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PBX-PFX-I-O Rev L Installation & Operation Manual Models: 502, 752, 1002, 1302, 1501, 1701, and 2001 Up To 5:1 Turndown 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.
Contents Hazard definitions ....................2 Please read before proceeding ................3 Ratings ........................5 The Power-fin -- How it works ................6 Determine unit location ..................9 Venting - Before You Begin ................13 Condensing vent options: CAT II & IV ............15 Non-Condensing vent options: CAT I ............
Installation & Operation Manual Please read before proceeding This is a gas appliance and should be installed Improper installation, adjustment, NOTICE WARNING by a licensed electrician and/or certified gas alteration, service or maintenance can supplier. Service must be performed by a cause injury or property damage.
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Installation & Operation Manual Please read before proceeding To minimize the possibility of serious WARNING sersonal 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.
Installation & Operation Manual Ratings LOW LEAD CONTENT Power-fin Other Specifications AHRI Rating Model Number Input Gross Air / Vent AHRI Appliance Output B = Boiler Sizes Ratings Water Water (Note 4) Water, Content Connections Connections F = Water Heater Gallons Note: Change “N”...
Installation & Operation Manual The Power-fin - How it works... 15. SMART SYSTEM Control Module Heat exchanger The heat exchanger allows system water to flow through specially The SMART System Control Module is the main control for the designed tubes for maximum heat transfer. The glass lined appliance.
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Installation & Operation Manual The Power-fin - How it works... (continued) 29. Flow switch 30. Drain port(s) The flow switch is a safety device that ensures flow through the Location from which the heat exchanger can be drained. heat exchanger during operation. This appliance is low mass and 31.
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Installation & Operation Manual The Power-fin - How it works... Models 1501 - 2001 Rear View Models 1501 - 2001 Front View Models 1501 - 2001 Left Side (inside unit) Models 1501 - 2001 Right Side (inside unit)
Installation & Operation Manual Determine unit location Recommended service clearances Location of unit 1. 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 unit.
Installation & Operation Manual Determine unit location 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 above.
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Installation & Operation Manual Determine unit location (continued) If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm per kW) of input (see FIG.
Installation & Operation Manual Determine unit location Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN B149.1 or B149.2. Check all local code requirements for combustion air. All dimensions based on net free area in square inches.
Installation & Operation Manual 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 15 Water PFN0502PM-M9...
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Installation & Operation Manual Venting Vent Materials: Category II/IV Vent Material Suppliers: Category II/IV flue pipe materials and vent adapters (see FIG. 2-1) 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...
Installation & Operation Manual Venting (continued) Condensing Vent Options: CAT II & IV (CAT II vent options A, B, & C requires an adapter kit - see page 14) Vertical vent with combustion air from Sidewall termination with combustion air from equipment room - see page 16.
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Installation & Operation Manual Venting Condensing vent options: CAT II & IV (CAT II vent options A, B, & C requires an adapter kit - see page 14) Vertical vent with combustion air from equipment room - see page 15. The flue outlet terminates on the rooftop.
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Installation & Operation Manual Venting (continued) Condensing vent options: CAT II & IV (CAT II vent options A, B, & C requires an adapter kit - see page 14) DirectAire Vertical installation with sidewall combustion air inlet - see page 15. The DirectAire Vertical with a Sidewall Combustion Air Vent system terminates the flue at the rooftop and air inlet at the sidewall.
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Installation & Operation Manual Venting Condensing vent options: CAT IV Horizontal direct vent installation with sidewall combustion air inlet - see page 15. 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.
Installation & Operation Manual Venting (continued) Non-Condensing Vent Options: CAT I A required field supplied barometric damper MUST BE installed in location shown. CAT I - F9 CAT I - B9 Vertical negative draft venting system - see Vertical negative draft venting system - see page 20.
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Installation & Operation Manual Venting Non-Condensing vent options: CAT I Vertical negative draft venting system - see page 19. 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.
Installation & Operation Manual Venting (continued) 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.
Installation & Operation Manual Venting 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.
Installation & Operation Manual Venting (continued) CAT IV Specific venting information : Vent options A, B, C, D, E, & F (continued) Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney. The weight of the venting system must not rest on the unit.
Installation & Operation Manual Venting Vertical Air Inlet: Vent options B, F, & H Vertical combustion air inlet The air inlet cap for the vertical rooftop air inlet is assembled from components purchased locally. The air inlet cap consists of two 90°...
Installation & Operation Manual Venting (continued) Horizontal Air Inlet: Vent options C, E, F, & I Sidewall combustion air inlet The sidewall termination caps for both the flue products and combustion air must be purchased from the appliance manufacturer. The part numbers for the required sidewall termination kit are listed under each designated table. Each kit includes both the special combustion air inlet cap and the sidewall flue cap for installation on an exterior sidewall.
Installation & Operation Manual Venting Length of air inlet pipe for both vertical and horizontal - Vent options: All Categories The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.52m) of equivalent length for each 90°...
Installation & Operation Manual Venting (continued) Vertical Vent Termination Clearances - Venting options: A, B, C, G, H & I Figure 2-8_Vent Termination from Flat Roof - 10 ft. Figure 2-6_Vent Termination from Peaked Roof - 10 ft. or Less From Parapet Wall or Less From Ridge Figure 2-7_Vent Termination from Peaked Roof - 10 ft.
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Installation & Operation Manual Venting Vertical Vent Termination Clearances - Venting options: A, B, C, G, H & I Flue gases from this appliance may contain large amounts of water vapor that will form a white plume in winter. Plume could obstruct window view.
Installation & Operation Manual Gas connections Gas supply Gas connection Verify that the appliance is supplied with the type of gas specified Safe operation of the appliance requires properly sized gas on the rating plate. This appliance is configured for operation supply piping.
Installation & Operation Manual Gas connections (continued) TABLE - 3C Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4...
NOTE: Massachusetts code requires a pressure regulator to be heat. installed upstream of the low gas pressure switch. Lochinvar Observe the gas supply pressure as the burner fires at 100% requires any inline regulator used MUST BE of the lockup of rated input.
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Installation & Operation Manual Gas connections (continued) High and low gas pressure switches (continued) F9 gas train TYPICAL PRESSURE REGULATOR STYLE MAY VARY FROM SHOWN The combination gas valve on this appliance uses line (120 “FIELD PROVIDED” REGULATING (IF REQUIRED BY LOCAL CODES) GAS VALVE GAS COCK VAC) voltage for operation.
Installation & Operation Manual Water connections Inlet and outlet connections For ease of service, install unions on the inlet and outlet of the appliance. The connection to the appliance marked “Water Inlet” on the header should be used for return from the system.
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Installation & Operation Manual Water connections (continued) 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 and water heaters. The flow switch must Hot water piping must be supported by suitable hangers or floor prove water flow before a trial for ignition can begin.
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Installation & Operation Manual Water connections The boiler primary piping system must have a circulator Circulator pump specifications installed in the main system loop to carry the heated boiler water Maximum operating pressure for the pump must exceed to the point of use in the main system. system operating pressure.
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Installation & Operation Manual Water connections (continued) Figure 4-3_Primary/Secondary Piping of a Single Boiler COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.) 2 1/2...
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Installation & Operation Manual Water connections Figure 4-4_Primary/Secondary Piping of Multiple Boilers COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.) 3 1/2 *Please note that these illustrations are meant to show system piping concept only, the installer is responsible...
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Installation & Operation Manual Water connections (continued) Figure 4-5_Boiler with Low Temperature Bypass Piping - Using a Thermostatic Mixing Valve Required for Systems Operating at less than 140°F (60°C) Return Water Temperatures from the Heating Return Loop COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, &...
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Installation & Operation Manual Water connections Figure 4-6_Primary/Secondary Piping with Buffer Tank COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.) 3 1/2 *Please note that these illustrations are meant to show system piping concept only, the installer is responsible...
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.
Installation & Operation Manual Electrical connections Boiler operating control module TABLE - 5A AMP DRAW DATA The operating temperature control for the appliance is the Blower & Approximate Total SMART SYSTEM control module. It is located on the inside Model Pump FLA* Controls Amps @ 120 VAC...
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DHW tank sensor If a tank sensor is used, it must be connected to the tank sensor terminals on the low voltage connection board. The correct Lochinvar sensor (TST2032) MUST BE USED. Figure 5-2_Routing Field Wiring...
Installation & Operation Manual Electrical connections (continued) Alarm contacts Louver proving switch The SMART SYSTEM 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...
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Installation & Operation Manual Electrical connections Figure 5-4_Low Voltage Field Wiring Connections...
Installation & Operation Manual Condensate disposal Condensate trap installation 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.
Installation & Operation Manual Start-up Check/control water chemistry 4. At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before Do not use petroleum-based cleaning or CAUTION proceeding further. sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the Eliminate all system leaks.
Installation & Operation Manual Start-up (continued) Check for gas leaks 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.
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Installation & Operation Manual Start-up Verify space heat circulator mode Boiler operation 10. Boiler should begin the start-up process for the The Space Heating Mode controls both the system (primary) sequence of operation. pump (if connected), and the boiler (secondary) pump. When the SMART SYSTEM control receives a space heating call for 11.
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Installation & Operation Manual Start-up Set clock Configuration of the cascade The SMART SYSTEM control has a built-in clock that it uses When installed in a Cascade system, the individual controls must for its night setback feature and for logging events. This clock be programmed for cascade operation.
Installation & Operation Manual Operating information (continued) General 0 - 10V input (set point or power) The Power-fin can be controlled by a Building Management How the appliance operates System (BMS) using a 0 - 10 VDC signal. The control can be configured by the installer to use this signal to either control set The Power-fin uses a copper finned tube heat exchanger to point or firing rate.
Installation & Operation Manual Operating information Temperature control Protection features Modulation Outlet temperature, flue temperature, and temperature The Power-fin is capable of modulating its firing rate from rise limiting a minimum of 20% (M9) or 60% (B9) to a maximum of The outlet temperature is monitored by the boiler outlet 100%.
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Installation & Operation Manual Operating information (continued) Boiler temperature regulation Low water cutoff protection Operating temperature (target) The SMART SYSTEM control module uses temperature sensing of both inlet and outlet areas of the heat exchanger. The SMART SYSTEM control module senses water temperature If the flow rate is too low or the outlet temperature too and regulates appliance firing and firing rate to achieve a target high, the control module modulates and shuts the appliance...
Installation & Operation Manual Operating information DHW, Night Setback, and Ramp Delay operation with The appliance will fire at its ignition speed and will then modulate its firing rate to maintain the set point (M9 and B9 cascade only). If the first appliance reaches 100% of its firing rate, the For indirect DHW operation any boiler(s) in the Cascade can Leader will calculate at what point the second appliance could be selected to provide heat for a DHW call.
Installation & Operation Manual Operating information (continued) Sequence of operation OPERATION DISPLAY HTR: Standby 1. The manual reset high limit must be closed before any action will take place. OUT: 123.8F(129) 2. Upon a call for heat the control turns on the appropriate pumps (system HTR: Standby and boiler pumps for space heating;...
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Installation & Operation Manual Operating information Power-fin control module Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor appliance operation. Access modes Figure 8-1_Control Panel - Operator Interface User The user can adjust the space heating target temperature and the tank target temperature (if a tank sensor is used) by using the UP and DOWN buttons (FIG.
Installation & Operation Manual Operating information (continued) Status display screens Status Display Screens By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the nine (9) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
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Installation & Operation Manual Operating information Status Display Screens (cont’d) By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the nine (9) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
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Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, you can navigate through the nine (9) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
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Installation & Operation Manual Operating information Status Display Screens (cont’d) Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
Installation & Operation Manual Domestic water heaters This section applies only to those appliances used to supply If higher flow rates are required through the water heater, an domestic hot water, installed with a storage tank(s). A circulating optional Cupro Nickel heat exchanger is available. Consult the pump MUST be installed in the piping assembly to the storage factory for specific application requirements.
Installation & Operation Manual Domestic water heaters Water chemistry If the temperature rise is too high, the water velocity is too low, adjust as follows: Water temperature rise and maximum flow NOTICE data is based on heating potable water with 1.
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Installation & Operation Manual Domestic water heaters (continued) Figure 9-1_Typical Water Heater Piping with Storage Tank COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.)
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Installation & Operation Manual Domestic water heaters Figure 9-2_Single Water Heater Piping with Two Storage Tanks COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.)
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Installation & Operation Manual Domestic water heaters (continued) Figure 9-3_Multiple Water Heater Piping with a Single Storage Tank COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.)
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Installation & Operation Manual Domestic water heaters Figure 9-4_Multiple Water Heater Piping with Multiple Storage Tanks COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 1501, 1701, & 2001 Models: 502, 752, 1002, & 1302 Diameter Diameter Number of Units Number of Units (in.) (in.)
Installation & Operation Manual Domestic water heaters (continued) The standard circulating pump on this water heater is sized TABLE 9C based on installation of a single storage tank and heater in close COMMON WATER MANIFOLD SIZE FOR proximity. If the number of fittings and straight pipe exceeds the specified maximum equivalent number of straight feet MULTIPLE WATER HEATER INSTALLATIONS for a specified diameter of pipe, non-warrantable operational...
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Installation & Operation Manual Domestic water heaters Thermostat adjustment procedure An appliance allowed to operate at return CAUTION temperatures below the specified minimum 1. Press the UP or DOWN key to view the set point setting may experience problems with setting.
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Installation & Operation Manual Domestic water heaters (continued) A high limit control is located on the inside of the left front The following chart (Table 9E) details the relationship of water panel, as shown in FIG. 9-6. The setting of this control knob temperature and time with regard to scald injury and may be limits maximum discharge water temperature.
Installation & Operation Manual Maintenance Maintenance and annual startup Table 10A_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 • Check appliance area •...
Installation & Operation Manual Maintenance (continued) Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the appliance. Failure to perform the service and maintenance could result in damage to the appliance or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual Maintenance Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or 1. Check for gastight seal at every connection, seam of air authorized inspection agency, to ensure piping, and vent piping periodically inspected by a qualified that the product has not been affected by...
Installation & Operation Manual Maintenance (continued) Perform start-up and checks Inspect/replace hot surface igniter 1. Start appliance and perform checks and tests specified in 1. Turn off main electrical power to the appliance. Section 7 - Start-up. 2. Turn off main manual gas shutoff to the appliance. 2.
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Installation & Operation Manual Maintenance Check flue gas passageways Access to the burner will require the following steps: Turn off main electrical power to the appliance. Any sign of soot around the inner jacket, outer jacket, flue pipe connections, burner or in the areas between the fins on Turn off main manual gas shutoff to the appliance.
Installation & Operation Manual Maintenance (continued) Inspect and clean the heat exchanger Turn off all power to the appliance. Turn off main gas to appliance. Remove the front outer jacket panel. Remove the inner jacket panel (see FIG. 10-3). Check the heat exchanger surface for soot. If soot is present, the heat exchanger must be cleaned and the problem corrected.
Revision Notes: Revision B (PBX-PFX-I&O-Rev B) reflects the addition of Models 502 - 1302 to the manual. Revision C (PBX-PFX-I&O-Rev C) reflects the changes made to the Venting, LWCO, and Gas Connections sections. Revision D (ECO #C02751) reflects the addition of the Maintenance Section to the manual.