Lochinvar Power-Fin Designer's Manual
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Lochinvar Power-Fin Designer's Manual

Lochinvar Power-Fin Designer's Manual

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H I G H E F F I C I E N C Y C O M M E R C I A L B O I L E R S
D E S I G N E R ' S G U I D E P O W E R - F I N
B O I L E R
87%
Up to
Thermal Efficiency
w w w . L o c h i n v a r .c o m

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Summary of Contents for Lochinvar Power-Fin

  • Page 1 ® H I G H E F F I C I E N C Y C O M M E R C I A L B O I L E R S D E S I G N E R ’ S G U I D E P O W E R - F I N B O I L E R Up to Thermal Efficiency...
  • Page 2 Dear Design-Build Contractor / Project Manager / Design Engineer, At Lochinvar, we have long recognized the importance of innovation to any product or service. Those who share in this business also face the challenge of meeting constantly changing needs and energy effi ciency demands.

  • Page 3: Table Of Contents

    Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Table of Contents Combustion Air …………..…..……………………… Page 5 Venting ….…………………………………………….. Page 8 Gas ….….…………….……………….………………… Page 21 Water …..……………………..……………………….. Page 23 Electricity & Controls ……………………………….. Page 28 Other Details ..………………………………………..

  • Page 4: Combustion Air

    300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com At Lochinvar, we know that designing a boiler is hard work. Designing a boiler system is no picnic either. Demands for greater efficiency and elaborate system control have made systems more complex.

  • Page 5: Combustion Air

    Therefore, a good, easy flow of clean air is 100% necessary for clean, efficient combustion. So, we need to provide a permanent and uninterrupted flow of air to the boiler. The Power-fin boiler is designed to receive combustion air by one of TWO methods. The boiler may draw combustion air from the room or have the air ducted directly to the boiler from an exterior space.
  • Page 6 This opening must be located within 12" (30 cm) of the top of the enclosure. Did you Know? THE POWER-FIN COMES WITH LOUVER CONTACTS AS STANDARD EQUIPMENT. THE CONTACTS WILL OPEN AND CLOSE A MOTORIZED LOUVER ON EACH CALL FOR HEAT.
  • Page 7 THE FORMATION OF CORROSIVE ACIDS THAT WILL DAMAGE THE APPLIANCE AND THE VENT. COMBUSTION AIR FILTER The Power-fin has a built-in air filter as standard equipment. Located at the combustion air inlet, the air filter is provided to help ensure clean air is used for the combustion process.

  • Page 8: Venting

    Here is the traditional vent category diagram, standard throughout the industry. Lochinvar offers twelve venting options that allow the Power-fin to be installed in any of three categories - Category I, Category II and Category IV. Depending upon the “Firing Code” chosen, the Power- fin boiler will be factory trimmed for direct connection either Category I or Category IV venting.
  • Page 9 So how does pressure apply to the Power-fin? Again, easy. Depending upon the model, the Power-fin boiler’s will be factory trimmed for a small vent connection to positive vent or a large vent connection to non-positive vent. This is explained further in Part 2, “Firing Code”.

  • Page 10: Category Iv Venting

    20%, they produce a comparatively low stack temperature that will likely cause condensation to occur in the stack. Condensing. Pressure – The Power-fin 0502-2001-M9 models are factory trimmed with a small diameter vent connection. The blower CAN PUSH the flue products through a similarly sized stack therefore creating a positive pressure.
  • Page 11 Chapter 1 of this designer’s guide. Maximum distance – 50 equivalent feet of vent. The Category IV Power-fin with a model number that features the M9 (Modulating Fire) Firing Code will be factory trimmed for Category IV vent connection in the following dimensions. MODEL...
  • Page 12 Maximum distance – 50 equivalent feet of air intake. The Category IV Power-fin with a model number that features the M9 (Modulating Fire) Firing Code will be factory trimmed for Category IV vent and air inlet connections in the following dimensions.
  • Page 13 Maximum distance – 50 equivalent feet of air intake. The Category IV Power-fin with a model number that features the M9 (Modulating Fire) Firing Code will be factory trimmed for Category IV vent and air inlet connections in the following dimensions.
  • Page 14 Maximum distance - 50 equivalent feet of vent. The Category IV Power-fin with a model number that features the M9 (Modulating Fire) Firing Code will be factory trimmed for Category IV vent connection in the following dimensions. The table also includes the kit part numbers for the sidewall exhaust caps which must be used.
  • Page 15 Maximum distance - 50 equivalent feet of air intake. The Category IV Power-fin with a model number that features the M9 (Modulating Fire) Firing Code will be factory trimmed for Category IV vent and air inlet connections in the following dimensions.
  • Page 16 Maximum distance - 50 equivalent feet of air intake. The Category IV Power-fin with a model number that features the M9 (Modulating Fire) Firing Code will be factory trimmed for Category IV vent and air inlet connections in the following dimensions.

  • Page 17: Category Ii Venting

    Retrofit of an original design Power-fin installed with Concentric Kit If your job is a retrofit of a Power-fin 0250-1000 built to the original design, here’s a little tip. If the PBN0250-F9, PBN0500-F9, PBN0750-F9 or PBN1000-F9 is installed wit a concentric vent kit, it is installed as a Category IV appliance.
  • Page 18 A field supplied barometric damper MUST be installed on Power-fin 1501-2001-B9. The Category I Power-fin with a model number that features the F9 or B9 Firing Code will be factory trimmed for Category I vent connection in the following dimensions.
  • Page 19 Maximum distance - 50 equivalent feet of air intake. The Category I Power-fin with a model number that features the F9 or B9 Firing Code will be factory trimmed for Category I vent and air inlet connections in the following dimensions.
  • Page 20 Maximum distance - 50 equivalent feet of air intake. The Category I Power-fin with a model number that features the F9 or B9 Firing Code will be factory trimmed for Category I vent and air inlet connections in the following dimensions. The table also includes the kit part numbers for the sidewall air intake caps which must be used.

  • Page 21: Gas

    In Chapter 3, we discuss delivering a steady and reliable supply of gas to the appliance. The key to the gas supply is sizing the gas line properly. The Power-fin will require less than a half a pound of pressure. The following Sizing Chart is based on less than ½ pound of pressure or less than 14 inches of pressure.
  • Page 22 Example, the model number changes from PBN0502-M9 to PBL0502-M9 from natural to L.P. gas. The Power-fin must be factory trimmed for the chosen gas type and may not be field converted from Natural to L.P. gas or vice versa.

  • Page 23: Water

    Installed piping to and from the boiler must be a minimum of 2 1/2 inch diameter. 2. Maximum Flow Rate The Power-Fin 502-1302 models have a max flow rate of 75 GPM. The Power-Fin 1501-2001 models have a max flow rate of 90 GPM.
  • Page 24 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Because system flow rates and boiler flow rates need to be controlled separately, you will want to design a Primary / Secondary piping loop. The Primary Loop, hereafter referred to as the “System Loop”...

  • Page 25: Water Temperature

    This is another easy question. What is the return water temperature from the System Loop? The minimum return water temperature to the Power-fin boiler is 140°F (60°C). Reason why? If the inlet water temperature is less than 140°F, condensate will occur on the outside of the copper-finned tube and in between the fins.
  • Page 26 5:1 Turndown. On a very cold winter day, all three air handlers will call for heat and the two Power-fin will fire at 100% input rate to meet the demand. On a comparatively cool autumn day, only one 400,000 Btu/hr air handler might be calling for heat.
  • Page 27 LEBANON, TN 37090 www.lochinvar.com The following table shows the maximum and minimum input and output rates for every Power-Fin with all of the available Firing Codes. Calculate the minimum load of your design to make sure the system demand or system volume will support minimum boiler output rate.

  • Page 28: Electricity & Controls

    BUILDING MANANGEMENT SYSTEM CONTROL For systems with more that eight Power-fin boilers or for systems with existing Building Management Systems, the Power-fin boiler is programmed to operate via a remote signal. A 0-10 Vdc input signal will control the boilers. The signal can be programmed to call the boilers to fire on a range of modulation or on a temperature range.
  • Page 29 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com CASCADE The Cascade feature in the Smart System control will operate up to eight boilers. Connected with 2-wire Daisy chain, any one boiler in the group is chosen as the Leader. The other boilers operate as Members.
  • Page 30 LEBANON, TN 37090 www.lochinvar.com LOW VOLTAGE TERMINAL BOARD Every Power-fin is equipped with a Low Voltage Terminal Board for a variety of other field connections and control features. Remote Enable / Disable Wired through the Low Voltage Terminal Strip, the Smart System control can be activated by a remote thermostat or controlled with an enable / disable signal.
  • Page 31 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DHW Tank Sensor A sensor mounted in the Domestic Water Storage tank. The Smart System will operate the DHW from this sensor. System Return Sensor A sensor mounted in the return line of the primary system loop BEFORE flow branches to the secondary boiler loop.
  • Page 32 Lochinvar offers PC Software. The PC software program can be downloaded onto a laptop computer and with the connection cable provided in the PC Software kit; you can connect to the PC port on the front of every Power-fin control panel. SCREEN SHOT OF PC SOFTWARE...

  • Page 33: Other Details

    Great Importance STANDARD CODES, STANDARD CONSTRUCTION The Power-fin boiler is design certified to the latest edition of ANSI Z21.13. The third party certification was performed by CSA International and the boiler bears the American Blue Star emblem and the Canadian Blue Flame emblem. The heat exchanger inside the boiler conforms to the latest edition of the ASME Boiler and Pressure Vessel Code, Section IV and the vessel bears the ASME “H”...
  • Page 34 1" *An Alcove is a closet without a door. CONDENSATE TRAP The Power-fin is fitted with a condensate trap to be field mounted on the floor behind the appliance. The trap is a requirement of the ANSI standard for any Category IV vented appliance with condensation forming in the stack.
  • Page 35 Relief Valve The standard relief valve offered on the Power-fin boiler is a 50 psi Pressure Only ASME relief valve. The Power-fin can be factory trimmed with a pressure only ASME relief valves with a higher pressure ratings of your choosing.

  • Page 36: Appendix A

    Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Appendix A Boiler Piping Diagrams...
  • Page 37 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PAGE A1 PRIMARY/SECONDARY or SYSTEM/BOILER PIPING The illustration is for concept only and should not be used for actual installation without engineering or technical advice from a licensed engineer. All necessary system equipment may not be illustrated.
  • Page 38 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PAGE A2 MULTIPLE UNIT – PRIMARY/SECONDARY or SYSTEM/BOILER PIPING Power-fin 0502, 0752, 1002 & 1302 Power-fin 1501, 1701 & 2001 Number of Combined Common Manifold Number of Combined...
  • Page 39 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PAGE A3 BUFFER TANK The illustration is for concept only and should not be used for actual installation without engineering or technical advice from a licensed engineer. All necessary system equipment may not be illustrated.
  • Page 40 Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PAGE A4 LOW TEMPERATURE VALVE PIPING The illustration is for concept only and should not be used for actual installation without engineering or technical advice from a licensed engineer. All necessary system equipment may not be illustrated.

  • Page 41: Appendix B

    Designer’s Guide / Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Appendix B Technical Data Boiler Component Breakdown...
  • Page 42 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Power-fin – the components, the design 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.
  • Page 43 Designer’s Guide Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com 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.
  • Page 44 Designer’s Guide Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Power-fin 0502 – 1302 Model 0502 – 1302 / Front View Model 0502 – 1302 / Rear View Model 0502 – 1302 / Right Side (inside view)
  • Page 45 Designer’s Guide Power-fin Boiler LOCHINVAR CORPORATION 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Power-fin 1501 – 2001 Model 1501 – 2001 / Front View Model 1501 – 2001 / Rear View Model 1501 – 2001 / Right Side (inside view)
  • Page 46 This is a screen shot of the Power-fin webpage. From the home page, click the “Boilers” button on the left side of the page. This takes you to a new page listing all the Lochinvar product families. Click on the Power-fin in the top row.
  • Page 47 NOTES...
  • Page 48 3 0 0 M a d d o x S i m p s o n P a r k w a y, L e b a n o n, T N 3 7 0 9 0 | 6 1 5 - 8 8 9 - 8 9 0 0 | f a x : 6 1 5 - 5 4 7 - 1 0 0 0 | w w w . L o c h i n v a r .c o m PB-DG-06 PDP-5M-4/08-Printed in U.S.A.

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