Table of Contents
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100275648_2000534387_Rev D
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.
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Table of Contents
Related Manuals for Lochinvar POWER-FIN PBN2500
Summary of Contents for Lochinvar POWER-FIN PBN2500
- Page 1 100275648_2000534387_Rev D 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.
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Page 2: Table Of Contents
Contents 5. WATER CONNECTIONS HAZARD DEFINITIONS ............ 2 Inlet and Outlet Connections ..........25 PLEASE READ BEFORE PROCEEDING ......3 THE POWER-FIN -- HOW IT WORKS ......4-5 Heat Exchanger ............... 25 RATINGS ................6 Minimum Water Temperatures ......... 25 1. -
Page 3: Please Read Before Proceeding
Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including The California Safe Drinking Water and WARNING WARNING this manual and the Power-fin Service Toxic Enforcement Act requires the Manual, before installing. Perform steps Governor of California to publish a list of in the order given. -
Page 4: The Power-Fin - How It Works
Installation & Operation Manual The Power-fin - How it works... 15. SMART TOUCH Control Module Heat exchanger The SMART TOUCH Control Module is the main control for the The heat exchanger allows system water to flow through specially appliance. This module contains the programming that operates designed tubes maximum... - Page 5 Installation & Operation Manual The Power-fin - How it works... (continued) DIR #2000528577 00 DIR #2000528576 00 Rear View Front View DIR #2000528590 00 DIR #2000528582 00 Left Side (inside unit) Right Side (inside unit)
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Page 6: Ratings
Installation & Operation Manual Ratings Power-fin Other Specifications AHRI Rating Vent Weight AHRI Model Number Input Gross Appliance Size w/Water Pipe Pipe Ratings Output Water Gas Inlet (lbs.) Size Size Size Water, Content Size Note: Change “N” to Outlet Inlet (Notes 4 - 6) Gallons “L”... -
Page 7: Determine Boiler Location
Installation & Operation Manual Determine boiler location Installation must comply with: If the optional neutralizing kit is to be used, elevate the boiler at least 3” above the floor. • Local, state, provincial, and national codes, laws, regulations, and ordinances. 8. -
Page 8: Clearances
Installation & Operation Manual Determine boiler location Provide air openings to room: Provide clearances: Clearances from combustible materials The Power-fin alone in boiler room - Hot water pipes ............1/4" - Sides ................0" 1. No air ventilation openings into the boiler room are - Rear ................ -
Page 9: Flooring And Foundation
Installation & Operation Manual Determine boiler location (continued) Flooring and foundation When using an existing vent system to install a new boiler: Flooring The Power-fin is approved for installation on combustible Failure to follow all instructions can result WARNING flooring, but must never be installed on carpeting. in flue gas spillage and carbon monoxide emissions, causing severe personal injury Do not install the boiler on carpeting even if... -
Page 10: Corrosive Contaminants And Sources
Installation & Operation Manual Determine boiler location When removing a boiler from existing Table 1A Corrosive Contaminants and Sources common vent system: Products to avoid: Do not install the Power-fin into a common DANGER vent with any other appliance except as Spray cans containing chloro/fluorocarbons noted in Section 2 on page 18. -
Page 11: Remove Boiler From Wood Pallet
Installation & Operation Manual Determine boiler location (continued) Remove boiler from wood pallet To remove the boiler from the pallet: Remove the eight (8) shipping brackets securing the unit to the right and left sides of the pallet (FIG. 1-2). b. - Page 12 Installation & Operation Manual Determine boiler location If air is taken from another interior space combined with Under no circumstances should the CAUTION equipment room ever be under negative the equipment room: (a) Two spaces on same story: Each of the two openings pressure.
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Page 13: Combustion Air Filter
Installation & Operation Manual 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 Inside Air from *Outside Air from *Outside Air from 2 Ducts Delivered from Interior Space *Outside Air from 2 Openings Directly from 2 Ducts Delivered from... -
Page 14: General Venting
Installation & Operation Manual General venting Direct venting 12" DIR #2000527722 00 DIR #2000527724 00 DIR #2000527727 00 Vertical Vent, Sidewall Air Vertical Sidewall Optional room air Outdoor venting DIR #2000533996 00 DIR #2000527728 00 DIR #2000527723 00 Sidewall Vertical... -
Page 15: Install Vent And Combustion Air Piping
Installation & Operation Manual General venting (continued) Install vent and combustion air piping The Power-fin must be vented and Sealing of Type “B” double-wall vent material or galvanized DANGER supplied with combustion and ventilation vent pipe material used for air inlet piping on a sidewall or air as described in this section. -
Page 16: Vent And Air Piping
Installation & Operation Manual General venting Air intake/vent connections When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe Combustion Air Intake Connector (FIG. 2-1) - Used to must be resealed to ensure that combustion air will be free of provide combustion air directly to the unit from outdoors. -
Page 17: Min./Max. Combustion Air & Vent Piping Lengths
Installation & Operation Manual General venting (continued) Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV ProTech Z Flex Heat Fab Model Adapter Intake Adapter Intake Adapter Flue Intake 810003397 9890 2500 810003982 2SVDSA09 2SVEE990 9901MAD CCK09TM 810003409 9992 810003435 91090... -
Page 18: Removing From Existing Vent
Installation & Operation Manual General venting To prevent the potential of severe personal When determining equivalent combustion air and vent length, WARNING injury or death, check for areas and products add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each listed in Table 1A, page 10 before installing 45°... -
Page 19: Outdoor Venting
Installation & Operation Manual General venting (continued) Outdoor venting Units are self-venting and can be used outdoors when installed with the optional outdoor kit. All vent materials must be fi eld • In order to properly vent the appliance in an outdoor supplied and supported per the vent manufacturer’s instructions. -
Page 20: Vertical Direct Venting
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when determining Figure 3-2 Vertical Termination of Air and Vent w/Rain WARNING vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to the WARNING vent pipe or multiple boilers to a common... -
Page 21: Multiple Vent/Air Terminations
Installation & Operation Manual Vertical direct venting (continued) 3. The vent piping must terminate in an up-turned coupling Figure 3-4 Alternate Vertical Terminations with Multiple as shown in FIG. 3-1. The top of the coupling or the Boilers rain cap must be at least 36" (914 mm) above the air intake. -
Page 22: Sidewall Direct Venting
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Follow instructions below when Sidewall vent and air inlet terminations WARNING WARNING determining vent location to avoid must terminate in the same pressure possibility of severe personal injury, death, zone. -
Page 23: Prepare Wall Penetrations
Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall Prepare wall penetrations Figure 4-2 Clearance to Doors and Windows Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. -
Page 24: Room Air
Installation & Operation Manual Sidewall direct venting 2. Place wall penetrations to obtain minimum clearance Figure 4-6 Room Air (Direct Exhaust Terminations) of 12 inches (305 mm) between vent pipe and adjacent air inlet, as shown in FIG. 4-4 for U.S. installations. For ROOM AIR (DIRECT EXHAUST TERMINATIONS) Canadian installations, provide clearances required by CSA B149.1 Installation Code. -
Page 25: Water Connections
Installation & Operation Manual Water connections Inlet and outlet connections Figure 5-2_Heat Exchanger For ease of service, install unions on the inlet and outlet of the appliance. The connection to the appliance marked “Water Inlet” on the rear jacket should be used for return from the system. -
Page 26: Water Flow Switch
Installation & Operation Manual Water connections Water flow switch The boiler system should not be operated at CAUTION less than 12 PSIG. A water flow switch is factory installed in the outlet piping on all heating boilers. The flow switch must prove water flow Hot water piping must be supported by suitable hangers or before a trial for ignition can begin. - Page 27 Installation & Operation Manual Water connections (continued) The boiler primary piping system must have a circulator Circulator pump specifications installed in the main system loop to carry the heated boiler Maximum operating pressure for the pump must exceed water to the point of use in the main system. system operating pressure.
- Page 28 Installation & Operation Manual Water connections Figure 5-3_Primary/Secondary Piping of a Single Boiler TO FLOOR DRAIN TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING SUPPLY LOOP 12” MAX OR 4 PIPE DIAMETERS HEATING RETURN LOOP DIR #2000527832 00 *Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 29 Installation & Operation Manual Water connections (continued) Figure 5-4_Primary/Secondary Piping with DHW Normal TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING SUPPLY LOOP CHECK VALVE SYSTEM PUMP INDIRECT BOILER DOMESTIC PUMP HOT WATER HEATING 12” MAX OR RETURN 4 PIPE DIAMETERS LOOP DIR #2000530477 00 *Please note that these illustrations are meant to show system piping concept only, the installer is responsible...
- Page 30 Installation & Operation Manual Water connections Figure 5-5_Primary/Secondary Piping of Multiple Boilers COMMON MANIFOLD SIZE (Min.) Number of Units Model 2500 6" 7" 8" 8" 10" 10" 12" 3000 6" 7" 8" 10" 10" 12" 12" 3500 7" 8" 9" 10"...
- Page 31 Installation & Operation Manual Water connections (continued) Figure 5-6_Boiler with Low Temperature Bypass Piping - Using a Thermostatic Mixing Valve Required for Systems Operating at less than 140°F (60°C) Return Water Temperatures from the Heating Return Loop TO FLOOR DRAIN TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING SUPPLY LOOP...
- Page 32 Installation & Operation Manual Water connections Figure 5-7_Primary/Secondary Piping with Buffer Tank COMMON MANIFOLD SIZE (Min.) Number of Units Model 2500 6" 7" 8" 8" 10" 10" 12" 3000 6" 7" 8" 10" 10" 12" 12" 3500 7" 8" 9" 10"...
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Page 33: Low Temperature Bypass Requirements
Installation & Operation Manual Water connections (continued) Minimum boiler water temperatures A boiler allowed to operate at set point CAUTION temperatures below the specified minimum Inlet water temperatures below the specified minimum of settings experience operational 140°F (60°C) can excessively cool the products of combustion problems with the operating controls and resulting in condensation on the heat exchanger. - Page 34 Installation & Operation Manual Water connections TABLE - 5B SYSTEM TEMPERATURE RISE CHART Temperature Rise and Head Loss Based on Boiler Output in Btu/hr 20°F T 25°F T 30°F T 35°F T 40°F T 45°F T 50°F T 55°F T 60°F T Btu/hr Input...
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Page 35: Gas Connections
Installation & Operation Manual Gas connections Connecting gas supply piping 5. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe 1. Refer to FIG. 6-1 to pipe gas to the boiler. joints so that pipe dope does not block gas flow. Install ground joint union for servicing, when Failure to apply pipe sealing compound WARNING... -
Page 36: Propane Gas
Installation & Operation Manual Gas connections Propane Gas: Adjust the temperature set point on the control panel of the SMART TOUCH control module to call for heat or utilize Service Mode, see page 47 of this manual. Check boiler rating plate to determine WARNING which fuel the boiler is set for. -
Page 37: Gas Pressure
Installation & Operation Manual Gas connections (continued) Table 6B Natural Gas Pipe Size Chart TABLE - 6B Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Length of Pipe in Straight Feet Pipe Size... -
Page 38: Boiler Operating Control Module
Installation & Operation Manual Electrical connections Boiler operating control module TABLE - 7A AMP DRAW DATA The operating temperature control for the appliance is the SMART TOUCH control module. It is located on the inside Model Amp Draw of the control panel, behind the front access door. Access 2500 to adjust the temperature set point and other user adjustable 3000... -
Page 39: Low Voltage Connections
Installation & Operation Manual Electrical connections (continued) Figure 7-1A_Line Voltage Field Wiring Connections_ Figure 7-2_Routing Field Wiring Models 2500 - 3000 LINE 1 BK LOW VOLTAGE SERVICE SWITCH WIRING KNOCKOUTS LINE 2 BK SERVICE SWITCH NEUTRAL W GROUND G BOILER PUMP DRY CONTACT SYSTEM PUMP DIR #2000529359 00... -
Page 40: Wiring Of The Cascade
Installation & Operation Manual Electrical connections Alarm contacts Louver proving switch The SMART TOUCH control closes another set of contacts 1. When the operation of a louver proving switch needs to whenever the heater is locked out or the power is turned off. be verified before the boiler fires, remove the jumper wire This can be used to turn on an alarm, or signal a Building from these terminals and connect them to the normally... - Page 41 Installation & Operation Manual Electrical connections (continued) Figure 7-4_Low Voltage Field Wiring Connections...
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Page 42: Condensate Disposal
Installation & Operation Manual Condensate disposal Condensate trap installation Figure 8-1_Install Condensate Trap Locate the condensate trap kit shipped loose with the appliance. The kit includes a sheet metal mounting base, two (2) nuts and the condensate trap. Install the condensate trap mounting base on the rear of the appliance in the lower left-hand corner as depicted in FIG. -
Page 43: Startup
Installation & Operation Manual Start-up Fill water Freeze protection (when used) Check/control fill water chemistry Determine freeze protection fluid quantity using system water content, following fluid manufacturer’s Conduct water quality testing prior to instructions. Boiler water content is listed on page 6. IMPORTANT installing the appliance. -
Page 44: Check For Gas Leaks
Installation & Operation Manual Start-up Check for gas leaks Figure 9-1_Condensate Trap Before starting the boiler, and during initial WARNING operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. -
Page 45: Start The Boiler
Installation & Operation Manual Start-up (continued) Final checks before starting the boiler Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air Read the Power-fin Service Manual to familiarize yourself piping, and vent piping. with SMART TOUCH control module operation. -
Page 46: For Your Safety Read Before Operating
Installation & Operation Manual Start-up Figure 9-2_Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. • A. This appliance does not have a pilot. It is Immediately call your gas supplier from a equipped with an ignition device which neighbor’s phone. - Page 47 Installation & Operation Manual Start-up (continued) Set space heating operation Set space heating set point temperature During normal operation, space heating set point Verify space heat circulator mode temperatures can be adjusted from the Home Screen by The system pump output can be programmed to never run pressing the DETAILS button on the bottom of the screen (OFF), run only when a space heating demand is present (see FIG.
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Page 48: Operating Information
Installation & Operation Manual Operating information Set Hot Water Generator (HW) operation Set maximum HW fan speed Note: If the rated input of the indirect tank is less than the maximum For more detailed instructions, please refer to the output of the boiler, change the maximum HW fan speed setting Power-fin Service Manual. -
Page 49: Configuration Of The Cascade
Installation & Operation Manual Operating information (continued) Configuration of the cascade Note: For more detailed instructions, please refer to the Power-fin Service Manual. When installed in a Cascade system, the individual controls must be programmed for cascade operation. Access the Cascade Setup options as follows: 1. -
Page 50: General
Installation & Operation Manual Operating information General HW priority The SMART TOUCH control allows the connection of a HW How the appliance operates thermostat or tank sensor to the low voltage connection board. When a tank sensor is connected, the HW thermostat input is The Power-fin uses a copper finned tube heat exchanger ignored. - Page 51 Installation & Operation Manual Operating information (continued) Gradient limiting Ramp Delay If during operation of the boiler the outlet water temperature For systems with lower flow, the SMART TOUCH can limit is rising too quickly, the control will reduce the firing rate to the firing rate (when enabled) when a space heating call for its lowest setting.
- Page 52 Installation & Operation Manual Operating information Monitor external limits High limit operations Connections are provided on the connection board for The Power-fin SMART TOUCH control has two (2) integral external limits such as an additional high limit. limits, one auto reset and one manual reset. The Power-fin SMART TOUCH control will shut off the burner and also has one auxiliary manual reset high limit.
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Page 53: Cascade
Installation & Operation Manual Operating information (continued) Cascade Sequence of the cascade When multiple boilers are installed, they can be wired together To equalize the run time of all boilers on the Cascade, the in a cascade sequence. A maximum of eight boilers can be firing sequence will automatically be changed at set intervals. -
Page 54: Sequence Of Operation
Installation & Operation Manual Operating information Sequence of operation Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call, HW pump for a hot water generator call). The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional). The control confirms that the gas pressure switch, blocked drain switch, limits, louver proving switch (optional) and contacts close. -
Page 55: Home Screen
There are three (3) main sections located next display the following: Outdoor Air, Hot Water Temp, to the Lochinvar icon: Home, View, and Setup. The Home System Supply Temperature, and System Return Section is the screen shown above. The View Section Temperature. -
Page 56: Maintenance
Installation & Operation Manual Maintenance Maintenance and annual startup Table 11A_Service and Maintenance Schedules Owner maintenance Service technician (see the Power-fin User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems, if any • Check boiler area •... -
Page 57: Address Reported Problems
Installation & Operation Manual Maintenance (continued) Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage. -
Page 58: Check Expansion Tank
Installation & Operation Manual Maintenance Check expansion tank 2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief 1. Expansion tanks provide space for water to move in valve. Ensure that the reason for relief valve weeping is and out as the heating system water expands due to the valve and not over-pressurization of the system due temperature increase or contracts as the water cools. -
Page 59: Check Burner Flame
Installation & Operation Manual Maintenance (continued) Check all wiring Normal Flame: A normal flame at 100% of burner input is blue, with slight yellow tips, a well defined flame and no flame lifting. 1. Inspect all wiring, making sure wires are in good condition Yellow Tip: Yellow tipping can be caused by blockage or partial and securely attached. - Page 60 Installation & Operation Manual Maintenance Inspect and clean burner For Models 3500 and 5000 only: a. Remove the air box top cover. The burner should be removed for inspection and cleaned b. Remove the nuts holding the combustion air on an annual basis. An appliance installed in a dust or dirt blower to the whirlwind.
- Page 61 Installation & Operation Manual Maintenance (continued) Inspect and clean the heat exchanger Figure 11-4_Location of the Heat Exchanger Inside Jacket Turn off all power to the appliance. Turn off main gas to appliance. Remove the front outer jacket panel. Remove the front inner jacket panel (see FIG. 11-4). Check the heat exchanger surface for soot.
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Page 62: Diagrams
Installation & Operation Manual Diagram Figure 12-1 Wiring Diagram_2.5 & 3.0 Models BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING BOARD X1-1 LARGE CONNECTION BOARD X1-2 LOW VOLTAGE X1-3 120 VAC SHIELD CN6-3 X6-3 INTEGRATED CONTROL CN6-2 X6-1 HIGH VOLTAGE OPTION CN6-1... - Page 63 Installation & Operation Manual Diagram (continued) Figure 12-2 Wiring Diagram_3.5 & 4.0 Models BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING BOARD X1-1 LARGE CONNECTION BOARD X1-2 LOW VOLTAGE X1-3 CN6-3 X6-3 120 VAC SHIELD INTEGRATED CONTROL CN6-2 X6-1 HIGH VOLTAGE OPTION...
- Page 64 Installation & Operation Manual Diagram Figure 12-3 Wiring Diagram_5.0 Model BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING BOARD X1-1 LARGE CONNECTION BOARD X1-2 LOW VOLTAGE X1-3 CN6-3 X6-3 120 VAC SHIELD INTEGRATED CONTROL CN6-2 X6-1 HIGH VOLTAGE OPTION CN6-1 X6-2...
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Page 65: Ladder Diagrams
Installation & Operation Manual Diagram (continued) Figure 12-4 Ladder Diagram_2.5 & 3.0 Models NEUTRAL JUNCTION BOX BOX DEPICTS L1 L2 L3 TERMINAL STRIP TERMINAL STRIP OPTIONAL ITEMS 240V 1 SUPPLY 240V SUPPLY "N" BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL X1-3 1.5A EACH MAX ON/OFF... - Page 66 Installation & Operation Manual Diagram Figure 12-5 Ladder Diagram_3.5 & 4.0 Models NEUTRAL JUNCTION BOX BOX DEPICTS L1 L2 L3 TERMINAL STRIP TERMINAL STRIP OPTIONAL ITEMS 208V 3 SUPPLY 208V SUPPLY "N" BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL X1-3 1.5A EACH MAX ON/OFF...
- Page 67 Installation & Operation Manual Diagram (continued) Figure 12-6 Ladder Diagram_5.0 Model NEUTRAL JUNCTION BOX BOX DEPICTS L1 L2 L3 TERMINAL STRIP TERMINAL STRIP OPTIONAL ITEMS 480V 3 SUPPLY 480V 30 SUPPLY "N" BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL X1-3 1.5A EACH MAX ON/OFF...
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Page 68: Revision Notes
Revision Notes: Revision A (Process #3000004033_Change #500004083) initial release. Revision B (Process #3000006244_Change #500006394) reflects edits made to the Inspect and Clean Burner Section. Revision C (PCP# 3000005648 / CN# 500006460) reflects an update to Figures 3-3 and 3-4 on page 21 and Figure 4-4 on page 24. Revision D (PCP# 3000009248 / CN# 500009030) reflects limit changes on pages 51-52 of the Operating Information section.