Installation & Operation Manual
4
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
headers and copper finned tubing are encased in a jacket that
contains the combustion process.
2.
Heat exchanger access cover (not shown)
The heat exchanger access cover is a stainless steel door which
allows access for service, maintenance, and removal of the heat
exchanger from inside the combustion chamber.
3. Blower
The blower pulls in air and gas through the venturi / whirlwind (see
item 5) and injects the fuel/air mixture into the burner, where they
burn inside the combustion chamber.
4. Gas
valve
The gas valve allows the proper amount of gas to pass into the
burner for combustion. The gas valve on the Power-fin works
under a negative pressure so gas should only be pulled through the
valve when the blower is in operation.
5. Venturi
/
whirlwind
The venturi (models 2.5 - 3.0 only) and whirlwind (models
3.5 - 5.0 only) attaches to the inlet (or suction) side of the blower
and generates the negative pressure needed by the gas valve.
6. Flue
sensor
The flue sensor is mounted in the exhaust collar of the unit and
monitors the flue gas temperature. If the temperature in the stack
exceeds the maximum temperature the unit will shut down to
prevent a hazardous condition.
7.
Outlet temperature sensor (not shown)
This sensor monitors the outlet water temperature. If selected
as the controlling sensor, the appliance will maintain set point by
adjusting the firing rate of the unit according to this sensor.
8.
Inlet temperature sensor (not shown)
This sensor monitors inlet water temperature. If selected as the
controlling sensor, the appliance will maintain set point by
adjusting the firing rate of the unit according to this sensor.
9.
Temperature and pressure gauge
The temperature and pressure gauge monitors the outlet
temperature of the appliance as well as the system water pressure.
10. Electronic
display
Digital controls with SMART TOUCH screen technology, full
color display, and an 8" user interface screen.
11. Burner (not shown)
The burner is made of a woven metal fabric over stainless steel screen
construction. The burner uses pre-mixed air and gas and provides
a wide range of firing rates.
12. Water outlet (system supply)
The water outlet is a 4" ANSI flange connection that supplies water
to the system with connections for a flow switch (see #28), a relief
valve (see #25), and a temperature and pressure gauge (see #9).
13. Water inlet (system return)
The water inlet is a 4" ANSI flange connection that receives water
from the system and delivers it to the heat exchanger.
14. Gas
connection
pipe
The gas connection pipe is a threaded black iron pipe
connection (see Gas Connections Section for specific model
pipe size requirements). This pipe should be connected to the
incoming gas supply to deliver gas to the boiler.
15. SMART TOUCH Control Module
The SMART TOUCH Control Module is the main control for the
appliance. This module contains the programming that operates
the blower, gas valve, and pumps in addition to other programmable
features.
16. Air
intake
The air intake pipe allows fresh air to flow directly to the
appliance. The air inlet is part of the filter box assembly where air
filtration is accomplished with a standard filter.
17. Line voltage terminal strip
The line voltage terminal strip provides a location to connect all of
the line voltage contact points to the unit.
18. Low
voltage
connection
boards
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.
19. Condensate
trap
The condensate trap is designed to prevent flue gases from
escaping the appliance through the combustion chamber drain.
20. Access cover - front
The front access cover provides access to the gas train as well as the
blower and other key components for service and maintenance.
21. Ignition
electrode
An electrical spark across the electrodes will ignite the burner.
22. Flame inspection window (sight glass)
The flame inspection window is a quartz glass window that
allows a visual inspection of the burner and flame during
operation.
23. Flame
rod
The flame rod is used to verify the presence of a flame. If no flame
is present, the gas valves will close, preventing gas to the main
burners.
24. High
limit
sensor
Device that monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting (field
adjustable), it will break the control circuit, shutting the
appliance
down.
25. Relief
valve
The relief valve is a safety device that ensures the maximum
pressure of the appliance is not exceeded. Boilers operate on
pressure only and are shipped from the factory at a rating of
50 PSI.
26. Power
switch
The power switch is used to engage and disengage power to the
appliance on the line voltage circuit.
27. Air
pressure
switch
This pressure switch monitors the pressure at the outlet of the
blower to prevent over pressurization due to a blockage in either
the heat exchanger or the vent.
28. Flow
switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass and
should never be operated without flow. The flow switch makes
contact when flow is detected and allows the unit to operate. If
flow is discontinued during operation for any reason the flow
switch will break the control circuit and the unit will shut down.
29. Drain
port(s)
Location from which the heat exchanger can be drained.
30. Manual shutoff valve (not shown)
Manual valve used to isolate the unit from the gas supply.
