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Lochinvar Power-fin 1002 Installation & Operation Manual

Other manuals for Power-fin 1002: User Manual, Service Manual

Summary of Power-fin 1002

  • Page 1

    Installation & operation manual models: 502, 752, 1002, 1302, 1501, 1701, and 2001 up to 5:1 turndown 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 ...

  • Page 2: Hazard Definitions

    2 hazard definitions ................................................................................................... 2 please read before proceeding ............................................................................... 3 ratings ............................................................

  • Page 3

    3 please read before proceeding notice this is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier.  warning if the information in these instructions is not fo...

  • Page 4

    Installation & operation manual 4 please read before proceeding  warning to minimize the possibility of serious 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...

  • Page 5: Ratings

    Installation & operation manual ratings 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...

  • Page 6

    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 t...

  • Page 7

    29. 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 o...

  • Page 8

    Installation & operation manual 8 31 28 models 1501 - 2001 left side (inside unit) models 1501 - 2001 right side (inside unit) 29 30 32 models 1501 - 2001 rear view models 1501 - 2001 front view the power-fin - how it works....

  • Page 9: Determine Unit Location

    Installation & operation manual 9 1 determine unit location notice clearances from combustible construction are noted on the appliance rating plate. 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, ...

  • Page 10: Determine Unit Location

    Installation & operation manual 10 1 determine unit location figure 1-2_combustion air direct from outside 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 ve...

  • Page 11: Determine Unit Location

    Installation & operation manual 1 determine unit location (continued) 11 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...

  • Page 12: Determine Unit Location

    Installation & operation manual 12 1 determine unit location 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 venti...

  • Page 13: Venting

    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 1...

  • Page 14: Venting

    Installation & operation manual 14 2 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., f...

  • Page 15: Venting

    Installation & operation manual 2 venting (continued) 15 condensing vent options: cat ii & iv (cat ii vent options a, b, & c requires an adapter kit - see page 14) a cat ii requires an adapter kit. See page 14. Vertical vent with combustion air from equipment room - see page 16. Cat ii/ iv d sidewal...

  • Page 16: Venting

    Installation & operation manual 16 2 venting a cat ii requires an adapter kit. See page 14. Cat ii/iv vertical vent with combustion air from equipment room - see page 15. The flue outlet terminates on the rooftop. The termination point for the flue products must follow the vertical vent termination ...

  • Page 17: Venting

    Installation & operation manual 2 venting (continued) 17 condensing vent options: cat ii & iv (cat ii vent options a, b, & c requires an adapter kit - see page 14) c cat ii requires an adapter kit. See page 14. Cat ii/iv directaire vertical installation with sidewall combustion air inlet - see page ...

  • Page 18: Venting

    18 2 venting e cat iv 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 in...

  • Page 19: Venting

    Installation & operation manual 2 venting (continued) 19 non-condensing vent options: cat i g vertical negative draft venting system - see pages 20 and 21. H directaire vertical venting with vertical air inlet - see pages 20 and 21. I directaire vertical venting with sidewall inlet - see pages 20 an...

  • Page 20: Venting

    Installation & operation manual 20 2 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 con...

  • Page 21: Venting

    Installation & operation manual 2 venting (continued) 21 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 ki...

  • Page 22: Venting

    Installation & operation manual 22 2 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 ca...

  • Page 23: Venting

    Installation & operation manual 2 venting (continued) 23 cat iv specific venting information (continued) : vent options a, b, c, d, e, & f 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 th...

  • Page 24: Venting

    Installation & operation manual 24 2 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° elbows installed at the point of terminatio...

  • Page 25: Venting

    Installation & operation manual 2 venting (continued) 25 multiple horizontal or vertical direct vent installations the combustion air inlet caps for multiple appliance installations must maintain the same minimum clearance from the closest vent cap installed within a 10 foot radius of the point of f...

  • Page 26: Venting

    Installation & operation manual 26 2 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 equival...

  • Page 27: Venting

    Installation & operation manual 2 venting (continued) 27 vertical vent termination clearances - venting options: a, b, c, g, h & i figure 2-6_vent termination from peaked roof - 10 ft. Or less from ridge figure 2-7_vent termination from peaked roof - 10 ft. Or more from ridge figure 2-8_vent termina...

  • Page 28: Venting

    Installation & operation manual 28 2 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. Flue gas condensate can freeze on e...

  • Page 29: Venting

    Installation & operation manual 2 venting (continued) 29 sidewall vent termination clearances - venting options: d, e, & f figure 2-10_vent to forced air inlet figure 2-11_vent to doors and windows mechanical draft vent termination 24" min. 12" min. Figure 2-12_vent above window figure 2-13_direct v...

  • Page 30: Gas Connections

    30 installation & operation manual gas supply verify that the appliance is supplied with the type of gas specified on the rating plate. This appliance is configured for operation up to 4000 feet altitude. Consult factory for installations above 4000 feet elevation. Inlet gas pressure: measured at th...

  • Page 31: Gas Connections

    31 installation & operation manual gas piping install piping to control 1. The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity. Verify pipe size with your gas supplier. 2. Use new, properly threaded black iron pipe free from chips. If t...

  • Page 32: Gas Connections

    32 installation & operation manual figure 3-2_gas supply pressure measurement 14. Turn on the gas supply at the manual valve, turn on lp gas at the tank if required. 15. Turn the power switch to the “on” position. 16. Adjust the temperature set point on the display of the smart system control module...

  • Page 33: Gas Connections

    Installation & operation manual high and low gas pressure switches (continued) downstream test valve manual shutoff valve venturi combination valve diaphram valve figure 3-4_gas train assembly f9 - models 502 - 1302 f9 gas train the combination gas valve on this appliance uses line (120 vac) voltage...

  • Page 34: Water Connections

    Figure 4-1_water connections heat exchanger this appliance uses a finned copper tube heat exchanger to maximize the heat transfer process. The heat exchanger is mounted in the inner jacket on the front side of the appliance. The heat exchanger is composed of two circular, glass lined, and cast iron ...

  • Page 35: Water Connections

    Water flow switch a water flow switch is factory installed in the outlet piping on all heating boilers and water heaters. The flow switch must prove water flow before a trial for ignition can begin. The flow switch requires a minimum flow of 26 gpm to make the flow switch and start burner operation....

  • Page 36: Water Connections

    The boiler primary piping system must have a circulator installed in the main system loop to carry the heated boiler water to the point of use in the main system. Multiple boilers may also be installed with a primary/secondary manifold system. Multiple boilers should be connected to the common manif...

  • Page 37: Water Connections

    Figure 4-3_primary/secondary piping of a single boiler common manifold size (min.) models: 502, 752, 1002, & 1302 number of units gpm diameter (in.) 1 75 2 1/2 common manifold size (min.) models: 1501, 1701, & 2001 number of units gpm diameter (in.) 1 90 2 1/2 37 4 water connections (continued) inst...

  • Page 38: Water Connections

    Figure 4-4_primary/secondary piping of multiple boilers common manifold size (min.) models: 502, 752, 1002, & 1302 number of units gpm diameter (in.) 2 150 3 1/2 3 225 4 4 300 5 5 375 6 6 450 6 7 525 6 8 600 8 common manifold size (min.) models: 1501, 1701, & 2001 number of units gpm diameter (in.) ...

  • Page 39: Water Connections

    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.) models: 502, 752, 1002, & 1302 number of units gpm diameter (in.) 1 75 ...

  • Page 40: Water Connections

    Figure 4-6_primary/secondary piping with buffer tank notice the inlet/outlet system tappings are shown in the optional location on the side of the tank for pictorial purposes. The standard location for the system tappings is 180° from the recirculation tappings. Common manifold size (min.) models: 5...

  • Page 41: Water Connections

    For example: night setback of the system loop water temperature, night shutdown and weekend shutdown of the entire boiler / heating system, and indoor / outdoor air reset of the system loop water temperature. If any of these building management system control functions are being utilized on the hydr...

  • Page 42: Water Connections

    42 installation & operation manual the installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded. The bypass will help to ensure...

  • Page 43: Electrical Connections

    5 electrical connections boiler operating control module the operating temperature control for the appliance is the smart system control module. It is located on the inside of the control panel, behind the front access door. Access to adjust the temperature set point and other user adjustable points...

  • Page 44: Electrical Connections

    44 installation & operation manual 5 electrical connections figure 5-1_line voltage field wiring connections low voltage connections 1. Route all low voltage wires through the knockouts in the rear of the heater, as shown in fig. 5-2. 2. Connect low voltage wiring to the low voltage connection board...

  • Page 45: Electrical Connections

    Installation & operation manual 5 electrical connections (continued) 45 louver proving switch 1. When the operation of a louver proving switch needs to be verified before the boiler fires, remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switc...

  • Page 46: Electrical Connections

    Figure 5-4_low voltage field wiring connections 5 electrical connections 46 installation & operation manual.

  • Page 47: Condensate Disposal

    47 condensate trap installation 1. 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. 2. Install the condensate trap mounting base on the rear of the appliance in the lower left-hand corner as depicted ...

  • Page 48: Start-Up

    48 check/control water chemistry do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard w...

  • Page 49: Start-Up

    49 check for gas leaks before starting the boiler, and during initial 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. Do not proceed with startup if there is any indication of a g...

  • Page 50: Start-Up

    50 boiler operation 10. Boiler should begin the start-up process for the sequence of operation. 11. The boiler will ignite at the proper ignition speed and will then modulate (b9/m9 models only) to meet the system demand. 12. Ensure that inlet water temperature does not fall below the specified mini...

  • Page 51: Start-Up

    Figure 7-2_operating instructions 51 7 start-up (continued) installation & operation manual.

  • Page 52: Start-Up

    52 configuration of the cascade when installed in a cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters. Input the installer code as described in the power-fin service manual. Once the control parameters have been...

  • Page 53: Operating Information

    53 general how the appliance operates the power-fin uses a copper finned tube heat exchanger to transfer heat from the flue products to the water. An electronic control module monitors various inputs to initiate a call for heat. The blower provides both primary and secondary air to the burner and fo...

  • Page 54: Operating Information

    54 temperature control modulation the power-fin is capable of modulating its firing rate from a minimum of 20% (m9) or 60% (b9) to a maximum of 100%. The f9 model can only fire at 100%. The firing rate is dictated by the call for heat (i.E., space heating or domestic hot water), the heating load, ra...

  • Page 55: Operating Information

    55 run-time and alarm outputs the appliance provides dry contacts for indicating when the appliance is running, and when it is unable to operate. Run-time and cycle counting the control uses two timers to monitor the total hours of burner operation. One timer monitors the time the appliance is firin...

  • Page 56: Operating Information

    56 the appliance will fire at its ignition speed and will then modulate its firing rate to maintain the set point (m9 and b9 only). If the first appliance reaches 100% of its firing rate, the leader will calculate at what point the second appliance could fire at its minimum firing rate. At this poin...

  • Page 57: Operating Information

    57 operation display 1. The manual reset high limit must be closed before any action will take place. Htr: standby out: 123.8f(129) 2. Upon a call for heat the control turns on the appropriate pumps (system and boiler pumps for space heating; dhw pump for dhw call). The flow switch and low water cut...

  • Page 58: Operating Information

    58 power-fin control module figure 8-1_control panel - operator interface use the control panel (fig. 8-1) to set temperatures, operating conditions, and monitor appliance operation. 8 operating information access modes user the user can adjust the space heating target temperature and the tank targe...

  • Page 59: Operating Information

    8 operating information (continued) installation & operation manual 59 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 des...

  • Page 60: Operating Information

    60 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:...

  • Page 61: 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: sc...

  • Page 62: Operating Information

    62 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 ...

  • Page 63: Domestic Water Heaters

    63 this section applies only to those appliances used to supply domestic hot water, installed with a storage tank(s). A circulating pump must be installed in the piping assembly to the storage tank and valves used to control water velocity through the appliance. Proper water velocity is important fo...

  • Page 64: Domestic Water Heaters

    64 if the temperature rise is too low, the water velocity is too high, adjust as follows: 1. Temperature rise can be increased by slowly closing the field-installed ball valve in the outlet piping from the water heater to the storage tank to achieve the proper temperature rise. 2. Sustained high wat...

  • Page 65: Domestic Water Heaters

    65 figure 9-1_typical water heater piping with storage tank cold water supply power-fin water heater relief valve outlet building return drain lock-temp storage tank relief valve mixing valve building hot water supply inlet common manifold size (min.) models: 502, 752, 1002, & 1302 number of units g...

  • Page 66: Domestic Water Heaters

    66 figure 9-2_single water heater piping with two storage tanks building hot water supply mixing valve power-fin water heater outlet cold water supply inlet relief valve lock-temp storage tank drain building return common manifold size (min.) models: 502, 752, 1002, & 1302 number of units gpm diamet...

  • Page 67: Domestic Water Heaters

    67 figure 9-3_multiple water heater piping with a single storage tank mixing valve cold water supply min. 4” common manifold size building hot water supply relief valve lock-temp storage tank drain building return common manifold size (min.) models: 502, 752, 1002, & 1302 number of units gpm diamete...

  • Page 68: Domestic Water Heaters

    68 installation & operation manual figure 9-4_multiple water heater piping with multiple storage tanks cold water supply power-fin water heater min. 4” common manifold size building return drain relief valve building hot water supply mixing valve common manifold size (min.) models: 502, 752, 1002, &...

  • Page 69: Domestic Water Heaters

    Installation & operation manual pump operation 1. The water heater must have a properly sized circulating pump. This pump is sized to circulate water between the heater and the storage tank only. 2. The pump is sized to the heater input and water chemistry specifications noted in the water chemistry...

  • Page 70: Domestic Water Heaters

    70 failure to press the enter key after changing the display value will result in the set point reverting back to its previous value after the current heat demand ends. The control may be adjusted any time regardless of call for heat status. When pressing the up or down key to enter any new set poin...

  • Page 71: Domestic Water Heaters

    71 location of cold water supply piping connections incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the primary heat exchanger and operational problems. The cold water supply piping must be installed in the dis...

  • Page 72: Maintenance

    72 10 maintenance maintenance and annual startup service technician (see the following pages for instructions) general: • address reported problems • inspect interior; clean and vacuum if necessary; • inspect condensate system and flush with fresh water • check for leaks (water, gas, flue, condensat...

  • Page 73: Maintenance

    73 10 maintenance (continued) follow the service and maintenance procedures given throughout this manual and in component literature 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 ...

  • Page 74: Maintenance

    74 10 maintenance flue vent system and air piping 1. Check for gastight seal at every connection, seam of air piping, and vent piping periodically inspected by a qualified service agency. Check water system 1. Verify all system components are correctly installed and operational. 2. Check the cold fi...

  • Page 75: Maintenance

    75 inspect/replace hot surface igniter 1. Turn off main electrical power to the appliance. 2. Turn off main manual gas shutoff to the appliance. 3. Carefully pull back the insulation flaps to expose the burner mounting flange. 4. Locate the hot surface igniter. Disconnect the two power leads to the ...

  • Page 76: Maintenance

    76 10 maintenance check flue gas passageways any sign of soot around the inner jacket, outer jacket, flue pipe connections, burner or in the areas between the fins on the copper heat exchanger indicates a need for cleaning. The following cleaning procedure must only be performed by a qualified servi...

  • Page 77: Maintenance

    77 10 maintenance (continued) inspect and clean the heat exchanger figure 10-3_location of the heat exchanger inside jacket 1. Turn off all power to the appliance. 2. Turn off main gas to appliance. 3. Remove the front outer jacket panel. 4. Remove the inner jacket panel (see fig. 10-3). 5. Check th...

  • Page 78: Wiring Diagram

    11 wiring diagram 78 3 2 1 p 2 4 5 outdoor sensor system supply sensor system return sensor tank sensor (-) (+) 0-10vdc cascade cable tx rx rs232c (-) (+) louver proving tank t'stat remote enable inlet sensor flue sensor outlet sensor blocked drain switch auto-reset high-limit connection board x4 x5...

  • Page 79: Ladder Diagram

    79 12 ladder diagram l boiler supply louver contacts blower relay louver relay proof of closure relay proof of closure valve blower 1 2 3 n g boiler supply pump supply l in system pump relay out system pump boiler pump dwh pump in out in out boiler pump relay dwh pump relay pump supply n on/off swit...

  • Page 80

    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 manua...