Lochinvar POWER-FIN PBN2500 User manual

Installation & Operation Manual
Models: 2500 - 5000
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual and the Power-fin Service Manual be
reviewed completely 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

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

33
Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions, including
this manual and the Power-fin Service
Manual, before installing. Perform steps
in the order given.
User – This manual is for use only
by a qualified heating installer/
service technician. Refer to the User’s
Information Manual for your reference.
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
When servicing boiler –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this boiler if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Boiler water –
• Thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency
heat exchanger can be damaged by build-up or
corrosion due to sediment.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals in
the system may be damaged. This can result in
substantial property damage.
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
and/or property may result.
• Continual fresh make-up water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the heat exchanger, and causes failure.
Addition of oxygen carried in by makeup water 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 writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
Consider piping and installation when
determining boiler location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Installation and service must be
performed by a qualified installer,
service agency, or the gas supplier.
WARNING
NOTICE
WARNING
WARNING
WARNING DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 10).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
WARNING The California Safe Drinking Water and
Toxic Enforcement Act requires the
Governor of California to publish a list of
substances known to the State of California
to cause cancer, birth defects, or other
reproductive harm, and requires businesses
to warn of potential exposure to such
substances.
This product contains a chemical known to
the State of California to cause cancer, birth
defects, or orther reproductive harm. This
boiler can cause low level exposure to some
of the substances listed in the Act.

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

Installation & Operation Manual
5
DIR #2000528576 00
20
10
Front View
DIR #2000528582 00
1
3
5
4
24
27
Left Side (inside unit)
DIR #2000528590 00
415
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)

6
Installation & Operation Manual
Ratings
Power-fin
AHRI Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
Input
MBH
(Notes 4 - 6)
Min Max
Gross
Output
MBH
(Note 1)
Net
AHRI
Ratings
Water,
MBH
(Note 2)
PBN2500 500 2500 2175 1870.5
PBN3000 600 3000 2610 2244.6
PBN3500 700 3500 3045 2618.7
PBN4000 800 4000 3480 2992.8
PBN5000 1000 5000 4350 3741.0
Other Specifications
Appliance
Water
Content
Gallons
Pipe
Size
Outlet
Pipe
Size
Inlet
Gas Inlet
Size
Air
Size
Vent
Size
(Note 3)
Weight
w/Water
(lbs.)
8.4 4" 4" 2" 9" 9" 1,205
9.3 4" 4" 2" 9" 10" 1,262
10.2 4" 4" 2" 10" 10" 1,406
11.2 4" 4" 2 1/2" 10" 12" 1,441
13.0 4" 4" 2 1/2" 12" 14" 2,260
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.
2. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for 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
4.5% for each 1,000 feet above sea level up to 4,500 feet.
5. High altitude Power-fin boilers are equipped to operate
from 3,000 to 5,500 feet only. e boiler will de-rate by
2.0% for each 1,000 feet above sea level up to 5,500 feet.
e operation given in this manual remains the same as
the standard boilers. A high altitude label (as shown in
FIG A.) is also axed to the unit.
De-rate values are based on proper combustion
calibration and CO2 ’s adjusted to the recommended
levels.
HIGH ALTITUDE
ONLY
DIR #2000530350 00
Figure A High Altitude Label Location
6. For Power-n boiler installations above 5,500 feet contact
the factory.
7. Ratings have been conrmed by the Hydronics Section of
AHRI.

Installation & Operation Manual
7
Installation must comply with:
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, NFPA 54 / ANSI Z223.1 –
latest edition.
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1 -
latest edition, when required.
• National Electrical Code, NFPA 70 - latest edition.
• For Canada only: CSA B149.1 Installation Code,
CSA C22.1 Canadian Electrical Code Part 1 and any
local codes.
1 Determine boiler location
The Power-fin gas manifold and
controls met safe lighting and other
performance criteria when the boiler
underwent tests specified in ANSI
Z21.13/CSA 4.9 – latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
2. 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 drain pan, adequately
drained, be installed under the appliance. The
pan must not restrict combustion air flow. Under no
circumstances is the manufacturer to be held
responsible for water damage in connection with
this appliance, or any of its components.
3. Check area around the boiler. Remove any
combustible materials, gasoline and other
flammable liquids.
NOTICE
Failure to keep boiler area clear
and free of combustible materials,
gasoline, and other flammable
liquids and vapors can result in
severe personal injury, death, or
substantial property damage.
4. The Power-fin must be installed so that gas control
system components are protected from dripping or
spraying water or rain during operation or service.
5. If a new boiler will replace an existing boiler, check
for and correct system problems, such as:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze 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 or the boiler combustion
air supply (see Table 1A on page 10). Prevent combustion
air contamination. Remove any of these contaminants from
the boiler area.
9. For outdoor models, you must install an optional vent kit.
Instructions for installing the vent kit are included in the
kit. Do not install outdoor models directly on the ground.
You must install the outdoor unit on a concrete, brick, block,
or other non-combustible pad. Outdoor models have
additional special location and clearance requirements. A
wind proof cabinet protects the unit from weather. Vent
materials are field supplied.
Adequate hydronic system antifreeze must be used. A snow screen
should be installed to prevent snow and ice accumulation around
the unit or its venting system.
Outdoor boiler installation
WARNING Do not install the appliance where the
appliance will be exposed to freezing
temperatures or to temperatures that exceed
100°F (37.8°C).
Do not install the appliance where the relative
humidity may exceed 93%. Do not install
the appliance where condensation may form
on the inside or outside of the appliance,
or where condensation may fall onto the
appliance.
Failure to install the appliance properly could
result in severe personal injury, death, or
substantial property damage.
DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 10).
Failure to comply could result in severe
personal injury, death, or substantial property
damage.
WARNING
This appliance requires a special venting
system. Use only the vent materials specified in
this manual. Failure to follow all instructions
can result in flue gas spillage and carbon
monoxide emissions, causing severe personal
injury or death.
WARNING

Installation & Operation Manual
8
1 Determine boiler location
Provide clearances:
Clearances from combustible materials
- Hot water pipes........................................................... 1/4"
- Sides.............................................................................. 0"
- Rear............................................................................... 4"
- Front ............................................................................. 0"
- Top................................................................................ 0"
- Floor........................................................... Combustible
- Vent pipe - Follow special vent system manufacturer’s
instructions
Figure 1-1 Clearances
0"
RIGHT
SIDE
0"
FRONT
MIN
0"
LEFT
SIDE
0"
TOP
MIN
4" REAR
MIN FROM
PIPING
DIR #2000527453 00
Provide air openings to room:
The Power-fin alone in boiler room
1. No air ventilation openings into the boiler room are
needed when clearances around the Power-fin are at
least equal to the SERVICE clearances shown in FIG. 1-1.
For spaces that do NOT supply this clearance, provide
two openings as shown in FIG. 1-1. Each opening must
provide one square inch free area per 1,000 Btu/hr of
boiler input.
2. Combustion air openings are required when using the
Room Air Option on 24 of this manual.
The Power-fin in the same space with other gas or
oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1
(Canada) to size/verify size of the combustion/ventilation
air openings into the space.
The space must be provided with
combustion/ventilation air openings
correctly sized for 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
Recommended clearances for service access
- Sides.............................................................................. 0"
- Rear............................................................................... 24"
- Front ............................................................................. 24"
- Top................................................................................ 24"
If you do not provide the recommended
service clearances shown, it may not be
possible to service the boiler without
removing it from the space.
NOTICE
Maintain minimum specified clearances for adequate
operation. All installations must allow sufficient space for
servicing the vent connections, water pipe connections, piping
and other auxiliary equipment, as well as the appliance. The
clearance labels on each appliance note the same service and
combustible clearance requirements as shown in this manual.
Multiple boilers may be installed side by side with no clearance
between adjacent boilers because this boiler is approved for
zero clearance from combustible surfaces; however, service
access will be limited from the sides.
Consult the Venting section of this manual for specific
installation instructions for the appropriate type of venting
system that you will be using.

Installation & Operation Manual
9
1 Determine boiler location (continued)
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
WARNING
When using an existing vent system to
install a new boiler:
Check the following venting components before installing:
• Material - For materials listed for use with this appliance,
see Section 2 - General Venting, Table 2A-1.
• Size - To ensure proper pipe size is in place, see Table 2C.
Check to see that this size is used throughout the vent
system.
• Manufacturer - Only use the listed manufacturers and
their type product listed in Table 2A-1 for CAT IV positive
pressure venting with flue producing condensate.
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. The supports
should adequately prevent sagging and vertical slippage,
by distributing the vent system weight. For additional
information, consult the vent manufacturer’s
instructions for installation.
• Terminations - Carefully review Sections 2 through 4 to
ensure requirements for the location of the vent and air
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical
options listed in the General Venting Section.
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 10.
With stainless steel vent, seal and connect all pipe and
components as specified by the vent manufacturer used.
Do not install the boiler on carpeting even if
foundation is used. Fire can result, causing
severe personal injury, death, or substantial
property damage.
If flooding is possible, elevate the boiler sufficiently to prevent
water from reaching the boiler.
Flooring 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. Note prevention of
combustion air contamination below when considering vent/
air termination.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall, unless
otherwise specified. 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.
Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits given in this
manual.
Prevent combustion air contamination
Install air inlet piping for the Power-fin as described in this
manual. Do not terminate vent/air in locations that can allow
contamination of combustion air. Refer to Table 1A, page
10 for products and areas which may cause contaminated
combustion air.
Ensure that the combustion air will not
contain any of the contaminants in Table
1A, page 10. Contaminated combustion
air will damage the boiler, resulting in
possible severe personal injury, death
or substantial property damage. Do not
pipe combustion air near a swimming
pool, for example. Also, avoid areas
subject to exhaust fumes from laundry
facilities. These areas will always contain
contaminants.
WARNING
WARNING
Assure that the floor and structure is
sufficient to support the installed weight
of the boiler, including the water content
in the heat exchanger. If not, structural
building failure will result, causing severe
personal injury, death, or substantial
property damage.
WARNING

Installation & Operation Manual
10
1 Determine boiler location When removing a boiler from existing
common vent system:
Do not install the Power-fin into a common
vent with any other appliance except as
noted in Section 2 on page 18. This will cause
flue gas spillage or appliance malfunction,
resulting in possible severe personal injury,
death, or substantial property damage.
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury or
death.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while the
other appliances remaining connected to the common venting
system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies, which
could cause an unsafe condition.
c. Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space in
which the appliances remaining connected to the common
venting system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e. Test for spillage 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 previous conditions of use.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CAN/CSA B149.1, Natural Gas and Propane Installation
Code. When re-sizing any portion of the common venting
system, the common venting system should be resized
to approach the minimum size as determined using the
appropriate tables in Part 11 of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code.
DANGER
WARNING
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other similar
products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Table 1A Corrosive Contaminants and Sources

Installation & Operation Manual
11
Remove boiler from wood pallet
1. To remove the boiler from the pallet:
a. Remove the eight (8) shipping brackets securing the unit
to the right and left sides of the pallet (FIG. 1-2).
b. The boiler can now be removed from the pallet
using a lift truck lifting from the front or rear of
the boiler. The lift truck forks must extend at
least half way under the boiler heat exchanger to
assure proper lifting technique with no damage to
the boiler.
Do not drop the boiler or bump the jacket
on the floor or pallet. Damage to the boiler
can result.
DIR #2000530041 00
BRACKETS (4X) ON BOTH
THE LEFT AND RIGHT
SIDES OF THE UNIT
Figure 1-2 Boiler Mounted on Shipping Pallet
NOTICE
1 Determine boiler location (continued)
Combustion and ventilation air
requirements for appliances drawing air
from the equipment room
Provisions for combustion and ventilation air must be in
accordance with Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas Code, NFPA 54 / ANSI
Z223.1, in Canada, the latest edition of CGA Standard B149
Installation Code for Gas Burning Appliances and Equipment,
or applicable provisions of the local building codes.
The equipment room MUST be provided with properly sized
openings and/or be of sufficient volume to assure adequate
combustion 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 appliance is
installed in a space with a volume NO LESS than 50 cubic feet
per 1,000 Btu/hr of all installed gas fired appliances and the
building MUST NOT be of “Tight Construction”3.
A combination of indoor and outdoor combustion air may
be utilized by applying a ratio of available volume to required
volume times the required outdoor air opening(s) size(s). This
must be done in accordance with the National Fuel Gas Code,
NFPA 54 / ANSI Z223.1.
Figure 1-3_Combustion Air Direct from Outside
1. If air is taken directly from outside the building
with no duct, provide two permanent openings to
the equipment room each with a net free area of one square
inch per 4000 Btu/hr input (5.5 cm2per kW) (see FIG. 1-3).
DIR #2000528613 00
Figure 1-4_Combustion Air Through Ducts
2. If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the
equipment room, each of the two openings should be
sized based on a minimum free area of one square inch
per 2000 Btu/hr (11 cm2per kW) of input (see FIG. 1-4).
Figure 1-5_Combustion Air from Interior Space
DIR #2000528615 00
DIR #2000528618 00

Installation & Operation Manual
12
1 Determine boiler location
3. If air is taken from another interior space combined with
the equipment room:
(a) Two spaces on same story: Each of the two openings
specified above should have a net free area of one square
inch for each 1000 Btu/hr (22 cm2per kW) of input, but
not less than 100 square inches (645 cm2) (see FIG. 1-5).
(b) Two spaces on different stories: One or more openings
should have a net free area of two square inches per 1000
Btu/hr (44 cm2per kW).
Figure 1-6_Combustion Air from Outside - Single Opening
DIR #2000528624 00
4. If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the
opening must be sized based on a minimum free area
of one square inch per 3000 Btu/hr (7 cm2per kW). This
opening must be located within 12” (30 cm) of the top of
the enclosure (see FIG. 1-6).
All dimensions based on net free area in square inches. Metal
louvers or screens reduce the free area of a combustion air
opening a minimum of approximately 25%. Check with
louver manufacturers for exact net free area of louvers.
Combustion air requirements are based on the latest edition
of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1; in
Canada refer to the latest edition of CGA Standard CAN/CSA
B149.1. Check all local code requirements 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 should the
equipment room ever be under negative
pressure. Particular care should be taken
where exhaust fans, attic fans, clothes dryers,
compressors, air handling units, etc., may
take away air from the unit.
The result is improper combustion and a non-warrantable,
premature appliance failure.
EXHAUST FANS: Any fan or equipment which exhausts air
from the equipment room may deplete the combustion air
supply and/or cause a downdraft in the venting system. Spillage
of flue products from the venting system into an occupied
living space can cause a very hazardous condition that must be
corrected immediately.
The combustion air supply must be completely free of any
flammable vapors that may ignite or chemical fumes which
may be corrosive to the appliance. Common corrosive
chemical fumes which must be avoided are fluorocarbons
and other halogenated compounds, most commonly present
as refrigerants or solvents, such as Freon, trichlorethylene,
perchlorethylene, chlorine, etc. These chemicals, when burned,
form acids which quickly attack the heat exchanger, headers,
flue collectors, and the vent system.

Installation & Operation Manual
13
TABLE - 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
Model
Number
FIG. 1-3 FIG. 1-4 FIG. 1-5 FIG. 1-6
*Outside Air from
2 Openings Directly from
Outdoors1
*Outside Air from
2 Ducts Delivered from
Outdoors1
Inside Air from
2 Ducts Delivered from Interior Space2*Outside Air from
1 Opening Directly
from Outdoors, in2
(cm2)1
Same Story Different
Stories
Top
Opening, in2
(cm2)
Bottom
Opening, in2
(cm2)
Top
Opening, in2
(cm2)
Bottom
Opening, in2
(cm2)
Top
Opening, in2
(cm2)
Bottom
Opening, in2
(cm2)
Total
Opening, in2
(cm2)
2500 625
(4033)
625
(4033)
1250
(8065)
1250
(8065)
2500
(16129)
2500
(16129)
5000
(32258)
833
(5381)
3000 750
(4839)
750
(4839)
1500
(9678)
1500
(9678)
3000
(19355)
3000
(19355)
6000
(38710)
1000
(6452)
3500 875
(5646)
875
(5646)
1750
(11291)
1750
(11291)
3500
(22581)
3500
(22581)
7000
(45162)
1167
(7530)
4000 1000
(6450)
1000
(6450)
2000
(12900)
2000
(12900)
4000
(25800)
4000
(25800)
8000
(51600)
1333
(8600)
5000 1250
(8062)
1250
(8062)
2500
(16129)
2500
(16129)
5000
(32250)
5000
(32250)
10000
(64500)
1667
(10750)
1 Determine boiler location (continued)
The above requirements 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 appliance is installed in a space with a volume NO LESS than 50 cubic feet per
1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”3.
1Outside air openings shall directly communicate with the outdoors.
2Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings 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
This unit has two (2) standard air filters located at the combustion
air inlet as shown above in FIG. 1-8. These air filters are
provided to help ensure clean air is used for the combustion
process. Check filters every month and replace when necessary.
The filter size for Models 2.5 - 3.5 is 20” x 14” x 1” (50.8 cm x
35.5 cm x 2.5 cm) and for Models 4.0 - 5.0 it is 25” x 16” x 1”
(63.5 cm x 40.6 cm x 2.5 cm). You can find these commercially
available filters at any home center or HVAC supply store.
Follow the steps below when replacing the
combustion air filter:
1. Locate the combustion air filter box mounted
on the rear of the appliance.
2. Remove four (4) #10 hex head fasteners from
the filter cover plates (see FIG. 1-8).
3. Lift and slide out both filter cover plates to gain
access to the air filters.
4. Slide each air filter out the back slot openings
of the air filter box.
5. Inspect the air filters for dirt and debris, replace
if necessary.
6. Replace the air filters and the filter box cover
plates. Replace the four (4) #10 hex head
fasteners to secure the filter cover plates to the
air filter box.
Replace filters with a MERV rating no greater
than 4.0.
NOTICE CAUTION
During construction the air filter should be
checked more frequently to ensure it does
not become clogged with combustion dirt
and debris.
NOTICE
Sustained operation of an appliance with
a clogged burner may result in nuisance
operational problems, bad combustion, and
non-warrantable component failures.

Installation & Operation Manual
14
Vertical
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

Installation & Operation Manual
15
2 General venting (continued)
Install vent and combustion air piping
DANGER The Power-fin must be vented and
supplied with combustion and ventilation
air as described in this section. Ensure the
vent and air piping and the combustion
air supply comply with these instructions
regarding vent system, air system, and
combustion air quality. See also Section 1
of this manual.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided
and with all requirements of applicable
codes.
Failure to provide a properly installed
vent and air system will cause severe
personal injury or death.
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from the following list:
ABS, PVC, or CPVC
Dryer Vent or Sealed Flexible Duct (not recommended
for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed
as specified in this section.
Type “B” double-wall vent with joints and seams sealed
as specified in this section.
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance
and the plastic air inlet pipe.
WARNING Using vent or air intake materials other
than those specified, failure to properly
seal all seams and joints or failure to follow
vent pipe 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-wall vent material or galvanized
vent pipe material used for air inlet piping on a sidewall or
vertical rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either
Aluminum Foil Duct Tape meeting UL Standard 723 or
181A-P or a high quality UL Listed silicone sealant such
as those manufactured by Dow Corning or General
Electric.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three sheet metal
screws or pop rivets. Apply Aluminum Foil Duct Tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and
sealed with the pipe manufacturer’s recommended solvents
and standard commercial pipe cement for the material used.
The ABS, PVC, CPVC, air inlet pipe should use a silicone
sealant to ensure a proper seal at the appliance connection
and the air inlet cap connection. Dryer vent or flex duct
should use a screw type clamp to seal the vent to the appliance
air inlet and the air inlet cap. Proper sealing of the air inlet
pipe ensures that combustion air will be free of contaminants
and supplied in proper volume.

16
Installation & Operation Manual
Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 2-1) - Used to
provide combustion air directly to the unit from outdoors.
A fitting is provided with the unit for final connection.
Combustion air piping must be supported per guidelines
listed in the National Mechanical Code, Section 305, Table
305.4 or as local codes dictate.
2. Vent Connector - Used to provide a
passageway for conveying combustion gases to the
outside. A transition fitting is provided on the unit for
final connection. Vent piping must be supported per the
National Building Code, Section 305, Table 305.4 or as
local codes dictate.
DIR #2000529298 00
COMBUSTION
AIR INTAKE
CONNECTOR
Figure 2-1 Combustion Air Adapter
Vent and air piping
The Power-fin is certified as a Category II/IV boiler. This
product has been approved for use with stainless steel vent
systems. All venting systems used with a Power-fin boiler
must be suitable for Category IV operation except for factory
approved common vent systems operating as allowed in the
Common Venting Section on page 18.
WARNING
NOTICE
NOTICE
When a sidewall or vertical rooftop combustion air supply
system is disconnected for any reason, the air inlet pipe
must be resealed to ensure that combustion air will be free of
contaminants and supplied in proper volume.
DANGER Failure to properly seal all joints and seams
as required 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
2 General venting
Use only the materials, vent systems, and
terminations listed in Tables 2A-1 and
2A-2. DO NOT mix vent systems of
different types or manufacturers, unless
listed in this manual. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
Installations must comply with applicable
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system
for Canada.
Installation of a stainless steel vent system
should adhere to the stainless steel vent
manufacturer’s installation instructions
supplied with the vent system.
NOTICE The Power-fin is supplied with an integral
FasNSeal vent connector. The installer
must use a specific vent starter adapter
supplied by the vent manufacturer to
adapt to different vent systems.
Table 2A-1 Approved Stainless Steel Vent Manufacturers
Approved Stainless Steel Vent Manufacturers
Make Model
ProTech Systems (Dura-Vent Co.) FasNSeal Vent
Z-Flex (Nova Flex Group) Z-Vent
Heat Fab (Selkirk Corporation) Saf-T Vent
Metal Fab Corr/Guard
Securities Chimneys International Secure Seal SS
Schebler Chimney Systems eVent

Installation & Operation Manual
17
Model
AIR INLET VENT Input
De-Rate per
25 feet of Vent
Air Intake
Diameter Air Intake Min. Length Air Intake Max. Length Vent Diameter
Vent
Min. Length
(CAT IV only)
Vent
Max. Length
(CAT IV only)
2500 9" 12' 100' 9" 18' 100' 2.5%
3000 9" 12' 100' 10" 18' 100' 2.5%
3500 10" 12' 100' 10" 18' 100' 2.5%
4000 10" 12' 100' 12" 18' 100' 2.5%
5000 12" 12' 100' 14" 18' 100' 2.5%
Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths
Model Vent
Diameter
Vent
Min. Length
(CAT IV only)
Vent
Max. Length
(CAT IV only)
Input De-Rate per
25 feet of Vent
2500 9" 18' 100' 1%
3000 9" 18' 100' 1%
3500 10" 18' 100' 1%
4000 12" 18' 100' 0%
5000 14" 18' 100' 0%
Table 2C Room Air Minimum / Maximum Allowable Air / Vent Lengths
2 General venting (continued)
Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV
Model ProTech Z Flex Heat Fab
Adapter Intake Adapter Intake Adapter Flue Intake
2500 810003982 810003397
810003409 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
2500 8FCGLCA MC
6-36" 8FCGSW90 SS9CRESTU SS0MCU 4" - 24"
SSE9E9OU
SDOST90AUK
4" - 10" HE-9DSA-F HE-9SCR-F
HE-9MC-F HE-8E90-F HE-9SCR-F
3000 - 3500 10FCGLCA MC
6-36" 10FCGSW90 SS10CRESTU SS0MCU 4" - 24"
SSE10E9OU
SDOST90AUK
4" - 10" HE-10DSA-F HE-10SCR-F
HE-10MC-F HE-10E90-F HE-10SCR-F
4000 12FCGLCA MC
6-36" 12FCGSW90 SS12CRESTU SS0MCU 4" - 24" SSE12E9OU HE-12DSA-F HE-12SCR-F HE-12MC-F HE-12E90-F HE-12SCR-F
5000 14FCGLCA MC
6-36" 14FCGSW90 SS14CRESTU SS0MCU 4" - 24" SSE14E9OU HE-14DSA-F HE-14SCR-F HE-14MC-F HE-14E90-F HE-14SCR-F
Model Jeremias
Adapter Flue Intake
2500 SWKL9-KLC SWKL9-WRC SWKL9-90ET
3000 - 3500 SWKL10-KLC SWKL10-WRC SWKL10-90ET
4000 SWKL12-KLC SWKL12-WRC SWKL12-90ET
5000 SWKL14-KLC SWKL14-WRC SWKL14-90ET

Installation & Operation Manual
18
2 General venting
Common venting CAT II:
Flues of multiple appliances may be combined by incorporating
a vent increaser to change the Category IV appliance to a
Category II vent system which can be common vented using
an engineered vent system. An increaser must be used and
the combined engineered vent system must be designed to
ensure that flue products will be properly exhausted from the
building at all times. Failure to use the correct vent increaser
or a properly sized vent system may result in a hazardous
condition where flue gases spill into an occupied living
space. Consult a vent designer to determine the diameter of
the common vent pipe required for combined vent installation.
It is recommended that all vent joints and seams are sealed
gastight. This vent system has specific vent material and
installation requirements. The negative draft in a conventional
vent installation must be within the range of 0.02 to 0.08 inches
w.c. to ensure proper operation. Make all draft readings while
the unit is in stable operation (approximately 2 to 5 minutes).
Model Category IV
Standard Vent Size Category II Increaser Size
2500 9" 10'
3000 10" 12'
3500 10" 12'
4000 12" 14'
5000 14" 16'
Table 2D Category IV to Category II Conversion Chart
Removing from existing vent
Follow the instructions in Section 1, page 10 of this manual
when removing a boiler from an existing vent system.
Vent and air piping
Vent and air system:
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.
You must also install air piping from outside to the boiler air
intake adapter. The resultant installation is direct vent (sealed
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 different
systems. The vent system could fail, causing
leakage of flue products into the living space.
Use only approved stainless steel pipe and
fittings.
Vent, air piping and termination:
The Power-fin vent and air piping can be installed through
the roof or through a sidewall. Follow the procedures in this
manual for the method chosen. Refer to the information in
this manual to determine acceptable vent and air piping length.
Air contamination
Pool and laundry products and common household and hobby
products often contain fluorine or chlorine compounds. When
these chemicals pass through the boiler, they can form strong
acids. The acid can eat through the boiler wall, causing serious
damage and presenting a possible threat of flue gas spillage or
boiler water leakage into the building.
Please read the information given in Table 1A, page 10,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of the
boiler combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per this manual.
If the boiler combustion air inlet is located
in a laundry room or pool facility, for
example, these areas will always contain
hazardous contaminants.
WARNING
To prevent the potential of severe personal
injury or death, check for areas and products
listed in Table 1A, page 10 before installing
the boiler or air inlet piping.
If contaminants are found, you MUST:
• Remove products permanently.
—OR—
• Relocate air inlet and vent
terminations to other areas.
WARNING

Installation & Operation Manual
19
2 General venting (continued)
Outdoor venting
• In order to properly vent the appliance in an outdoor
configuration the optional outdoor vent kit must be used
(see Table 2E).
• Vent materials for outdoor venting are to be field supplied.
• The vent must terminate at least 36 inches above the top of
the unit.
• All vent materials must be supported as recommended by
the vent manufacturer.
• The terminations in Table 2F must be used.
Model Outdoor Kit
2500 - 3000 100274941
3500 100274942
4000 100274943
5000 100274944
Table 2E Outdoor Vent Kits
Before installing a venting system, follow
all requirements found in the General
Venting section of this manual.
Outdoor vent / air inlet location
Keep venting areas free of obstructions. Keep area clean and free
of combustible and ammable materials. Maintain minimum
clearances to combustibles as stated in this manual.
Do not install outdoor models directly on the ground. You must
install the outdoor unit on a concrete, brick, block, or pressure-
treated wood platform.
NOTICE
Only install outdoor models outdoors,
and only use the 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 eld
supplied and supported per the vent manufacturer’s instructions.
Combustion air supply must be free of contaminants (see the
Combustion and Ventilation Air Requirements section of this
manual). To prevent recirculation of the ue products into the
combustion air inlet, follow all instructions in this section.
WARNING
Model ProTech Z-Flex Heat Fab Metal Fab Security Chimney
Adapter Flue Adapter Flue Adapter Flue Adapter Flue Adapter Flue
2500 810003982 FSCN0907 2SVDSA09 2SVSXITC09 9901MAD CCA09EX07 8FCGLCA 9FCSEC-C60 SS9CRESTU SS9ECU
3000 - 3500 810003984 FSCN1008 2SVDSA10 2SVSXITC10 91001MAD CCA10EX08 10FCGLCA 10FCSEC-C60 SS9CRESTU SS10ECU
4000 810003987 FSCN1210 2SVDSA12 2SVSXITC12 91201MAD CCA12EX10 12FCGLCA 12FCSEC-C60 SS12CRESTU SS12ECU
5000 810003990 FSCN1412 2SVDSA14 2SVSXITC14 91401MAD CCA14EX12 14FCGLCA 14FCSEC-C60 SS14CRESTU SS14ECU
Table 2F_Approved Adapters and Flue Terminations

Installation & Operation Manual
20
3 Vertical direct venting
Vent/air termination – vertical
Prepare roof penetrations
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole per the vent manufacturer’s instructions.
b. Insert a galvanized metal thimble in the vent pipe
hole (when required by local codes).
3. Space the air and vent holes to provide the minimum
spacing shown in FIG. 3-1.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Termination and fittings
1. Prepare the vent termination coupling and the air
termination elbow (FIG. 3-1) by inserting bird screens.
Bird screens should be obtained locally.
2. The air piping must terminate in a down-turned 180°
return bend as shown in FIG. 3-1. Locate the air inlet
pipe no further than 2 feet (.6 m) from the center of the
vent pipe. This placement avoids recirculation of flue
products into the combustion air stream.
5. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
WARNING
12" [305 MM] MINIMUM
ABOVE ROOF /
SNOW LINE
VENT OUTLET
36" [914 MM] MINIMUM
A
BOVE AIR INLET
BIRD SCREEN
[TYPICAL]
Figure 3-2 Vertical Termination of Air and Vent w/Rain
Cap
Follow instructions below when determining
vent location to avoid possibility of severe
personal injury, death or substantial 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 comply could result in
severe personal injury, death, or substantial
property damage.
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 page 17
of this manual.
2. The vent must terminate at least 3 feet above the highest
place in which the vent penetrates the roof and at least 2 feet
above any part of a building within 10 horizontal feet.
3. The air piping must terminate in a down-turned 180°
return pipe no further than 2 feet (.6 m) from the center of
the vent pipe. This placement avoids recirculation of flue
products into the combustion air stream.
4. The vent piping must terminate in an up-turned coupling
as shown in FIG. 3-1. The top of the coupling or the rain
cap must be at least 36" (914 mm) above the air intake. The
air inlet pipe and vent pipe can be located in any desired
position on the roof, but must always be no further than 2
feet (.6 m) apart and with the vent termination at least 36"
(914 mm) above the air intake.
Rooftop vent and air inlet terminations
must terminate in the same pressure zone,
unless vertical vent sidewall air is set up as
shown in the General Venting - Vertical
Vent, Sidewall Air Section.
BIRD SCREEN
[TYPICAL]
VENT OUTLET
36" MINIMUM
A
BOVE AIR INLET
VENT
COMBUSTION AIR
12" [305 MM] MINIMUM
ABOVE ROOF /
SNOW LINE
Figure 3-1 Vertical Termination of Air and Vent