2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Contents
HAZARD DEFINITIONS
.................................................... 2
PLEASE READ BEFORE PROCEEDING
........................ 3
THE POWER-FIN -- HOW IT WORKS
........................... 4-5
RATINGS
........................................................................... 6
1. DETERMINE BOILER LOCATION
Outdoor Boiler Installation ................................................... 7
Clearances ......................................................................... 8
Provide Air Openings to Room .......................................... 8
Flooring and Foundation ................................................... 9
Vent and Air Piping ............................................................ 9
Prevent Combustion Air Contamination ............................. 9
Using an Existing Vent System to Install a New Boiler ..... 9
Corrosive Contaminants and Sources ............................. 10
Removing a Boiler from Existing Common Vent .............. 10
Remove Boiler from Wood Pallet ..................................... 11
Combustion and Ventilation Air Requirements ........... 11-13
Combustion Air Filter ......................................................... 13
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 and Fittings ........................................ 20-21
Multiple Vent/Air Terminations .................................... 21
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall ................................... 22-24
Determine Location ................................................ 22-24
Prepare Wall Penetrations .......................................... 23
Termination and Fittings ............................................. 23
Multiple Vent/Air Terminations ............................... 23-24
Room Air ..................................................................... 24
5. WATER CONNECTIONS
Inlet and Outlet Connections ............................................ 25
Heat Exchanger ............................................................... 25
Minimum Water Temperatures ......................................... 25
Water Flow Switch ........................................................... 26
Low Water Cutoff ............................................................. 26
Relief Valve ...................................................................... 26
Heating Boiler Installations .......................................... 26-34
6. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................ 35
Natural Gas ...................................................................... 35
Pipe Sizing for Natural Gas ........................................ 35
Natural Gas Supply Pressure Requirements ............. 35
Propane Gas .................................................................... 36
Pipe Sizing for Propane Gas ...................................... 36
Propane Supply Pressure Requirements ................... 36
Check Inlet Gas Supply ................................................... 36
Gas Pressure ................................................................... 37
Gas Valve Replacement .................................................. 37
7. FIELD WIRING
Boiler Operating Control Module ....................................... 38
Line Voltage Connections ................................................ 38
Low Voltage Connections ................................................ 39
Wiring of the Cascade ...................................................... 40
8. CONDENSATE DISPOSAL
Condensate Trap Installation ........................................... 42
9. STARTUP
............................................................... 43-47
10. OPERATING INFORMATION
Set Hot Water Generator (HW) Operation ........................ 48
Configuration of the Cascade ..................................... 49
General .........................................................................50-52
Cascade ........................................................................... 53
Sequence of Operation .................................................... 54
Home Screen ................................................................... 55
11. MAINTENANCE
Maintenance & Annual Startup .............................. 56-61
12. DIAGRAMS
Wiring Diagrams ................................................. 62-64
Ladder Diagrams .................................................65-67
Revision Notes .................................................. Back Cover