Lochinvar PFN0502-M9, PFN0752-M9, PFN1002-M9, PFN1302-M9, PFN1501-M9 Installation Manual

...

100280321_2000538685_Rev L

Installation & Operation Manual

Models: 502, 752, 1002, 1302,

1501, 1701, and 2001

Up To 5:1 Turndown

Beginning with

Serial #1707104971206

 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 ..................... 3-4

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

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

Installation & Operation Manual

 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 13). Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

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.

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.

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.

Please read before proceeding

Installation & Operation Manual

 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 gasfired 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.

Installation & Operation Manual

The Power-fin - How it works...

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.

Installation & Operation Manual

Models 502 - 1302 Front View

DIR #2000537294 00

DIR #2000537298 00

Models 502 - 1302 Rear View

DIR #2000537314 00

Models 502 - 1302 Right Side (inside unit) - M9

DIR #2000537322 00

Models 502 - 1302 Left Side (inside unit) - F9

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

Installation & Operation Manual

Models 1501 - 2001 Front View

DIR #2000538550 00

DIR #2000538552 00

Models 1501 - 2001 Rear View

DIR #2000538553 00

Models 1501 - 2001 Right Side (inside unit)

DIR #2000538558 00

Models 1501 - 2001 Left Side (inside unit)

Ratings

Installation & Operation Manual

Power-Fin

Water Heater Ratings

Model Number

Note: Change “N” to

“L” for L.P. gas models

PFN0502-M9 100 500 515

PFN0752-M9 150 750 773

PFN1002-M9 200 1000 1030

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 1000 1030

PFN1302-F9 N/A 1300 1339

PFN1501-F9 N/A 1500 1545

PFN1701-F9 N/A 1700 1752

PFN2001-F9 N/A 2000 2061

Min Max

Input MBH

(Note 4)

GPH

at 100°F

Rise

HLW

LOW LEAD CONTENT

Other Specifications

Appliance

Water Content Gallons

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"

Water

Connections

Gas

Connections

Air / Vent

Sizes

(Note 3)

Power-Fin

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models

PBN0502-M9 100 500 425 370

PBN0752-M9 150 750 637 554

PBN1002-M9 200 1000 850 739

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 750 637 554

PBN1002-F9 N/A 1000 850 739

PBN1302-F9 N/A 1300 1105 961

PBN1501-B9 900 1500 1260 1096

PBN1701-B9 1020 1700 1428 1242

PBN2001-B9 1200 2000 1680 1461

Min Max

Input MBH

(Note 4)

Gross

Output

MBH

(Note 1)

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Other Specifications

Appliance

Water Content Gallons

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 2.0" 1 1/4" 5" - 7"

4.0 2.0" 1 1/4" 5" - 9"

4.3 2.0" 1 1/4" 6" - 10"

4.8 2.0" 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"

Water

Connections

Gas

Connections

Air / Vent

Sizes

(Note 3)

Ratings (continued)

Installation & Operation Manual

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

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 a xed to the unit.

NOTICE

Maximum allowed working pressure is located on the rating plate.

De-rate values are based on proper combustion calibration and CO2’s adjusted to the recommended levels.

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

ONLY

DIR #2000530350 00

Figure A High Altitude Label Location

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.

NOTICE

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.

 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 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.

Outdoor 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 unit location (continued)

Installation & Operation Manual

Provide clearances:

Clearances from combustible materials

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

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

- Rear ............................................................................... 0"

- 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 unit location

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. 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.

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 - Venting.

• 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 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.

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 13 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 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.

1 Determine unit location (continued)

Installation & Operation Manual

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

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

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.

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.

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.

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 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.

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.

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

Installation & Operation Manual

DIR #2000528613 00

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 cm2 per kW) (see FIG. 1-2).

DIR #2000528615 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 cm2 per kW) of input (see FIG. 1-3).

DIR #2000528618 00

Figure 1-4_Combustion Air from Interior Space

1 Determine unit location (continued)

Installation & Operation Manual

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 cm2) (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 cm2 per kW).

Figure 1-5_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. 1-5).

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

DIR #2000528624 00

 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, perchlorethylene, 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 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.

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.

Installation & Operation Manual

1 Determine unit location

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

*Outside Air from

Model

Number

502

752

1002

1302

1501

1701

2001

2 Openings Directly from

Outdoors

Top

Opening, in

125

(807 cm2)

188

(1213 cm2)

250

(1613 cm2)

325

(2097 cm2)

375

(2420 cm2)

425

(2742 cm2)

500

(3226 cm2)

Bottom

Opening, in

(807 cm2)

(1213 cm2)

(1613 cm2)

(2097 cm2)

(2420 cm2)

(2742 cm2)

(3226 cm2)

125

188

250

325

375

425

500

*Outside Air from 1 Opening Directly from Outdoors, in

167

(1077 cm2)

250

(1613 cm2)

333

(2149 cm2)

433

(2794 cm2)

500

(3226 cm2)

567

(3658 cm2)

667

(4303 cm2)

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.

Inside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

Bottom

250

(1613 cm2)

375

(2420 cm2)

500

(3226 cm2)

650

(4194 cm2)

750

(4839 cm2)

850

(5484 cm2)

1000

(6452 cm2)

250

375

500

650

750

850

1000

Inside Air from

2 Ducts Delivered from

Interior Space

Top

Opening, in

500

(3226 cm2)

750

(4839 cm2)

1000

(6452 cm2)

1300

(8388 cm2)

1500

(9678 cm2)

1700

(10968 cm2)

2000

(12904 cm2)

Opening, in

(3226 cm2)

(4839 cm2)

(6452 cm2)

(8388 cm2)

(9678 cm2)

(10968 cm2)

(12904 cm2)

Bottom

500

750

1000

1300

1500

1700

2000

Figure 1-7_Filter Access

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:

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.

NOTICE

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

CAUTION

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

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

Venting options:

B C

E F

NOTICE

Category II venting is required when common venting multiple M9 models .

CAT II requires vent increaser kit.

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(*)

 DANGER

Failure to use correct venting materials can result in loss of life from flue gas spillage into working or living space.

Venting options:

G H I

*CAT I “B9” models require field supplied barometric dampers.

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.

2 Venting

Vent Materials:

Installation & Operation Manual

NOTICE

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.

Category II/IV Vent Material Suppliers:

Category II/IV flue pipe materials and vent adapters (see FIG. 2-1A) can be obtained from the following manufacturers:

Heat-Fab Inc., Saf-T CI Vent with AL29-4C stainless steel Protech Systems Inc., Fas N Seal Vent with AL29-4C stainless

steel Flex-L International Inc., StaR 34 Vent with AL29-4C stainless

steel

Metal-Fab Inc., Corr/Guard Vent with AL29-4C stainless steel Z-Flex, Z-Vent with AL29-4C stainless steel

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.

Figure 2-1A_Category IV Vent Adapter

Increaser

FLUE CONNECTION

RAIN SHIELD

DIR #2000553146

Connector

Figure 2-1B_Flue vs. Rain Shield Connection

CAUTION

DO NOT attach vent pipe to rain shield. Vent pipe should be connected directly to

Figure 2-2_Category IV to II Conversion Kit

the flue pipe (see FIG. 2-1B).

TABLE - 2A

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"

CATEGORY IV TO CATEGORY II

MODEL FLUE SIZE KIT NUMBER

PB/FN0502-M9 4" to 7" 100157750 PB/FN0752-M9 5" to 9" 100157751 PB/FN1002-M9 6" to 10" 100157752 PB/FN1302-M9 8" to 12" 100157753 PB/FN1501-M9 6" to 8" 100157736 PB/FN1701-M9 7" to 9" 100157737 PB/FN2001-M9 8" to 10" 100157738

TABLE - 2B

CONVERSION KITS

*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.

Category I Vent Material Suppliers:

Category I venting materials are readily available from your local plumbing/HVAC supply houses.

Installation & Operation Manual

000533996

2 Venting (continued)

Condensing Vent Options: CAT II & IV (CAT II vent options A, B, & C requires an adapter kit - see page 18)

CAT II/

CAT II requires an adapter kit.

See page 18.

CAT II/

Vertical vent with combustion air from equipment room - see page 20.

Vertical Direct Vent installation with rooftop combustion air inlet - see page 20.

Sidewall termination with combustion air from equipment room - see page 21.

CAT IV

Horizontal Direct Vent installation with sidewall combustion air inlet - see page 22.

CAT IV

CAT II requires an adapter kit.

See page 18.

CAT II/

CAT II requires an adapter kit.

See page 18.

Vertical DirectAire installation with sidewall combustion air inlet - see page 21.

Horizontal DirectAire installation with vertical combustion air inlet - see page 22.

CAT IV

OUTDOOR

VENTING

see page 23

DIR #2000533996 00DIR #2

Installation & Operation Manual

2 Venting

Condensing vent options: CAT II & IV (CAT II vent options A, B, & C requires an adapter kit - see page 18)

Vertical vent with combustion air from equipment room - see page 19.

CAT II/IV

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.

CAT II requires an adapter kit.

See page 18.

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).

TABLE - 2C

VENT TERMINATION SIZES

MODEL

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"

CAT II

VENT SIZE

CAT IV

VENT SIZE

MODEL

-- -- --

CAT II

VENT SIZE

CAT IV

VENT SIZE

Vertical direct vent installation with rooftop combustion air inlet - see

CAT II/IV

CAT II requires an adapter kit.

See page 18.

MODEL

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"

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 optional Direct Vent system requires the installation of specific venting materials that are purchased locally.

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 - 2D

AIR & VENT TERMINATION SIZES

CAT II CAT IV

AIR

SIZE

VENT

SIZE

AIR

SIZE

VENT

SIZE

MODEL

-- -- -- -- --

CAT II CAT IV

AIR

SIZE

VENT

SIZE

AIR

SIZE

VENT

SIZE

Installation & Operation Manual

2 Venting (continued)

Condensing vent options: CAT II & IV (CAT II vent options A, B, & C requires an adapter kit - see page 18)

DirectAire Vertical installation with sidewall combustion air inlet - see

CAT II/IV

CAT II requires an adapter kit.

See page 18.

Air Inlet Cap

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 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 - 2E

AIR INLET CAP TERMINATIONS

MODEL

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

CAT II CAT IV

AIR

SIZE

VENT

SIZE

AIR

SIZE

VENT

SIZE

CAT IV

KIT

NUMBER

MODEL

-- -- -- -- -- --

CAT II CAT IV

AIR

SIZE

VENT

SIZE

AIR

SIZE

VENT

SIZE

CAT

IV KIT

NUMBER

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

CAT IV

Vent Cap

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 2F. 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 - 2F

FLUE VENT TERMINATION SIZES

MODEL

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

CAT IV

VENT SIZE

CAT IV

KIT

MODEL

CAT IV

VENT SIZE

CAT IV

KIT

MODEL

CAT IV

VENT SIZE

-- --

CAT IV

KIT

2 Venting

Condensing vent options: CAT IV

Horizontal direct vent installation with sidewall combustion air inlet - see page 19.

CAT IV

Air Inlet Cap

Vent Cap

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.

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.

SIDEWALL AIR AND VENT TERMINATION SIZES

CAT IV

MODEL

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

AIR

SIZE

VENT

SIZE

CAT IV

KIT

MODEL

TABLE - 2G

CAT IV

AIR

VENT

SIZE

Installation & Operation Manual

CAT IV

KIT

MODEL

-- -- -- --

CAT IV

AIR

SIZE

VENT

SIZE

CAT IV

KIT

CAT IV

Vent Cap

MODEL

PB/FN0502-M9 PB/FN0752-M9 PB/FN1002-M9 PB/FN1302-M9

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 2H. 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.

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 - 2H

CAT IV

AIR

SIZE

VENT

SIZE

CAT IV

KIT

MODEL

-- -- --

AIR

SIZE

CAT IV

VENT

SIZE

CAT IV

KIT

CAT IV

AIR

SIZE

5" 5" 6"

SIDEWALL VENT TERMINATION SIZES

VENT

SIZE

CAT IV

KIT

4" 100169247 PB/FN0502-F9 5" 4" 100169234 PB/FN1501-M9 6" 6" 100169201 5" 100169248 PB/FN0752-F9 5" 5" 100169235 PB/FN1701-M9 7" 7" 100169202 6" 100169201 PB/FN1002-F9 6" 6" 100169236 PB/FN2001-M9 8" 8" 100169246

8" 100169246 PB/FN1302-F9 6" 8" 100169237

MODEL

2 Venting (continued)

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 2J must be used.

Installation & Operation 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

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.

Table 2I Outdoor Vent Kits

Model Outdoor Kit No. Description

502 - 1302 100280318 M/B Series

1501 - 2001 100280319 M Series

1501 - 2001 100280320 B Series

NOTICE

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

Table 2J_Approved Outdoor Terminations

Model

PB/PF 502

PB/PF 752

PB/PF 1002

PB/PF 1302

PB/PF 1501

PB/PF 1701

PB/PF 2001

Diameter Heat Fab Z-Flex Metal-Fab

4 CCA04RC/5400CI 2SVSRCF04 4CGSWC

5 CCA05RC/5500CI 2SVSRC05 5CGSWC

6 CCA06RC/5600CI 2SVSRC06 6FCSSWCB

8 CCA08RC/5800CI 2SVSRC08 8FCSSWCB

6 CCA06RC/5600CI 2SVSRC06 6FCSSWCB

7 CCA07RC/5700CI 2SVSRC07 7FCSSWCB

8 CCA08RC/5800CI 2SVSRC08 8FCSSWCB

Category IV (AL29-4C)

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.

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.

Model

PB/PF 502

PB/PF 752

PB/PF 1002

PB/PF 1302

PB/PF 1501

PB/PF 1701

PB/PF 2001

*Requires increaser for diameter of termination.

Note:  e terminations listed above can be used on indoor installations, but are required on all outdoor installations.

Diameter Heat Fab Z-Flex Metal-Fab

7 CCA07RC/5700CI 2SVDRC07 7MC

9 CCA09RC/5900CI 2SVDRC09 10MC*

10 CCA10RC/51000CI 2SVDRC10 10MC

12 CCA12RC/51200CI 2SVDRC12 12MC

14 CCA14RC/51400CI 2SVDRC14 14MC

Category I

2 Venting

Non-Condensing Vent Options: CAT I

A required field supplied barometric damper MUST BE installed in location shown.

Installation & Operation Manual

INCORRECT

INSTALLATIONS

CAT I - B9

Vertical negative draft venting system - see pages 25 and 26.

12"

A required field supplied barometric damper MUST BE installed in location shown.

DirectAire vertical venting with vertical air inlet

- see pages 25 and 26.

CAT I - F9

Vertical negative draft venting system see page 25.

CAT I - F9CAT I - B9

DirectAire vertical venting with vertical air inlet - see page 25.

A required field supplied barometric damper MUST BE installed in location shown.

CAT I - B9

DirectAire vertical venting with sidewall inlet see pages 25 and 26.

CAT I - F9

DirectAire vertical venting with sidewall inlet - see page 25.

2 Venting (continued)

Non-Condensing vent options: CAT I

Vertical negative draft venting system - see page 24.

CAT I

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).

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"

Installation & Operation Manual

TABLE - 2K

-- --

CAT I

Air Inlet Cap

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 - 2L

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 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).

TABLE - 2M

AIR INLET CAP

MODEL

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

AIR

SIZES

VENT

SIZES

KIT

NUMBER

MODEL

AIR

SIZES

VENT

SIZES

-- --

KIT

NUMBER

Installation & Operation Manual

2 Venting

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

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.

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.

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.

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.

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