3 Vertical Terminations with Multiple Boilers

12” (305 MM)

DIR# 2000539525

4 Sidewall direct venting

Vent/air termination – sidewall

Installation & Operation Manual

 WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

 WARNING

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

 CAUTION

Sidewall venting commercial products will result in large exhaust plumes in cold climates. Consideration should be taken when locating in proximity to windows, doors, walkways, etc.

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 17 of this manual.

2. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice build-up where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

 WARNING

Sidewall vent and air inlet terminations must terminate in the same pressure zone.

f. Do not terminate above any door or above or below any window. Condensate can freeze, causing ice formations. g. Locate or guard vent to prevent condensate damage to exterior finishes.

Figure 4-1 Sidewall Termination of Air and Vent

NOTICE

PVC/CPVC or ABS is acceptable air inlet pipe material.

FROM BOILER VENT PIPE CONNECTION

TO BOILER INTAKE AIR CONNECTION

36" MIN

12" MIN

GRADE OR SNOW LINE

3. Maintain clearances as shown in FIG.’s 4-1 thru 4-3, pages 22 and 23. The vent termination should not be located in traffic areas such as walkways, adjacent buildings, operable windows, or doors. Also maintain the following:

a. Vent must terminate:

• At least 6 feet (1.8 m) from adjacent walls.

• Not less than 7 feet (2.1 m) above grade where located

adjacent to public walkways.

• No closer than 12 inches (305 mm) below roof overhang.

• At least 3 feet (.9 m) above any forced air intake within 10 feet (3 m).

• No closer than 4 feet (1.2 m) horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches (305 m) above grade or snow line; at least 36 inches (914 mm) below the vent termination. c. Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) horizontally.

4. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to build-up of leaves or sediment.

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