power fin designers guide

7/29/2019 Power Fin Designers Guide

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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

www.Loch invar .com

D E S I G N E R S G U I D E P O W E R - F I N W A T E R H E A T E R

Up to 87%Thermal Efficiency


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Dear Design-Build Contractor / Project Manager / Design Engineer,At Lochinvar, we have long recognized the importance of innovation to anyproduct or service. Those who share in this business also face the challengeof meeting constantly changing needs and energy effi ciency demands.

The designers guide you are now holding has been designed to make it moreconvenient for you to select the perfect Lochinvar boiler for your projectsand provide correct specifi cations for your teams.

All information has been organized and presented in a succinct, easy-to-usemanner, so you can use and share information confi dently and with minimaleffort.

However, it is important to remember that this guide is not intended toreplace our installation manual. Installers should refer to our installationmanual for specifi c installation instructions and more detail. This guide willmake regular reference to other documents like the Installation & OperationManual that are available on the Lochinvar website,www.Lochinvar.com.

We hope this manual will make your work easier and more productive.Thanks again for specifying the Lochinvar family of quality standard andcustom-built water heaters and boilers.

Sincerely,


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LOCHINVAR CORPORATION300 MADDOX SIMPSON PKWYLEBANON, TN 37090www.lochinvar.com

Designers Guide/ Power-fin Water Heater

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Table of Contents

Combustion Air .... Page 5

Venting ... Page 8

Gas .... Page 21

Water ...... Page 23

Electricity & Controls ... Page 29

Other Details .... Page 33

Appendix A .... Page 36

Appendix B Page 41

.


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At Lochinvar, we know that designing a water heater is hard work. Designing a domesticwater heating system is no picnic either. Demands for greater efficiency and elaborate

system control have made systems more complex.

This designers guide will break down the system requirements that match the Power-finwater heater to assure safe operation, highly efficient heating and long life.

There are five major elements of domestic water heating system

design:

Combustion Air(See page 5)

Venting(See page 8)

Gas(See page 21)

Water(See page 23)

Electricity& Controls(See page 29)

Plus many other important details:

Locations Available Options(See page 34 for Location of Unit) (See page 35 for Options)

High Altitude Requirements Suggested Piping Diagram(See page 35 for High Altitude Applications) (See Appendix Section A)

GasWater

Electricity

& Controls

Air

Venting


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Chapter 1 Combustion and

Ventilation AirEverybodys gotta breathe. Even water heaters need air. Air seems easy enough. You stand inthe equipment room and you breathe comfortably, dont you? Open a door. Open a window.This is a big room. Theres lots of air in here for the water heater.

The average person inhales 400 to 500 cubic feet of air in a 24 hour period. A one million Btu/hrwater heater will draw 226.38 cubic feet of air every MINUTE! A 20 by 20 by 8 foot equipmentroom holds 3200 cubic feet of air. Thats a volume of air to last you or me over six days. A onemillion Btu/hr Power-fin will consume 3200 cubic feet of air in 14 minutes.

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 water heater. The Power-fin

water heater is designed to receive combustion air by one of TWO methods. The water heatermay draw combustion air from the room or have the air ducted directly to the water heater froman exterior space.

This chapterexplains the methods for air from the room.Chapter 2 explains air ducted directly to the waterheater. Again, this chapterlists several techniques tosize the air openings that will deliver room air. If there areother appliances in the room requiring air, their airrequirements must be including when sizing the airopenings.

Provisions for combustion and ventilation air must bedesigned and installed in accordance with Air forCombustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, (inCanada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliancesand Equipment) or applicable provisions of the local building codes.

NEGATIVE PRESSURE IN THE EQUIPMENT ROOMIt is important to NEVER have a negative pressure on the equipment room. Exhaust fans arepopular in equipment rooms to exchange the air. If the exhaust fan pulls air OUT, then a negativepressure occurs in the room. The combustion and ventilation air must be sized to supply all theequipment PLUS the air for the exhaust fan.

COMBUSTION AND VENTILATION AIR SIZING CALCULATIONSThe sizing calculations in this section are based on Free Area. The louvers or grill used on theair openings must have a net free area equal to or greater than the value derived in the

calculations. The Free Area in a louver or grill is defined as the open, unblocked area. Thelouvers, grills, mesh, blades, all will block a given amount of space in the louvers overalldimension. Consult the louver manufacturer for exact net free area of the louver.

Air


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1. COMBUSTION AIR FROM OUTSIDE

If air is taken directly from outside the building with noduct, provide two permanent openings to theequipment room:(a) Combustion air opening, with a minimum free areaof one square inch per 4000 Btu/hr input (5.5 cmperkW). This opening must be located within 12" (30 cm)of the bottom of the enclosure.(b) Ventilation air opening, with a minimum free area ofone square inch per 4000 Btu/hr input (5.5 cmperkW). This opening must be located within 12" (30 cm)of the top of the enclosure.

2. COMBUSTION AIR THROUGH DUCTS

If combustion and ventilation air is taken from the outdoors using

a duct to deliver the air to the equipment room, each of the twoopenings should be sized based on a minimum free area of onesquare inch per 2000 Btu/hr (11 cmper kW) of input.

3. COMBUSTION AIR FROM INTERIORSPACEIf air is taken from another interior space,each of the two openings specified aboveshould have a net free area of one squareinch for each 1000 Btu/hr (22 cmper kW) ofinput, but not less than 100 square inches(645 cm).

THE POWER-FIN COMES WITH LOUVER CONTACTS AS STANDARD EQUIPMENT. THE CONTACTS

WILL OPEN AND CLOSE A MOTORIZED LOUVER ON EACH CALL FOR HEAT.

Did ou Know?


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4. DIRECT OUTSIDE AIR, SINGLE OPENING

If a single combustion air opening is provided to bringcombustion air in directly from the outdoors, the openingmust be sized based on a minimum free area of onesquare inch per 3000 Btu/hr (7 cmper kW). This openingmust be located within 12" (30 cm) of the top of theenclosure.

COMBUSTION AIR FILTER

The Power-fin has a built-in air filter as standardequipment. Located at the combustion air inlet, the airfilter is provided to help ensure clean air is used for thecombustion process.

The filter size on models 502-1302 is 16" x 12" x 1"(40.6 cm x 30.4 cm x 2.5 cm) and on models 1501 -2001 is 16" x 16" x 1" (40.6 cm x 40.6 cm x 2.5 cm).You can find these commercially available filters at anyhome center or plumbing supply store.

THE COMBUSTION AIR MUST BE FREE OF ANY CONTAMINANTS OR CHEMICAL FUMES. SALTS,

REFRIGERANTS AND SOLVENTS INTRODUCED INTO THE COMBUSTION PROCESS WILL RESULT IN

THE FORMATION OF CORROSIVE ACIDS THAT WILL DAMAGE THE APPLIANCE AND THE VENT.

Caution


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Chapter 2 VentingVenting is a difficult design element for the installation of a gas fired appliance. It has a variety ofchoices, it has several available vent configurations, it has the important rules and regulations

that govern the installation and most important of all, it bears a requirement for human safety.

Lochinvar offers twelve different vent configurations on the Power-fin water heater to meet thebuildings requirements. There are six layouts or footprints across three different vent categories.They areVertical Vent with Air from the Equipment Room Category I, Category II or Category IVVertical Vent with Air from the Rooftop Category I, Category II or Category IV

Vertical Vent with Air from the Sidewall Category I, Category II or Category IVSidewall Vent with Air from the Equipment Room Category IV onlySidewall Vent with Air from the Rooftop Category IV onlySidewall Vent with Air from the Sidewall Category IV only

Thats a lot of choices. Plus there is an importantnew consideration about specifying the correctFiring Code. Allow me to overexplain.

Part 1

Vent Categories

Here is the traditional vent category diagram, standard throughout the industry. Lochinvar offerstwelve 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 water heater will be factory trimmed for direct connection either Category I or Category IVventing. Part 2 explains Firing Codes and their relationship to Category I and Category IV.Well explain Category II later.

CATEGORY I

Non-Condensing

Non-Positive Pressure

CATEGORY III

Non-Condensing

Positive Pressure

CATEGORY II

Condensing


CATEGORY IV

Condensing

Positive Pressure

SPILLAGE OF FLUE PRODUCTS AND CARBON MONOXIDE EMISSIONS PRODUCED BY THE

COMBUSTION PROCESS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

Warning

Venting


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The four basic Vent Categories are determined by two characterisitics, Condensation andPressure.

CONDENSING VERSUS NON-CONDENSINGThe possibility for condensation to form in a stack is based on the temperature of the flueproducts. If the temperature of the flue products remains consistantly above dewpoint,condensation will not form. If the temperature drops below dewpoint, condensation will form.

So how does condensation apply to the Power-fin? Easy. The Power-fins firing rate determinesthe stack temperature. Depending upon the model, the Power-fin may operate at a high firingrate producing a high stack temperature to stay above dewpoint or it may modulate down to a lowfiring rate producing a low stack temperature that allows the flue gas temperature to drop belowdewpoint. This is explained further in Part 2, Firing Code.

POSITIVE VERSUS NON-POSITIVEPositive or non-positive pressure in the vent is determined by the capacity of the appliancesblower AND the diameter of the vent in order to PUSH the flue products. If the same appliance is

connected to a larger diameter stack, the blower CANNOT PUSH the flue products. The positivepressure goes negative, or non-positive.

So how does pressure apply to the Power-fin? Again, easy. Depending upon the model, thePower-fin will be factory trimmed for a small vent connection to positive vent or a large ventconnection to non-positive vent. This is explained further in Part 2, Firing Code.

Part 2

Firing Codes

The model number for all Lochinvar products has a Firing Code.

Example: PFN0752PM-M9

PFN0752PM is the basic model number / -M9 is the Firing Code.

This collection of letters and numbers has a specific meaning. The Firing Code is importantbecause it specifies a particular feature set that is factory trimmed to match the planned ventingsystem. With the correct firing code, Lochinvar will factory trim your water heater to fire at correctinput rate and provide the correct vent connection to meet your needs.

There are THREE basic firing codes. Heres how they work.

F9 models / Power-fin 0502-1302 onlyF9 means Full Fire or 100% Full Fire with no modulation. (No Turndown)Temperature Firing at 100% of input rate, the Power-fin 0502-1302-F9 models will alwaysproduce a high stack temperature. Non-Condensing.

Pressure The Power-fin 0502-1302-F9 models are factory trimmed with a large diameter ventconnection. The blower CANNOT PUSH the flue products through a similarly sized stacktherefore creating a non-positive pressure. Non-Positive Pressure.F9 models are Category I.

B9 models / Power-fin 1501-2001 onlyB9 means Bi-level Fire or 50% to 100% firing rate. (2:1 Turndown)Temperature Even firing at the lowest input rate of 50%, the Power-fin 1501-2001-B9 modelswill produce a high stack temperature. Non-Condensing.


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PressureThe Power-fin 1501-2001-B9 models are factory trimmed with a large diameter ventconnection. The blower CANNOT PUSH the flue products through a similarly sized stacktherefore creating a non-positive pressure. Non-Positive Pressure.B9 models are Category I.

M9 models / Power-fin 0502-2001M9 means Modulating Fire or 20% to 100% firing rate. (5:1 Turndown) Temperature When the Power-fin 0502-2001-M9 models modulate down to their lowest inputrate of 20%, they produce a comparatively low stack temperature that will likely causecondensation to occur in the stack. Condensing.Pressure The Power-fin 0502-2001-M9 models are factory trimmed with a small diameter ventconnection. The blower CAN PUSH the flue products through a similarly sized stack thereforecreating a positive pressure. Positive Pressure.M9 models are Category IV.

Part 3

Choose your vent configuration

Now, that you know your vent category and the matching Firing Code , its time to choose the ventconfiguration or system layout. Lets start with Category IV venting.

Category IV Venting

This is likely to be the most common because it offers modulation and it offers the largest varietyof vent configurations. All six layouts listed on page eight can be installed as Category IV

venting. The following pages offer a diagram of the six layouts, important design information anda list of the available vent kits that are required to install some of these configurations.

Vertical Vent with Air from the Equipment Room Category IVVertical Vent with Air from the Rooftop Category IVVertical Vent with Air from the Sidewall Category IVSidewall Vent with Air from the Equipment Room Category IV onlySidewall Vent with Air from the Rooftop Category IV onlySidewall Vent with Air from the Sidewall Category IV only

CATEGORY I

Non-Condensing


F9 or B9 Models

CATEGORY III

CATEGORY IICATEGORY IV

Condensing

Positive Pressure

M9 Models


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CATEGORY IV VENTING M9 FIRING CODEVERTICAL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM.The flue outlet terminates on the rooftop. The combustion air is drawnnaturally from the equipment room.

BULLET POINTS

Category IV vent material is required, such asAL29-4C.

All vent joints and seams must be sealed gastightand may not be common vented.

The vent must have a condensate drain withprovisions to properly collect and dispose of anycondensate that may occur in the vent pipe.

All vent material for this configuration includingvent termination will be obtained locally.

The air is delivered to the equipment room bymeans defined in Chapter 1 of this designersguide.

Maximum distance 50 equivalent feet of vent.

The Category IV Power-fin with a model number that features the M9 (Modulating Fire) FiringCode will be factory trimmed for Category IV vent connection in the following dimensions.

MODEL CAT IV VENT CONNECTION

PFN0502PM-M9 4"

PFN0752PM-M9 5"PFN1002PM-M9 6"

PFN1302PM-M9 8"

PFN1501PM-M9 6"

PFN1701PM-M9 7"

PFN2001PM-M9 8"

THIS CONFIGURATION MAY BE INSTALLED AS CATEGORY II. SEE PAGE 17 FOR DETAILS.

Ti


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CATEGORY IV VENTING M9 FIRING CODEVERTICAL VENT WITH COMBUSTION AIR FROM THE ROOFTOP.The flue outlet terminates on the rooftop. The combustion air is ducted tothe appliance from outdoors through the rooftop. This is true Direct Ventwith the flue termination and the air inlet port in the same pressure zone.

BULLET POINTS




All other vent material for this configuration

Including vent termination will be obtained locally.The air is delivered to the appliance via a separateduct. The air intake material can be galvanizedpipe, PVC, CPVC or ABS and must be sealedairtight.


Maximum distance 50 equivalent feet of air intake.

The Category IV Power-fin with a model number that features the M9 (Modulating Fire) FiringCode will be factory trimmed for Category IV vent and air inlet connections in the followingdimensions.

MODEL CAT IV VENT CONNECTION AIR INLET CONNECTION

PFN0502PM-M9 4" 5"

PFN0752PM-M9 5" 5"

PFN1002PM-M9 6" 6"

PFN1302PM-M9 8" 6"

PFN1501PM-M9 6" 6"

PFN1701PM-M9 7" 7"

PFN2001PM-M9 8" 8"


Ti


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CATEGORY IV VENTING M9 FIRING CODEVERTICAL VENT WITH COMBUSTION AIR FROM THE SIDEWALL(DirectAire).The flue outlet terminates on the rooftop. The combustion air is ducted tothe appliance from outdoors through the sidewall. This is not true DirectVent with the flue termination and the air inlet port in different pressurezones.

BULLET POINTS




The sidewall exhaust cap must be provided byLochinvar. See table below for kit part numbers.All other vent material for this configuration will beobtained locally.

The air is delivered to the appliance via a separateduct. The air intake material can be galvanizedpipe, PVC, CPVC or ABS and must be sealedairtight.


Maximum distance 50 equivalent feet of airintake.

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 followingdimensions. The table also includes the kit part numbers for the sidewall exhaust caps whichmust be used.

MODEL CAT IV VENT CONNECTION AIR INLET CONNECTION SAK KIT NUMBER

PFN0502PM-M9 4" 5" SAK3003

PFN0752PM-M9 5" 5" SAK3003

PFN1002PM-M9 6" 6" SAK3004

PFN1302PM-M9 8" 6" SAK3004

PFN1501PM-M9 6" 6" SAK3004

PFN1701PM-M9 7" 7" SAK3005

PFN2001PM-M9 8" 8" SAK3006

The main component in Sidewall Air Intake Kit is the Sidewall Air Intake Cap.


Ti


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CATEGORY IV VENTING M9 FIRING CODESIDEWALL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM.The flue outlet terminates out the sidewall. The combustion air is drawnnaturally from the equipment room.

BULLET POINTS



The vent must have a condensate drainwith provisions to properly collect and dispose ofany condensate that may occur in the vent pipe.

The sidewall exhaust cap must beprovided by Lochinvar. See table below for kit part

numbers. All other vent material for thisconfiguration will be obtained locally.

The air is delivered to the equipment room bymeans defined in Chapter 1 of this designersguide.

Maximum distance - 50 equivalent feet of vent.

The Category IV Power-fin with a model number that features the M9 (Modulating Fire) FiringCode will be factory trimmed for Category IV vent connection in the following dimensions. Thetable also includes the kit part numbers for the sidewall exhaust caps which must be used.

MODEL CAT IV VENT CONNECTION SVK KIT NUMBER

PFN0502PM-M9 4" SVK3069

PFN0752PM-M9 5" SVK3070PFN1002PM-M9 6" SVK3018

PFN1302PM-M9 8" SVK3068

PFN1501PM-M9 6" SVK3018

PFN1701PM-M9 7" SVK3019

PFN2001PM-M9 8" SVK3068

The main component in Sidewall Vent Kit is the Sidewall Exhaust Cap.


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CATEGORY IV VENTING M9 FIRING CODESIDEWALL VENT WITH COMBUSTION AIR FROM THE ROOFTOP(DirectAire).The flue outlet terminates out the sidewall. The combustion air is ductedto the appliance from outdoors through the rooftop. This is not true DirectVent with the flue termination and the air inlet port in different pressurezones.

BULLET POINTS



The vent must have a condensate drain withprovisions to properly collect and dispose ofany condensate that may occur in the vent pipe.

The sidewall exhaust cap must be provided byLochinvar. See table below for kit part numbers.All other vent material for this configuration will beobtained locally.

The air is delivered to the appliance via a separateduct. The air intake material can be galvanizedpipe, PVC, CPVC or ABS and must be sealedairtight.


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 followingdimensions. The table also includes the kit part numbers for the sidewall exhaust caps whichmust be used.

MODEL CAT IV VENT CONNECTION AIR INLET CONNECTION SVK KIT NUMBER

PFN0502PM-M9 4" 5" SVK3069

PFN0752PM-M9 5" 5" SVK3070

PFN1002PM-M9 6" 6" SVK3018

PFN1302PM-M9 8" 6" SVK3068

PFN1501PM-M9 6" 6" SVK3018

PFN1701PM-M9 7" 7" SVK3019

PFN2001PM-M9 8" 8" SVK3068

The main component in Sidewall Vent Kit is the Sidewall Exhaust Cap.


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CATEGORY IV VENTING M9 FIRING CODESIDEWALL VENT WITH COMBUSTION AIR FROM THE SIDEWALL.The flue outlet terminates out the sidewall. The combustion air is ductedto the appliance from outdoors through the sidewall. This is true DirectVent with the flue termination and the air inlet port in the same pressurezone.

BULLET POINTS




The sidewall exhaust cap and the sidewall airintake cap must be provided by Lochinvar. Seetable below for kit part numbers. All other ventmaterial for this configuration will be obtainedlocally.

The air is delivered to the appliance via a separateduct. The air intake material can be galvanizedsteel pipe, PVC, CPVC or ABS and must be sealedairtight.



The Category IV Power-fin with a model number that features the M9 (Modulating Fire) FiringCode will be factory trimmed for Category IV vent and air inlet connections in the followingdimensions. The table also includes the kit part numbers for the sidewall exhaust caps and airintake caps which must be used.

MODEL CAT IV VENT CONNECTION AIR INLET CONNECTION HDK KIT NUMBER

PFN0502PM-M9 4" 5" HDK3052

PFN0752PM-M9 5" 5" HDK3053

PFN1002PM-M9 6" 6" HDK3049

PFN1302PM-M9 8" 6" HDK3054

PFN1501PM-M9 6" 6" HDK3049

PFN1701PM-M9 7" 7" HDK3050

PFN2001PM-M9 8" 8" HDK3051

The main components in the Horizontal Direct Vent Kit are the Sidewall Exhaust Cap and theSidewall Air Intake Cap.


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Final note about Category IVRetrofit of an original design Power-fin installed with Concentric KitIf your job is a retrofit of a Power-fin 0250-1000 built to the original design, heres a little tip. If thePFN0250PM-F9, PFN0500PM-F9, PFN0750PM-F9 or PFN1000PM-F9 is installed with a

concentric vent kit, it is installed as a Category IV appliance. The F9 firing code on the originalPower-fin is not 100% equal to the F9 firing code on the new Power-Fin. An original Power-fininstalled with concentric vent more closely matches the M9 models. Therefore, when specifyingthe new replacement, remember to check the type of vent system currently installed.

Category II Venting

An important detail in the Category IV section is Category IV venting MAY NOT be commonvented. Category IV is positive pressure stack and you cannot combine positive pressure stacks.This is where switching to Category II can be useful.

We take the standard Power-fin M9 Firing Code with its lowBtu/hr input and low stack temperature and we increase the stack

diameter. That changes the stack pressure from positive to non-positive. Plus the stack will remain a condensing stack becauseof the potential for low Btu/hr input and corresponding low stacktemperature. This changes the vent Category from IV to II.

Of the six layouts listed on page 8, three can be installed asCategory II venting. Notice that only vertical termination ispermissible with Category II venting.

Vertical Vent with Air from the Equipment Room Category IIVertical Vent with Air from the Rooftop Category IIVertical Vent with Air from the Sidewall Category II

There are three important considerations when specifying Category II venting.1. The Power-fin MUST be M9 Firing Code. The appliance willhave modulating fire and a Category IV vent connection.

2. A special vent adapter MUST be specified to convert theappliance from Category IV vent diameters to Category IIvent diameters. The increase in vent diameter is crucial tochange from Category IV positive pressure to Category IInon-positive pressure.

3. The combined vent MUST be properly sized for thecombined appliances.

The Category II kits are as follows:

MODEL VENT CONNECTION INCREASER KIT NUMBER

PFN0502PM-M9 4" to 7 KIT3131

PFN0752PM-M9 5" to 9 KIT3132

PFN1002PM-M9 6" to 10 KIT3133

PFN1302PM-M9 8" to 12 KIT3134

PFN1501PM-M9 6" to 8 KIT3106

PFN1701PM-M9 7" to 9 KIT3107

PFN2001PM-M9 8" to 10 KIT3108

CATEGORY I

Non-Condensing


F9 or B9 Models

CATEGORY III

CATEGORY II

Condensing


M9 w/ Vent Increaser

CATEGORY IV

Condensing

Positive Pressure

M9 Models


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Category I Venting

Of the six layouts listed on page 8, three can be installed as Category I venting. The followingoffers a diagram of the three layouts, important design information and a list of the available ventkits that are required to install in these configurations. Notice that only vertical termination ispermissible with Category I venting.

Vertical Vent with Air from the Equipment Room Category IVertical Vent with Air from the Rooftop Category IVertical Vent with Air from the Sidewall Category I

CATEGORY I VENTING F9 OR B9FIRING CODEVERTICAL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM.The flue outlet terminates on the rooftop. The combustion air is drawnnaturally from the equipment room.

BULLET POINTS

Category I double wall B vent is required.

All vent material for this configuration including vent termination will be obtained locally.

The air is delivered to the equipment room by means defined in Chapter 1.

A field supplied barometric damper is optional on Power-fin 0502-1302-F9.

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 befactory trimmed for Category I vent connection in the following dimensions.

MODEL CAT I VENT CONNNECTIONPFN0502PM-F9 7"

PFN0752PM-F9 9"

PFN1002PM-F9 10"

PFN1302PM-F9 12"

PFN1501PM-B9 12"

PFN1701PM-B9 14"

PFN2001PM-B9 14"


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CATEGORY I VENTING F9 OR B9 FIRING CODEVERTICAL VENT WITH COMBUSTION AIR FROM THE ROOFTOP(DirectAire).The flue outlet terminates on the rooftop. The combustion air is ducted tothe appliance from outdoors through the rooftop.

BULLET POINTSCategory I double wall B vent is required.

All vent material for this configuration including vent termination will be obtained locally.

The air is delivered to the appliance via a separate duct. The air intake material can bePVC, CPVC or ABS, galvanized steel pipe, double wall B vent, etc

A field supplied barometric damper is optional on Power-fin 0502-1302-F9.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 befactory trimmed for Category I vent and air inlet connections in the following dimensions.

MODEL CAT I VENT CONNECTION AIR INLET CONNECTION

PFN0502PM-F9 7 5"

PFN0752PM-F9 9" 5"

PFN1002PM-F9 10" 6"

PFN1302PM-F9 12" 6"

PFN1501PM-B9 12" 6"

PFN1701PM-B9 14" 7"

PFN2001PM-B9 14" 8"


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CATEGORY I VENTING F9 OR B9 FIRING CODEVERTICAL VENT WITH COMBUSTION AIR FROM THE SIDEWALL(DirectAire).The flue outlet terminates on the rooftop. The combustion air is ducted tothe appliance from outdoors through the sidewall.

BULLET POINTS

Category I double wall B vent is required.

The sidewall exhaust cap must be provided by Lochinvar. See table below for kit partnumbers. All other vent material for this configuration will be obtained locally.

The air is delivered to the appliance via a separate duct. The air intake material can bePVC, CPVC or ABS, galvanized steel pipe, double wall B vent, etc.

A field supplied barometric damper is optional on Power-fin 0502-1302-F9.

A field supplied barometric damper MUST be installed on Power-fin 1501-2001-B9.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 befactory trimmed for Category I vent and air inlet connections in the following dimensions. Thetable also includes the kit part numbers for the sidewall air intake caps which must be used.

MODEL CAT I VENT CONNECTION AIR INLET CONNECTION SAK KIT NUMBER

PFN0502PM-F9 7 5" SAK3003

PFN0752PM-F9 9" 5" SAK3003

PFN1002PM-F9 10" 6" SAK3004

PFN1302PM-F9 12" 6" SAK3004

PFN1501PM-B9 12" 6" SAK3004PFN1701PM-B9 14" 7" SAK3005

PFN2001PM-B9 14" 8" SAK3006

The main component in Sidewall Air Intake Kit is the Sidewall Air Intake Cap.


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Chapter 3 Gas SupplyLochinvar products are designed with the concept of flame control. We develop combustionsystems that tightly control the flow of air and gas to deliver a clean and efficient burn. In

Chapters 1 and 2, we showed the various methods to deliver an ample quantity of air to theappliance. In Chapter 3, we discuss delivering a steady and reliable supply of gas to theappliance.

The key to the gas supply is sizing the gas line properly. The Power-fin will require less than ahalf a pound of pressure. The following Sizing Chart is based on less than pound of pressureor less than 14 inches of pressure. The table is derived from the ANSI Z223.1, the National FuelGas Code.

Simply calculate the total linear feet of straight gas pipe. Figure each elbow as equal to fivestraight feet of pipe. Working down the column that matches your pipe length, find the valueGREATER THAN the total Btu/hr input of the water heater or water heaters. This will identify theminimum nominal iron pipe size.

GAS PIPE SIZING CHART

Nominal

Iron Length of Pipe in Straight Feet

Pipe

Size 10 20 30 40 50 60 70 80 90 100 125 150 175 200

3/4" 369 256 205 174 155 141 128 121 113 106 95 86 79 74

1" 697 477 384 328 292 267 246 256 210 200 179 164 149 138

1 1/4" 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287

1 1/2" 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441

2" 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820

2 1/2" 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300

3" 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340

4" 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720

The Power-fin features a Negative-Regulation or Neg-Reg gascombustion system. The gas is introduced upstream of thecombustion blower. As the blower draws air in, the negativepressure on the inlet of the blower pulls the gas from the gasvalve. The gas/air mixture is pushed through the blower into theburner. The gas/air mixture filters through the ceramic burnermesh and is ignited by the Hot Surface Igniter.

On full fire, a crisp blue flame rises off the surface of the burner.As demand decreases, the operating control reduces the blower

speed. The flame is reduced and touches the burner surface.The ceramic burner material is designed to burn infra-red safely without being damaged by directcontact of the flame. Even at this reduced Btu/hr input, the gas/air mixture is balanced to provideclean, efficient combustion.

Gas


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The list below shows the gas connection size on the water heater. Logically, the gas pipe sizefrom the meter to the water heater may be larger than the appliance connection.

MODEL PIPE SIZE MODEL PIPE SIZE

PFN0502PM 1 PFN1501PM 2"

PFN0752PM 1-1/4" PFN1701PM 2"

PFN1002PM 1-1/4 PFN2001PM 2"

PFN1302PM 1-1/4

The table below lists the Minimum and Maximum Inlet Gas Pressures. Note how the B9, F9 andM9 models have different requirements.

INLET GAS PRESSURE

Model Firing NATURAL GAS L.P. GAS

Number Code Max. w.c. Min. w.c. Max. w.c. Min. w.c.PFN0502 1302PM F9 10.5 4.2 13.0 11.0

PFN0502 1302PM M9 14.0 4.0 13.0 11.0

PFN1501 2001PM B9 14.0 4.0 14.0 8.0

PFN1501 2001PM M9 14.0 4.0 14.0 8.0

L.P. GAS MODELSIf you are specifying a model for connection to L.P. gas, make sure that is noted on your designspecification. Example, the model number changes from PFN0502PM-M9 to PFL0502PM-M9from natural to L.P. gas. The Power-fin must be factory trimmed for the chosen gas type andmay not be field converted from Natural to L.P. gas or vice versa.

GAS PRESSURE REGULATORS

Lochinvar recommends the use of Lock-Up Type gas pressure regulators on the system gassupply. A Lock-Up Type gas pressure regulator features a seat that seals the regulator orificewhen the appliance is off and there is no demand for gas. The seat will seal against the orificeshutting off the flow of gas to the appliance.

A standard regulator without a Lock-Up mechanism will allow the system pressure to reach theboiler when it is off. The system pressure can creep up pressing against the appliance gas trainwith excessive system pressures. This can damage the components in the gas train.

HIGH PRESSURE GAS REGULATORS MUST BE THE LOCK-UP VARIETY AND MUST BE INSTALLED NOT

LESS THAN 10 EQUIVALENT FEET FROM THE BOILER TO PROVIDE AN ADEQUATE VOLUME OF GASFOR SMOOTH IGNITION.

Im ortant


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Chapter 4 WaterDomestic water pipe design seems easy enough. The Power-fin water heater is connected to astorage tank. Water recirculates between the two to maintain a prescribed water temperature.

Hot water is drawn off the top of the tank to supply the system. Fresh water flows in from the city.The Power-fin fires again to maintain the temperature of the system.

However, there are other concerns, other detailsregarding the system design that we must check toprovide the water heater with safe and comfortableoperating conditions. There are temperature and watercapacity demands, water chemistry and multiple unitpiping and many more.

Here is a short list of important details to keep in mind aswe design our system.

SINGLE HEATER / SINGLE TANKThe most common design is for a single water heaterpiped to a single tank. The water flows from the waterheater into the tank and then back from the tank to theheater. A factory supplied circulation pump creates

the flow in this water heater loop only.

A system loop carries hot water away from the tankand the building return line is connected to the waterheater loop. A field supplied circulation pump willcreate the flow in the system loop.

IMPORTANT BULLET POINTS FOR WATER PIPING1. Water Connections

All models have 2 1/2 inch copper sweat pipe inlet and outlet connections.Installed piping to and from the tank must be a minimum of 2 1/2 inch diameter.

2. Maximum Flow RateThe Power-Fin 502-1302 models have a specified flow rate of 75 GPM.The Power-Fin 1501-2001 models have a specified flow rate of 90 GPM.

3. Working PressureThe appliance should not be operated at less than 12 PSIG.

4. Minimum Inlet Water TemperatureThe minimum inlet water temperature returned to the appliance is 140F (60C).

5. Flow RateThe appliance requires a constant flow rate through the heat exchanger. Do not varythe flow rate through the water heater during a call for heat.

6. Unions and Ball ValvesThe water piping to the tank should have unions and ball valves at the inlet and outletof the water heater to isolate the unit for service and flow adjustment. Use only full portball valves.

Water

Reference Drawing A1 Page 37


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FACTORY SUPPLIED PUMPAgain, the circulation pump in the water heater loop is factory supplied. It is sized based on agiven amount of pipe and so many fittings. The standard pump is based on 45 feet of straightpipe with:

6 90 Elbows 2 Ball Valve2 Unions 1 Cold Water Tee

For each fitting in excess of those shown above, deduct 6.5 feet from the straight pipe. If yoursystem exceeds this math, the pump may be increased in size to provide the necessary flow.

Please consult Lochinvar Technical Service for details.

MULTIPLE HEATERS / MULTIPLE TANKSThe second most common design is for multiple waterheaters piped to multiple tanks. Multiple heatersprovide water heating redundancy. Multiple tanksincrease storage on capacity in easy to managevessels.

The key element in having multiple water heaters is youhave multiple pumps; multiple pumps that sharecommon piping. When that happens, the pipediameters MUST be increased to accommodate the

increased flow.

Here are the common manifold pipe sizes and thecombined flow rates for the Power-fin product family.

Power-fin 0502, 0752, 1002 & 1302 Power-fin 1501, 1701 & 2001

Number of Combined Common Manifold Number of Combined Common Manifold

Units GPM Pipe Diameter Units GPM Pipe Diameter

2 150 3-1/2" 2 180 4"

3 225 4" 3 270 5"

4 300 5" 4 360 6"

5 375 6" 5 450 6"

6 450 6" 6 540 6"

7 525 6" 7 630 7"

8 600 7" 8 720 7"

Regardless of the number of tanks, when you have more than one heater, the common pipe sizemust increase because the number of pumps increased. However, if you have multiple tanks butonly one heater, you do not have to increase the common manifold size because you only haveone pump.

THE POWER-FIN COMES WITH INTERMITTENT PUMP CONTACTS AS STANDARD EQUIPMENT. THE

CONTACTS WILL OPERATE THE RECIRCULATION PUMP ON EACH CALL FOR HEAT AND THE PUMP

DELAY TIMING IS FIELD PROGRAMMABLE.

Did ou Know?



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TWO HEATERS / ONE TANK ONE HEATER / TWO TANKSUpsize the Common Manifold Do not upsize the Common Manifold

Now that weve seen some designs, lets consider three important concepts for designing thedomestic water piping system. They are

WATER FLOW

WATER TEMPERATURE

WATER VOLUME

Basically, a water heater or bank of water heaters has a given range of operation under thesethree concepts. A water heater has a water flow rate range. A water heater has a watertemperature range. A water heater has a water volume range. If you design a system that letsthe appliance operate within its comfort zone, it lives a long and prosperous life. If the systemforces the appliance to operate outside any one of the three comfort zones, it suffers.

WATER FLOWThe flow rate concept is easy. The water MUST flow through the Power-fin at a specified flowrate. Period.The specified flow rate for the Power-fin 502-1302 models is 75 GPM.

The specified flow rate for the Power-fin 1501-2001 models is 90 GPM.

The idea behind flow rate is to avoid lime scale buildup. All water contains minute quantities ofcalcium, referred to as water hardness and free floating particulate, referred to as Total DissolvedSolids (TDS).

When water is heated the calcium precipitates or boils out to become free floating particulate.This newly released calcium along with other free floating particulate can stick to the inside of thecopper-finned tubes. Over time, lime scale could build up on the inside of the tubes.

REMEMBER TO SPECIFY STORAGE TANKS RECIRCULATION TAPPINGS THAT WILL MATCH THE SIZE

OF THE COMMON MANIFOLD.

Ti



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This layer of lime scale can become so thick it will interfere with the heat transfer process.Normally, heat is transferred efficiently from the flame through the copper and into the water. Thelime scale becomes a layer of insulation between the copper and the water. If the copper cantinstantly release the heat into the water, then the copper will overheat. This leads to a failure ofthe copper and ultimately, the entire heat exchanger.

Here is why flow rate is important to lime scale. If the flow rate is too low, the calcium has achance to adhere to the copper. But if we flow the water fast enough, the calcium doesnt get achance to adhere to the tube. In addition, at the proper flow rate, the water creates a scouringaction that tumbles along the ribbed interior of the copper tube, keeping it clear of lime scale.

Therefore, too low a flow rate is bad. Conversely, too high a flow rate can also damage thetubes. At too high a flow rate, the scouring action of the water becomes so aggressive that itchips away at the copper tube, eroding the tube and causing tube failure. Thats not warrantableeither.

Temperature Rise Chart Temperature Rise Chart

Copper Heat Exchanger Copper-Nickel Heat Exchanger

Model Temperature Model Temperature

Number Rise F Number Rise F

PFN0502PM 11 PFN0502PM 9


PFN1002PM 23 PFN1002PM 18PFN1302PM 30 PFN1302PM 24




COPPER-NICKEL HEAT EXCHANGERSThese flow rates will deliver the proper temperature rises for lime scale free operation in thecopper-finned tubes that are standard equipment on all Power-fins. For water that is just outsidethe specified range, the Power-fin water heaters can be factory trimmed with Copper-Nickel heatexchangers.

90% copper, 10% nickel, the Copper-Nickel finned tube is a harder alloy than pure copper. With

a harder alloy, we can flow the water through the heat exchanger at a greater speed. If you havewater chemistry in the following range, you can use a copper-nickel exchanger instead of a watersoftener. The higher flow rates for the Copper-Nickel heat exchanger are 25% faster.

WATER CHEMISTRYWhile flow rate has been our main focus, there is a companion concept to mention. We return tothe idea of water chemistry, the amount of calcium and Total Dissolved Solid in the water. Now,lets add Ph to the list and look at them closely.

FAILURE OF THE HEAT EXCHANGER DUE TO LIME SCALE BUILDUP IS A NON-WARRANTABLE

FAILURE.

Warning


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Yes, with a specified flow rate, the Power-fin can give you lime scale free operation. But that isbased on a normal amount of material in the water. Obviously, it is possible to have so muchcalcium and TDS in the water that no amount of water flow can wash it away.

Based on the copper-finned tube design, the water chemistry must be in the following range:Minimum Water Hardness: 5 GrainsMaximum Water Hardness: 25 GrainsMax Total Dissolved Solids: 350 PPMAcceptable PH: 7.2 to 7.8

If the water is outside these parameters, water softeners or other measures must be taken to putthe water chemistry inside the specified range. Failure of a heat exchanger due to bad waterconditions is a non-warrantable failure.

WATER TEMPERATURE

Water temperature is also an easy concept. The water temperature delivered to the Power-finmust be high enough to avoid condensation in the heat exchanger. Period.

The minimum return water temperature to the Power-fin water heater is 140F(60C).

Reason why? If the inlet water temperature is less than 140F, condensate will occur on theoutside of the copper-finned tube and in between the fins. The condensate will collect particlesfrom the flue products. The moisture and particles build up over time and ultimately will clog thefins. This leads to improper combustion, sooting, elevated temperatures and premature failure ofthe heat exchanger.

Since the water flowing into the water heater comes directly from the storage tank, Lochinvar

recommends maintaining a stored water temperature of 140F or greater. That works perfectlyfor kitchens, laundries and other processes that use highwater temperatures.

In addition, 140F or greater water temperature will kill thebacteria that causes Legionella disease, a major concern inpublic water distribution systems.

The flip side of that coin is the issue of scald. Direct contactwith 140F water will cause a scald injury. Water to publicshowers and sinks require lower water temperatures. Mostareas ofthe country have safety standards for nursing homes,

schools and hotels that require no more than 110F waterdelivered to the customer.

So we are caught between the need to maintain a returnwater above 140F and a system supply temperature below140F. Whats a designer to do?

We strongly recommend you store your water temperature at 140F, then use a mixing valve todeliver a lower water temperature to the system.

140 140


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This is a single heater, single tank diagram featuringa three way mixing valve. The valve in thisillustration takes 140F water from the tank, mixes itwith the cold water from the city supply and sendsmixed water below 140F to the system.

There are a variety of choices in mixing valves.There are valves that mix at the storage tank. Thereare faucets and other fixtures that limit the watertemperature at the point of use. Whatever methodyou use, consult the valve manufacturer for detailson how to pipe that particular brand.

WATER VOLUMEThe Power-fin water heater is often misinterpreted as an instantaneous water heater. Yes, itdoes heat water very quickly but the water heater alone cannot react quickly enough to providean uninterrupted flow of hot water at a prescribed temperature. A storage tank MUST beinstalled.

Even then, systems are often designed to rely primarily on the Power-fin heating capacity to carrythe system demand with a very small storage tank acting as a buffer. This can work but, logically,it is possible to undersize the tank. When that happens, the Power-fin water heater suffers toolow an inlet water temperature and the heat exchanger will condense.

Heres a basic calculation to determine the minimum gallon capacity of the tank. Divide theBtu/Hr input by 4000. Example: the Power-fin 500,000 Btu/hr model would require a minimumstored gallon capacity of 125 gallons. OK, you can shave that a bit and install the RJS120 orRJA120 tank.

Even though the Power-fin series has a 5:1 turndown and will fire as low as 20% of the totalBtu/hr input. The tank must be sized for maximum demand and maximum firing rate. So, size forthe full Btu/hr input.

Model Minimum Recommended

Number Gallon Capacity Loch-Temp Tank

PFN0502PM 125 RJS120 or RJA120

PFN0752PM 188 RJA200

PFN1002PM 250 RGA257PFN1302PM 325 RGA318

PFN1501PM 375 RGA432





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Chapter 5 Electrical &

ControlsThe first idea for this chapter is supplying power to the water heater. A 120 VAC, 15 Amp, 1 ph,60 Hz circuit is required for operation of the water heater.

The appliance, when installed, must be electrically grounded in accordance with the requirementsof the authority having jurisdiction, or in the absence of such requirements, with the latest editionof the National Electrical Code ANSI/NFPA No. 70. When the unit is installed in Canada, it mustconform to the CAE C22.1, Canadian Electrical Code, Part I and/or local Electrical Codes.

1. All wiring between the appliance and field installed devices shall be made with type T wire[63F (35C) rise].2. All voltage wire exterior to the appliance must be enclosed in approved conduit or approvedmetal clad cable.3. The appliance must be provided with proper overload protection.

AMP DRAW DATA

Btu/Hr Blowers & Pump Total Amps

Input Controls FLA 120 VAC

PFN0502 6.7 8.8 15.5

PFN0752 6.7 8.8 15.5

PFN1002 6.7 8.8 15.5

PFN1302 6.7 8.8 15.5

PFN1501 6.5 8.8 15.3

PFN1701 6.5 8.8 15.3

PFN2001 6.5 8.8 15.3

SMART SYSTEM CONTROLSThe Power-fin features the Smart System control. The Smart Systemcontrol is designed to operate all the various elements of domestic hotwater heating system. The Smart System will control temperature,operate the pump and dispense a large amount of operational data.But its best feature is Cascade, the organized control of up to eightseparate water heaters.

CASCADEThe Cascade feature in the Smart System control will operate up toeight water heaters. Connected with 2-wire daisy chain, any one waterheater in the group is chosen as the Leader. The other heaters operateas Members. The Leader unit is provided with the tank sensing probeand makes the decision on which water heater is firing and at what rateto meet the demand.

Each day, a different water heater is assigned the role as first in the firing sequence. This built-inLead-Lag feature distributes even usage over the life of the heaters.

Electricity& Controls


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Built-in Cascade of up to eight water heaters

PUMP CONTROL

If the Smart System control is going to control up to eight water heaters with Cascade or operatefrom a BMS signal, it is only reasonable for the Smart System control to operate the circulatorpumps. The terminal strip is rated for 1 HP pumps maximum adequate to control the all-bronzepump supplied with every Power-fin water heater. Intermittent pump operation. 30 second pumpdelay (programmable).

HIGH VOLTAGE TERMINAL STRIP CONNECTIONSAlarm on Any Failure Contacts

Should the Smart System control detect a fault, it will send an alarm signal through thesedry contacts to a remote control board or activate an alarm bell.

Run Time ContactsThe Smart System control will make dry contacts for the duration of the Main Burner.

LOW VOLTAGE TERMINAL BOARDEvery Power-fin is equipped with a Low Voltage Terminal Board for a variety of other fieldconnections and control features.

Tank Sensor or Tank ThermostatThe Smart System control will operate the water heater based on a signal from a tanksensor with a resistance signal or a tank thermostat with an enable / disable signal.

Louver ContactsThe Smart System control will open and close equipment room louvers on a call for heatwith Louver Proving Switch for control safety.

CascadePreviously noted, up to eight water heaters can be connected to one another with twistedpair wire and programmed for sequenced operation.

BMS Control with 0-10 vdc Input

The Smart System control can be activated by a Building Management System with a 0-10 Vdc signal. The signal can control either the setpoint or the modulation directly. It cancontrol a single water heater or eight water heaters in cascade.

Leader Member2Member1 Member3 Member4 Member5 Member6 Member7

DRAW THE SENSORS AND THE SENSOR LOCATIONS INTO YOUR BUILDING AND PIPING PLANS.

Ti


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SMART SYSTEM OPERATIONAL FEATURESThe following is a list of just a few of the many other operational features built-in to the SmartSystem control For the complete list of features with more detailed explanations plus

programming parameters, refer to the Installation & Operation Manual, the Service Manual or theUser Manual.

ClockThe Smart System has a clock for date and time. This must be set for record keepingand night setback functions.

Freeze ProtectionThe Smart System control automatically monitors the water temperatures and willoperate the pump and if necessary, fire the appliance to protect the heat exchanger fromfreezing.

Inlet Water TemperatureThe Smart System will monitor inlet water temperature and report persistent flow of waterless than 130F which will cause condensation in the heat exchanger.

Anti-CyclingThe Smart System control will monitor burn cycles and force a minimum off time toreduce short cycling.

Night SetbackThe Smart System will reduce the DHWsetpoints during periods where the building isunoccupied. This is a programmable parameter.

Service ReminderThe Smart System control can display a reminder to the customer that it is time for aservice call. This time frame is a programmable parameter.

Low Voltage Circuit Board


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AND MOREOpen / Shorted Sensor Detection Monitoring of Safety DevicesFan Speed Low & Fan Speed High Ramp DelayFlame Current Support Run Time and Cycle CountFlue Temperature Limiting Temperature Rise LimitingOutlet Temperature Limiting High Limit OperationLow Voltage Blocking Low Water Cutoff Protection

PC SOFTWAREAll of these features are built into the Smart System control standard on every model. To helpyou see them better, Lochinvar offers PC Software. The PC software program can bedownloaded onto a laptop computer and with the connection cable provided in the PC Softwarekit; you can connect to the PC port on the front of every Power-fin control panel.

SCREEN SHOT OF PC SOFTWARE


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Chapter 6 Other Details of

Great ImportanceSTANDARD CODES, STANDARD CONSTRUCTIONThe Power-fin water heater is design certified to the latest edition of ANSI Z21.10.3, the waterheater standard. The third party certification was performed by CSA International and the waterheater bears the American Blue Star emblem and the Canadian Blue Flame emblem. The heatexchanger inside the water heater conforms to the latest edition of the ASME Boiler and PressureVessel Code, Section IV and the vessel bears the ASME HLW Stamp.

The installation of an water heater with a storage tank is governed by local boiler and waterheater codes. The water heater and tank shall be installed in accordance with those installationregulations and shall be carefully followed in all cases. Authorities having jurisdiction shall beconsulted before installations are made. The local code may require a feature on the waterheater above and beyond the ANSI requirements. Check the list of factory installed options on

page 35. Again, these options are factory installed and must be specified on the originalpurchase order. Review the local code especially inregard to the venting requirements.

In the absence of local codes, U.S. installations shallconform to the latest edition of the National Fuel GasCode, ANSI Z223.1. In Canada, the installation mustcomply with the Canadian Gas Association Code,CAN/CGA-B149.1 and/or B149.2 and/or local codes.

CSA International CSA International ASME, Section IVBlue Star for United States Blue Flame for Canada HLW stamp Water Heaters

OPTIONAL CODES, ADDITIONAL CONSTRUCTIONPrimarily, local building code inspectors inspect boiler installations. When reviewing water heaterinstallations, inspectors occasionally ask for the water heaters to comply with well known boilercodes, such as CSD1, the American Society of Mechanical Engineers Safety Code for Controlsand Safety Devices for Automatically Fired Boilers. Also, theyll ask forFactory Mutual orGEGap, popular insurance codes that call for CSD-1 requirements.

CSD-1 is strictly a space heating boiler code. Per CSD-1 code, Section CG-130, Exclusions,

water heaters are exempt from the boiler requirements. The standard water heater built to theANSI Z21.10.3 requirements is acceptable.

STATE CODES, ADDITIONAL CONSTRUCTIONAll states have their own boiler and water heater installation codes, but some states have codesthat require special equipment on the water heater itself. Currently, California, Massachusetts,Minnesota and Kentucky have state codes that require additions to Lochinvar products. Checkwith your local Lochinvar sales office or Lochinvar Customer Service for details.

Details


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DETERMINE THE UNIT LOCATION1. Locate the appliance so that if water connections should leak, water damage will not

occur. When such locations cannot be avoided, it is recommended that a suitable drainpan, adequately drained, be installed under the unit. The pan must not restrictcombustion airflow.Under no circumstances is the manufacturer to be held responsible for water damage inconnection with this unit, or any of its components.

2. DO NOT install this appliance in any location where gasoline or flammable vapors arelikely to be present.

3. The appliance must be installed on a level floor. Combustible floor locations may beused. Maintain required clearances from combustible surfaces.

4. The appliance must be installed indoors where it is protected from exposure to wind, rain,and weather.

5. This appliance may condense the products of combustion if operated at watertemperatures below 140F (60C). Ensure that the appliance is located near anacceptable drain where condensate that may form in the venting system can be properlycollected and disposed.

6. Access to the rear of the appliance MUST be maintained.

CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

Right Side Zero inches

Left Side Zero inches

Rear 6" (Minimum 24" suggested for service to

the pump and other components)

Front - Alcove* (Minimum 24" suggested for service)

Top 6" (Minimum 24" suggested for service)

Flue 2"Hot WaterPipes 1"

*An Alcove is a closet without a door.

CONDENSATE TRAPThe Power-fin is fitted with a condensate trap to befield mounted on the floor behind the appliance. Thetrap is a requirement of the ANSI standard for anyCategory IV vented appliance with condensation

forming in the stack.


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HIGH ALTITUDE APPLICATIONSAtmospheric pressure decreases as the height above sea level increases. At any altitude abovesea level, a cubic foot contains less gas than a cubic foot at sea level. Thus, the heating value of

a cubic foot of fuel gas will decrease as height above sea level increases. Therefore arecalculation of heat input rate should be performed on any appliance beginning at 2000 feet.Ratings should be reduced at the rate of 4 percent for each 1000 feet above sea level.The Power-fin water heater must be factory trimmed for installation at an altitude rangeGREATER than 4000 feet above sea level.

FACTORY INSTALLED OPTIONAL EQUIPMENTLochinvar provides the following selection of optional equipment to meet your buildingrequirements.

Alarm BellFactory installed onto the inner front panel of the appliance and wired to the Alarm on Any Failure

contacts. It will sound on any failure. A silencing switch is provided. Alarm on Any Failurecontacts are standard on every Power-fin water heater for connection to a remote alarm bell orBuilding Management System.

High & Low Gas Pressure Switches with Manual ResetThe switches are mounted just inside the upper front chamber. The High Gas Switch willinterrupt the call for heat should high gas pressure be sensed in the gas line. The Low GasSwitch will interrupt the call for heat if the gas pressure supplied to the appliance is too low toachieve a safe burner flame. Both switches require manual reset to restart the appliance.The High and Low Gas Pressure Switches with Manual Reset is part of the Factory Mutual, GEGap or CSD1 option packages. Per CSD-1s exemption of the water heater, the Gas Pressureswitched may be ordered by name individually and not as part of CSD-1 code package.

Low Water Cut-Off, Probe Type with Manual ResetThe electronic board is mounted in the control panel with a sensing probe mounted in the topheader of the heat exchanger. The LWCO is set to interrupt the call for heat if a low watercondition is sensed. The LWCO requires manual reset to restart the appliance. This is offeredfor many local codes that do not accept the standard-equipped flow switch as a low water cut offdevice. Check with local code authorities for acceptance of the standard flow switch as a lowwater cut off device.

Cupro-Nickel Heat Exchanger90% copper, 10% nickel, the Copper-Nickel Heat Exchanger is a harder alloy than the standardcopper-tubed heat exchanger and is suggested for chemically treated water and for hard waterconditions.

Relief ValveThe standard relief valve offered on the Power-fin water heater is a 150 psi temperature &Pressure ASME relief valve. The Power-fin can be factory trimmed with a temperature &pressure relief valves with a different pressure rating of your choosing.


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Appendix A

Water HeaterPiping Diagrams
https://www.lochinvar.com/default.asp


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PAGE A1

SINGLE HEATER / SINGLE 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.


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PAGE A2

TWO HEATER / ONE TANK WITH COMMON MANIFOLD PIPING




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PAGE A3

TWO HEATER / TWO TANK WITH COMMON MANIFOLD PIPING



See page 24 for Common Manifold Pipe Size Tables


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PAGE A4

TWO TEMPERATURE SYSTEM WITH 3-WAY MIXING VALVE




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Appendix B

Technical Data

andWater Heater

Component Breakdown
https://www.lochinvar.com/default.asp


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Designers Guide Power-fin Water Heater

Power-fin the components, the design

1. Heat exchangerThe 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 coverThe heat exchanger access cover is a stainless steel door which allows access for service, maintenance, andremoval of the heat exchanger from inside the combustion chamber.

3. BlowerThe blower pulls in air and gas through the venturi (see item 5) and injects the fuel/air mixture into the burner, wherethey burn inside the combustion chamber.

4. Gas valveThe 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. VenturiThe venturi attaches to the inlet (or suction) side of the blower and generates the negative pressure needed by thegas valve.

6. Flue sensor

The flue sensor is mounted in the exhaust collar of the unit and monitors the flue gas temperature. If the temperaturein the stack exceeds the maximum temperature the unit will shut down to prevent a hazardous condition. In B9models, the flue sensor helps to control the amount of modulation to prevent condensation in the stack.

7. Outlet temperature sensorThis sensor monitors the outlet water temperature. If selected as the controlling sensor, the appliance will maintainset point by adjusting the firing rate of the unit according to this sensor.

8. Inlet temperature sensorThis sensor monitors inlet water temperature. If selected as the controlling sensor, the appliance will maintain setpoint by adjusting the firing rate of the unit according to this sensor.

9. Temperature and pressure gaugeThe temperature and pressure gauge monitors the outlet temperature of the appliance as well as the system waterpressure.

10. Electronic displayThe electronic display consists of 7 buttons and a dual line 32-character liquid crystal display used to monitor the

operation of the heater as well as enter and view the programming of the main control board.11. BurnerThe burner is made of a woven fabric over steel screen construction. The burner uses pre-mixed air and gas andprovides a wide range of firing rates.

12. Water outlet (supply)The water outlet is a 2 1/2" pipe connection that supplies water to the system with connections for a flow switch (see#28), a relief valve (see #25).

13. Water inlet (return)The water inlet is a 2 1/2" pipe connection that receives water from the tank and delivers it to the heat exchanger.

14. Gas connection pipeThe gas pipe connection on this appliance is 1", 1 1/4", or 1 1/2" NPT. To deliver the correct amount of gas volume tothe appliance it may be necessary to have a larger gas line and reduce to the appliance connection size at theappliance. Please reference the National Fuel Gas Code charts for more details.

15. SMART SYSTEM Control ModuleThe SMART System Control Module is the main control for the appliance. This module contains the programmingthat operates the blower, gas valve, and pumps in addition to other programmable features.

16. Air intakeThe air intake pipe allows fresh air to flow directly to the appliance. The air inlet is part of the filter box assemblywhere air filtration is accomplished with a standard filter.

17. Line voltage terminal stripThe line voltage terminal strip provides a location to connect all of the high voltage (120 VAC) contact points to theunit, such as the contacts to control the recirculation pump.


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18. Low voltage connection boardThe low voltage connection board provides a location to tie in all of the low voltage contacts to the appliance. This iswhere most of the external safety devices are connected to the unit such as the tank thermostat or tank sensor.

19. Condensate trapThe condensate trap is designed to prevent flue gases from escaping the appliance through the combustion chamberdrain.

20. Access cover - frontThe front access cover provides access to the gas train as well as the blower and other key components for serviceand maintenance.

21. Hot surface igniter (HSI)The hot surface igniter is a device that is used to ignite the air/gas mixture as well as monitor the performance of theflame during operation. This device also acts as a flame sense electrode.

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 duringoperation.

23. Gas shut off valve (downstream test cock)The downstream test cock is provided in the gas train to ensure complete shut off of the gas to the burner in case ofmaintenance, inspection, or testing of the valve.

24. High limit sensorA 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 valveThe relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded. Waterheaters receive 150 PSI Temperature & Pressure relief valves.

26. Power switchThe power switch is used to engage and disengage power to the appl iance on the 120 VAC circuit.

27. Air pressure switchThe air pressure switch is a safety device which ensures proper blower operation. The air pressure switch is wired inseries with the low voltage control circuit in such a way that if the fan does not engage or shuts down prematurely thedevice will break the control circuit and the unit will shut down.28. Flow switchThe 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 andallows the unit to operate. If flow is discontinued during operation for any reason the flow switch will break the controlcircuit and the unit will shut down.

29. Drain port(s)Location from which the heat exchanger can be drained.

30. Ventilation fanProvides air circulation around the controls inside the unit.

31. Manual shutoff valveManual valve used to isolate the unit from the gas supply.


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Power-fin 0502 1302

Model 0502 1302 / Front View Model 0502 1302 / Rear View

Model 0502 1302 / Right Side (inside view) Model 0502 1302 / Left Side (inside view)


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Power-fin 1501 2001

Model 1501 2001 / Front View Model 1501 2001 / Rear View

Model 1501 2001 / Right Side (inside view) Model 1501 2001 / Left Side (inside view)


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Go towww.lochinvar.comfor more information on all Lochinvar products.

This is a screen shot of the Power-fin webpage. From the home page, click the Water Heaters buttonon the left side of the page. On the next page, click Better Idea Split System. This takes you to a newpage listing all the Lochinvar product families. Click on the Power-fin in the top row.

In this Power-fin webpage, you will be able to download the Installation Manual, the Service Manual, thePower-fin Brochure, Piping Diagrams, Plan View Drawings and much more.
http://www.lochinvar.com/http://www.lochinvar.com/http://www.lochinvar.com/http://www.lochinvar.com/


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power fin designers guide

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