Lochinvar PBL0502-F9 Installation & Operation Manual Download Page 67 | Manualshive

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Diagram

(continued)

JUNCTION BOX

TERMINAL STRIP
480V 3

O

SUPPLY

TERMINAL STRIP
480V 30 SUPPLY "N"

NEUTRAL

INTEGRATED CONTROL

ON/OFF

SWITCH

F2

3.15 A

F4

5.0 A

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

X1-1

X1-2

X1-4

X1-8

BLOWER

CONTACTOR

GAS

VALVE RELAY

X1-6

X10-1

X10-2

GAS
VALVE RELAY

X10-5

X10-4

GAS

VALVE

TERMINAL STRIP

SYSTEM PUMP

CONTACTOR

BOLIER PUMP

CONTACTOR

DHW PUMP

CONTACTOR

BLOWER

CONTACTOR

BLOWER

X6-10

X6-1

4

BAS

2

-

1

X

1

-

1

X

X1-3

24V

TRANSFORMER

X6-3

X1-12

X1-3

LWCO

BOARD

TEST

SWITCH

LWCO

PROBE

LWCO RESET

J3-6

J3-3

J2-1

J2-2

J3-5

J3-2

J3-4

X6-5

X6-12

X13-1

X6-6

X3-3

X3-4

X3-1

X3-2

X6-11

X6-2

X6-14

INTEGRATED

CONTROL

GPS1

GPS2

AIR PRESSURE

SWITCH

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

ALARM
CONTACTS

RUN-TIME
CONTACTS

TANK
THERMOSTAT

LOUVER
PROVING

24 VAC LOUVER
RELAY COIL

ENABLE

R

W

SMALL

CONNECTION BOARD

CN1-4

CN1-5

CN1-6

CN1-12

CN1-10

X6-13

CN1-11

CN1-9

CN1-8

CN1-7

CN1-1

X1-5

X1-7

X1-10

FLAME

SENSE 1

SPARK

GENERATOR

SPARK

ROD

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

SHIELD

SHIELD

A

B

BAS
OPTION

+

-

RATE
OUT

SYSTEM RETURN
SENSOR

SYSTEM SUPPLY
SENSOR

0-10V

TANK
SENSOR

OUTDOOR
SENSOR

+

+

-

-

0-10V

0-10V

BMS
IN

SYSTEM
PUMP IN

SHIELD

SHIELD

A

B

CASCADE

LARGE

CONNECTION BOARD

CN6-1

CN3-6

CN3-14

CN3-13

CN3-11

CN3-9

CN3-8

CN3-1

CN3-2

CN3-3

CN3-4

CN6-2

CN6-3

CN3-10

CN3-12

BAS

BOARD

X4-1

X4-2

X4-3

X6-

3

X6-1

X6-2

X8-20

X8-10

X7-8

X8-13

X8-14

X8-12

INTEGRATED

CONTROL

X8-5

X8-15

X8-11

X8-6

X8-16

X8-7

X8-17

X8-18

-T

-T

-T

-T

INLET SENSOR

OUTLET SENSOR (S9)

OUTLET SENSOR (S1)

FLUE SENSOR

X8-3

X8-8

X8-2

X8-4

GROUND

X6-18

X6-9

X6-17

X6-8

1

5

SMALL BLOWER

1.5A EACH MAX

X11

X4

X5-1

X5-7

X5-2

X5-8

X5-3

X5-9

X5-4

X5-10

X5-5

X5-41

X5-6

X5-12

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

HIGH VOLTAGE

LOW VOLTAGE
120 VAC

Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C.
in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same
wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables
must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems
which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper
connector block locations when using diagrams to troubleshoot unit.

USB

INTERFACE

"X5"

BLOCK WIRING

IS MODEL

DEPENDANT

L1 L2 L3

1
2

3

LADDER DIAGRAM

100273960 REV A

X8-1

CN3-4

OPTIONAL

ETHERNET CABLE

1

4

2

5

SMALL BLOWER

E

GND

WIFI

DONGLE

SW1

J2

8

43

J6

J9
J17

J23

J12

J11

LG CON BRD

J8

LCD

DISPLAY

USB CABLE

LCD

DISPLAY

J10

J7

BAS

CN6-1

CN6-3

24V

CN6-2

OPTIONAL USB/WIFI

EXTENSION CABLE

LCD

DISPLAY

3 WAY
VALVE

GROUND

OPEN SWITCH 1

CLOSE SWITCH
24 VAC

480V

TRANSFORMER

X6-4

HIGH LIMIT

SWITCH

CN1-2

X6-7

X6-16

CN1-3

Installation & Operation Manual

Figure 12-6 Ladder Diagram_5.0 Model

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Summary of Contents for PBL0502-F9

Page 1: ...ce 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 WARNING Save this manual for future reference 100275648_2000534387_Rev D ...

Page 2: ...3 2 GENERAL VENTING Venting Options 14 Install Vent and Combustion Air Piping 15 Air Inlet Pipe Materials 15 Vent and Air Piping 16 Air Intake Vent Connections 16 Min Max Combustion Air Vent Piping Lengths 17 Vent and Air Piping 18 Common Venting CAT II 18 Outdoor Venting 19 3 VERTICAL DIRECT VENTING Vent Air Termination Vertical 20 Determine Location 20 Prepare Roof Penetrations 20 Termination an...

Page 3: ...ater can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent the need for makeup water Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems When calling or ...

Page 4: ... 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 theblower gasvalve andpumpsinadditiontootherprogrammable features 16 Air intake The air intake pi...

Page 5: ...00528576 00 20 10 Front View DIR 2000528582 00 1 3 5 4 24 27 Left Side inside unit DIR 2000528590 00 4 15 21 6 22 26 23 Right Side inside unit DIR 2000528577 00 17 14 18 13 25 12 29 19 16 28 9 Rear View The Power fin How it works continued ...

Page 6: ...ments of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 3 Power fin boilers require special gas venting Use only the vent materials and methods specified in the Power fin Installation and Operation Manual 4 Standard Power fin boilers are equipped to operate from sea level to 4 500 feet only The boiler will de rate by 4...

Page 7: ...reeze protection in boiler water causing system and boiler to freeze and leak 6 The appliance must be installed on a level floor both front to back and side to side for proper condensate drainage WARNING 7 If the optional neutralizing kit is to be used elevate the boiler at least 3 above the floor 8 Check around the boiler for any potential air contaminants that could risk corrosion to the boiler ...

Page 8: ...or all other appliances located in the same space as the Power fin Failure to comply with the above warnings could result in severe personal injury death or substantial property damage 2 Size openings only on the basis of the other appliances in the space No additional air opening free area is needed for the Power fin when it takes its combustion air from outside direct vent installation WARNING R...

Page 9: ... and foundation Flooring The Power fin is approved for installation on combustible flooring but must never be installed on carpeting Vent and air piping The Power fin requires a special gas vent system designed for pressurized venting The boiler is to be used for either direct vent installation or for installation using indoor combustion air When room air is considered see page 24 of this manual N...

Page 10: ...llage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their pr...

Page 11: ...air and proper ventilation for all gas fired appliances in the equipment room to assure adequate combustion air and proper ventilation The requirements shown are for the appliance only additional gas fired appliances in the equipment room will require an increase in the net free area and or volume to supply adequate combustion air for all appliances No combustion air openings are needed when the a...

Page 12: ...uirements for combustion air Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the equipment room Each opening must have a net free area as specified in Table 1B Single openings shall commence within 12 30 cm of the ceiling The minimum dimension of air openings shall not be less than 3 80 mm CAUTION Under no circumstances sho...

Page 13: ...gs MUST NOT be of Tight Construction 3 Tight Construction is defined as a building with less than 0 40 ACH air changes per hour For buildings of Tight Construction provide air openings into the building from outside DIR 2000529297 00 AIR FILTERS LIFT AND SLIDE OUT BOTH FILTER COVER PLATES TO GAIN ACCESS TO THE AIR FILTERS Figure 1 8_Filter Access Combustion air filter Thisunithastwo 2 standardairf...

Page 14: ...ical Sidewall Direct venting Vertical Vent Sidewall Air Sidewall Vertical Optional room air 3 12 DIR 2000527727 00 DIR 2000527724 00 DIR 2000527723 00 DIR 2000527722 00 DIR 2000527728 00 2 General venting DIR 2000533996 00 Outdoor venting ...

Page 15: ...e manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance NOTICE The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air Sealing of Type B double w...

Page 16: ...ired in the air inlet piping may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death The Power fin uses model specific combustion air intake and vent piping sizes as detailed in Tables 2B and 2C on page 17 Increasing or decreasing combustion air or vent piping to sizes not specified in this manual is not authorized NOTICE...

Page 17: ...3409 2SVDSA09 2SVEE990 9901MAD CCK09TM 9890 9992 3000 3500 810003984 810003435 810003447 2SVDSA10 2SVEE1090 91001MAD CCK10TM 91090 91092 4000 810003987 810003476 810003488 2SVDSA12 2SVEE1290 91201MAD CCK12TM 91290 91292 5000 810003990 810003516 810003528 2SVDSA14 2SVEE1490 91401MAD CCK14TM 91490 91492 Model Metal Fab Security Chimney ICC Adapter Flue Intake Adapter Flue Intake Adapter Flue Intake ...

Page 18: ...led combustion You may use any of the vent air piping methods covered in this manual Do not attempt to install the Power fin using any other means NOTICE WARNING When determining equivalent combustion air and vent length add 5 feet 1 5m for each 90 elbow and 3 feet 9 m for each 45 elbow EXAMPLE 20 feet 6 m of pipe 4 90 elbows 3 45 elbows 49 equivalent feet 15 m of piping DO NOT mix components from...

Page 19: ...he vent caps specified in this manual Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors Properly install all covers doors and jacket panels to ensure proper operation and prevent a hazardous condition Units are self venting and can be used outdoors when installed with the optional outdoor kit All vent materials must be field supplied and s...

Page 20: ...ubstantial property damage Installation must comply with local requirements and with the National Fuel Gas Code NFPA 54 ANSI Z223 1 latest edition for U S installations or CSA B149 1 Installation Code for Canadian installations WARNING NOTICE WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe except as noted in Section 2 on page 18 Failure to comp...

Page 21: ... It is not classified as a forced air intake with regard to spacing from adjacent boiler vents 12 305 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM DIR 2000539525 Figure 3 3 Vertical Terminations with Multiple Boilers 12 305 MM 12 305 MM 12 305 MM 12 305 MM DIR 2000539526 Figure 3 4 Alternate Vertical Terminations with Multiple Boilers WARNING 3 The vent piping must term...

Page 22: ...th or substantial property damage Installation must comply with local requirements and with the National Fuel Gas Code NFPA 54 ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on pag...

Page 23: ...in boilers terminate each vent air connection as described in this manual FIG 4 4 WARNING 4 Sidewall direct venting continued Vent air termination sidewall 4 4 Figure 4 2 Clearance to Doors and Windows VENT TERMINATION IF LESS THAN 10 36 MIN FORCED AIR INLET AIR TERMINATION Figure 4 3 Clearance to Forced Air Inlets Prepare wall penetrations 1 Air pipe penetration a Cut a hole for the air pipe Size...

Page 24: ...R 2000539531 Figure 4 4 Multiple Vent Terminations must also comply with Figure 4 1 DIRECT VENT TERMINATIONS Air Inlet Vent Termination Dryer Inlet Straight 90 Elbow Mitered 23 Elbow Figure 4 5 Direct Vent Terminations ROOM AIR DIRECT EXHAUST TERMINATIONS Vent Termination 23 Elbow 45 Elbow 90 Elbow Figure 4 6 Room Air Direct Exhaust Terminations Room air The Power fin boiler may be installed with ...

Page 25: ...ion of the appliance and prevents condensate formation on the heat exchanger An appliance allowed to sustain operation at water temperatures lower than the specified minimum temperature may not provide enough heat from the burner to maintain water temperature in the heat exchanger above the 140 F 60 C dew point of flue products Operation of the appliance at a temperature below the specified minimu...

Page 26: ...d diaphragm type expansion tank is used The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation CAUTION The boiler system should not be operated at less than 12 PSIG Hot water piping must be supported by suitable hangers or floor stands NOT by the boiler Copper pipe systems will be subject to considerable expansion and contract...

Page 27: ...nt oil or lubricant specified by the pump manufacturer The boiler is recommended for installation in a primary secondary piping system This type of system uses a separate boiler circulating pump to supply flow to and from the boiler only The secondary pump is sized based on the head loss of the boiler and related pipe and fittings in the secondary loop only A properly sized primary system pump pro...

Page 28: ...AKEUP WATER SYSTEM HEATING SUPPLY LOOP HEATING RETURN LOOP 12 MAX OR 4 PIPE DIAMETERS 28 Installation Operation Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE 5 Water connections ...

Page 29: ...URN LOOP SYSTEM PUMP 12 MAX OR 4 PIPE DIAMETERS BOILER PUMP CHECK VALVE FROM TO INDIRECT DOMESTIC HOT WATER 29 Installation Operation Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE 5 Water connections continued ...

Page 30: ...sponsible for all equipment and detailing required by local codes NOTICE 5 Water connections COMMON MANIFOLD SIZE Min Model Number of Units 2 3 4 5 6 7 8 2500 6 7 8 8 10 10 12 3000 6 7 8 10 10 12 12 3500 7 8 9 10 10 12 12 4000 7 8 9 10 12 12 14 5000 7 8 9 10 12 12 14 DIR 2000528661 00 MAKEUP WATER SYSTEM TO SYSTEM COMMON MANIFOLD CAP EACH MANIFOLD TO FLOOR DRAIN 12 MAX OR 4 PIPE DIAMETERS ...

Page 31: ...oop DIR 2000527835 00 TO FLOOR DRAIN TO EXPANSION TANK AND MAKEUP WATER SYSTEM HEATING SUPPLY LOOP HEATING RETURN LOOP MIXING VALVE 12 MAX OR 4 PIPE DIAMETERS 31 5 Water connections continued Installation Operation Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE ...

Page 32: ...l location on the side of the tank for pictorial purposes The standard location for the system tappings is 180 from the recirculation tappings 5 Water connections 32 Installation Operation Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE COMMON MANIFOLD SIZE Min Model...

Page 33: ...er is not generally recommended because most piping methods allow the three way valve to vary flow to the boiler This boiler is a low mass high efficiency appliance which requires a constant water flow rate for proper operation Low flow rates can result in overheating of the boiler water which can cause short burner cycles system noise relief valve discharge and in extreme cases a knocking flash t...

Page 34: ...al type temperature pressure gauge This gauge is factory installed in the outlet side of the boiler piping The gauge has one scale to read system pressure and a separate scale to read water temperature in degrees Fahrenheit The temperature pressure gauge is provided to meet code requirements Water temperatures can be more accurately monitored from the data provided in the digital display in the Op...

Page 35: ...gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment NOTICE WARNING Ensure that the high gas pressure regulator is at least 10 feet 3 m upstream of the appliance 3 Purge all air from the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a The appliance must be disconnected from the g...

Page 36: ...r or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage WARNING Check inlet gas supply 6 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 7 Observe the gas supply pressure as the burner fires ...

Page 37: ...standby static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet 3 m from the Power fin boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure Ignition problems are especially noticeable in NEW LP install...

Page 38: ...clad cable 3 The circulating pump must run continuously when the appliance is being fired 4 To avoid serious damage DO NOT energize the appliance until the system is full of water Ensure that all air is removed from the heat exchanger and piping before beginning initial operation Serious damage may result if the appliance is operated without proper flow 5 Provide the appliance with proper overload...

Page 39: ... be switched on and off by making or breaking a 24 VAC control circuit Remove the factory jumper between the enable terminals on the low voltage connection board and connect the remote temperature control in its place see FIG 7 4 on page 41 DIR 2000529363 00 REMOTE ON OFF WIRE CONNECTION Ensure that all wiring used to connect the switching contacts of the remote temperature controller to the conne...

Page 40: ...signal a Building Management System that the boiler is down Wiring of the cascade When wiring the heaters for Cascade operation select one heater as the Leader heater The remaining heaters will be designated as Members See page 49 Configuration of the Cascade for a detailed explanation of this procedure On boilers connect the system supply sensor and outdoor air sensor if used to the Leader boiler...

Page 41: ...DIR 2000534157 00 GROUND 3 WAY VALVE BOILER ONLY Figure 7 4_Low Voltage Field Wiring Connections 41 7 Electrical connections continued Installation Operation Manual ...

Page 42: ... off if the condensate trap becomes too full of liquid 8 Remove the four 4 screws securing the top cover to the condensate trap and remove the cover FIG 8 1 9 Locate the plastic ball inside the float tube Verify there is nothing under the ball causing it to not seat properly FIG 8 1 10 Replace the cover 11 Replace the four 4 screws removed in Step 8 12 A 1 2 pipe connection is supplied on the cond...

Page 43: ... mix in some potable water at the inlet to increase the hardness of the water to above 5 grains gallons pH between 6 5 and 9 5 1 pH levels below 6 5 can cause an increase in the rate of corrosion pH of 9 5 or higher can potentially cause lime scale buildup Total Dissolved Solids TDS below 2 000 ppm 1 Total dissolved solids are all minerals salts metals and charged particles that are dissolved in w...

Page 44: ...hese two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked...

Page 45: ...as spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler for gas odor following the procedure on page 35 of this manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until c...

Page 46: ... Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatica...

Page 47: ...hanges to be reprogrammed Set space heating operation Verify space heat circulator mode The system pump output can be programmed to never run OFF run only when a space heating demand is present ON or run continuously except during warm weather shutdown WWSD If the boiler is not heating an indirect HW Hot Water Generator tank it also turns on the boiler pump After the space heating call for heat en...

Page 48: ...y temperature to a set point This set point is set at the factory to 180 F If a different set point is desired the appropriate parameter in the control must be changed See the Power fin Service Manual for a detailed explanation of this procedure Set maximum HW fan speed If the rated input of the indirect tank is less than the maximum output of the boiler change the maximum HW fan speed setting to ...

Page 49: ...cascade operation Access the Cascade Setup options as follows 1 Press the SETUP button on the top of the display screen 2 Enter the installer password 3 Scroll through the scrolling menu feature to access the Cascade option as shown in FIG 9 6 4 Press the CASCADE button 5 Once all the updates are complete press the SEND UPDATE button at the top of the screen FIG 9 6 to save changes Note The SEND U...

Page 50: ...n a tank sensor is connected the HW thermostat input is ignored When a boiler is programmed for HW Normal Mode the maximum firing rate can be limited to match the input rating of the indirect tank coil HW space heating SH cycling If a HW call for heat is received while a space heating call is in progress and the HW is in Normal Mode the control will start the HW pump and shut the boiler pump off T...

Page 51: ... This output may be connected to a Building Management System BMS to allow it to monitor the actual firing rate Connect the terminal to the COM or terminal on the BMS and connect the terminal to the 0 10V or terminal on the BMS Ramp Delay For systems with lower flow the SMART TOUCH can limit the firing rate when enabled when a space heating call for heat starts or when switching from a DHW call fo...

Page 52: ...s not installed Target temperature is calculated as described under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations The Power fin SMART TOUCH control has two 2 integral limits one auto reset and one manual reset The Power fin also has one auxiliary manual reset high limit The integral and auxiliary high limits are UL353 certified When...

Page 53: ...boilers at a time as possible This method will not bring on another boiler until the current number of boilers cannot meet the demand The parameters for both types of Cascade are adjustable Reference the Power fin Service Manual for a more detailed description of these adjustments Sequence of the cascade To equalize the run time of all boilers on the Cascade the firing sequence will automatically ...

Page 54: ...ode 7 If the control does not detect flame current the control will lockout indefinitely until the RESET button on the touch screen LCD is pressed 8 If the control detects flame current the control will hold the blower speed constant for a few seconds to allow the flame to stabilize then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperatu...

Page 55: ...the screen and displays how the unit is currently running i e Off Stand by Blocking and Lockout including the Power Button current driving demand i e Space Heat or Hot Water the next Space Heat or Hot Water Setback scheduled the reason for any blocking or lockout and the current set point temperature with a button that allows you to change the set points The Navigation Section is located across th...

Page 56: ...and performance verification per Section 9 Flame inspection stable uniform Check both flame signals at least 10 microamps at high fire Clean the heat exchanger Test low water cutoff reference the Power fin Service Manual If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheels ANNUAL START UP Owner maintenance see the...

Page 57: ...ondensate drain line vent line condensate PVC fittings and condensate trap Flush condensate trap with water 1 Remove the four 4 screws securing the top cover to the condensate trap and remove the cover FIG 11 1 2 Locate the plastic ball inside the float tube Verify there is nothing under the ball causing it to not seat properly 3 Replace the top cover and the screws removed in Step 1 Eliminate all...

Page 58: ...be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed 2 After following the a...

Page 59: ...ate supply of combustion and ventilation air Check all wiring 1 Inspect all wiring making sure wires are in good condition and securely attached Check control settings 1 Set the SMART TOUCH control module display to Parameter Mode and check all settings See Section 1 of the Power fin Service Manual Adjust settings if necessary See Section 1 of the Power fin Service Manual for adjustment procedures...

Page 60: ...he burner Use extreme care when operating an appliance for temporary heat during new construction Airborne contaminants such as dust dirt concrete dust or drywall dust can be drawn into the burner with the combustion air and block the burner port area External combustion air filters are provided with the appliance These filters help ensure clean air is used for the combustion process Check filters...

Page 61: ...cation of the Heat Exchanger Inside Jacket Inspect and clean the heat exchanger 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 front inner jacket panel see FIG 11 4 5 Check the heat exchanger surface for soot If soot is present the heat exchanger must be cleaned and the problem corrected 6 Remove the burner as described in ...

Page 62: ...HIELD A B BAS OPTION RATE OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR 0 10V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE OR OR BK BK L B T R T BK Y R B HIGH LIMIT SWITCH R X6 1 X6 2 X6 3 Y G R R P BAS BOARD Y G R O W L B PK R P R BL W GY Y R W BL J3 5 J3 4 J3 6 LWCO BOARD J3 3 J3 2 J2 1 J2 2 X6 3 R O K B R O K B R O TEST SWITCH LWCO PROBE R O R O LWCO RE...

Page 63: ...B R O K B R O TEST SWITCH LWCO PROBE R O R O LWCO RESET X6 5 GPS1 GPS2 R P PR X6 12 BLOCKED FLUE T X6 6 BLOCKED DRAIN SWITCH K B X8 3 X8 8 X8 2 X8 4 INLET SENSOR OUTLET SENSOR S9 OUTLET SENSOR S1 FLUE SENSOR X4 1 X4 2 X4 3 X8 20 X8 10 X5 8 X5 7 X5 3 X5 9 X5 2 X5 4 X5 10 X5 5 X5 41 X5 6 X5 12 X5 1 X5 BLOCK WIRING IS MODEL DEPENDANT PK BN PR R X10 1 X1 3 X10 4 X1 1 X1 12 X1 2 X1 4 X10 2 X10 5 X1 6 O...

Page 64: ...TEST SWITCH LWCO PROBE R O R O LWCO RESET X6 5 GPS1 GPS2 R P PR X6 12 BLOCKED FLUE T X6 6 BLOCKED DRAIN SWITCH K B X8 3 X8 8 X8 2 X8 4 INLET SENSOR OUTLET SENSOR S9 OUTLET SENSOR S1 FLUE SENSOR X4 1 X4 2 X4 3 X8 20 X8 10 X5 8 X5 7 X5 3 X5 9 X5 2 X5 4 X5 10 X5 5 X5 41 X5 6 X5 12 X5 1 X5 BLOCK WIRING IS MODEL DEPENDANT PK BN PR R X10 1 X1 3 X10 4 X1 1 X1 12 X1 2 X1 4 X10 2 X10 5 X1 6 ON OFF SWITCH G...

Page 65: ...X11 X4 X5 1 X5 7 X5 2 X5 8 X5 3 X5 9 X5 4 X5 10 X5 5 X5 41 X5 6 X5 12 BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING HIGH VOLTAGE LOW VOLTAGE 120 VAC Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replac...

Page 66: ... 1 X5 7 X5 2 X5 8 X5 3 X5 9 X5 4 X5 10 X5 5 X5 41 X5 6 X5 12 BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING HIGH VOLTAGE LOW VOLTAGE 120 VAC Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it mus...

Page 67: ...TROL X8 5 X8 15 X8 11 X8 6 X8 16 X8 7 X8 17 X8 18 T T T T INLET SENSOR OUTLET SENSOR S9 OUTLET SENSOR S1 FLUE SENSOR X8 3 X8 8 X8 2 X8 4 GROUND X6 18 X6 9 X6 17 X6 8 1 5 SMALL BLOWER 1 5A EACH MAX X11 X4 X5 1 X5 7 X5 2 X5 8 X5 3 X5 9 X5 4 X5 10 X5 5 X5 41 X5 6 X5 12 BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING HIGH VOLTAGE LOW VOLTAGE 120 VAC Notes 1 All wiring must be install...

Page 68: ...its 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 MM 100275648_DIR 2000534387 Rev D 06 17 Printed in U S A ...

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