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Lennox GWB9, Installation Instructions Manual, Page: 1 / 72

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Lennox GWB9 Installation Instructions Manual Download Page 1

 P/N# 14683450, Rev. B  [09/08]

Retain these instRuctions foR 

futuRe RefeRence

These instructions must be 

affixed on or adjacent to the boiler.

WARNING

 

improper  installation,  adjustment, 

alteration, service, or maintenance can 

cause injury or property damage.

 Refer 

to this manual. For assistance or additional 

information  consult  a  qualified  installer, 

service agency, or the gas supplier.

GWB9

GAS-FIRED, DIRECT VENT, 

CONDENSING, HOT WATER 

BOIlER

installation 

instRuctions

ProducT LiTeraTure

Lennox  Industries Inc.

Dallas, Texas

Summary of Contents for GWB9

Page 1: ...nstallation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency...

Page 2: ...stallation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional in formation consult a qualified installer service agency...

Page 3: ...rn Lines 15 B Pressure Relief Valve 19 C Expansion Tank And Make Up Water 19 D Condensate Drain Piping 22 E Filling Condensate Trap With Water 23 F Chilled Water Piping 23 Combustion Air and Vent Pipe...

Page 4: ...42 A Verify Proper Sequence Of Operation 42 B Inspect Venting And Air Intake System 43 C Inspect Condensate Drain 43 D Inspect System Piping 43 E Test Ignition System Safety Shutoff Device 43 F Test...

Page 5: ...tically reduced CO and NOx emissions which contribute to a cleaner and healthier environment This appliance unlike normal residential atmospheric and induced draft units takes its combustion air direc...

Page 6: ...to heat water A small portion is heat from the jacket and surfaces of the boiler and it is assumed that this heat stays in the structure The Net I B R Rating represents the portion of the remaining h...

Page 7: ...nifold pressure adjustment based upon calorific Btu value of supply gas Refer to Table 2 for altitude orifice kit part number For replacing the orifice refer to specific instructions included with the...

Page 8: ...lue of LP Gas Settings 2300 2350 2400 2450 2500 Altitude in Ft 0 5 000 5 000 10 000 Normal Input MBH 75 Manifold Pressure In W C 2 5 3 5 3 5 3 5 3 3 Orifice 43331093 43331096 For model 90 75 LP units...

Page 9: ...Mechanical Vent And Domestic Hot Water Appliances For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential...

Page 10: ...ns Inspection the state or local gas inspector of the side wall 4 horizontally vented gas fueled equipment shall not ap prove the installation unless upon inspection the inspec tor observes carbon mon...

Page 11: ...ired to access another side for cleaning or servicing inspection or replacement of any parts that normally may require such attention Allow at least 24 at the front and left side and 8 at the top for...

Page 12: ...ll not be connected into any portion of mechanical draft systems operating under positive pressure Solvent cements are combustible Keep away from heat sparks and open flame Use only in well ventilated...

Page 13: ...CSA B 149 for Canadian standards G Foundation Requirements Boiler must be placed on level surface Boiler is NOT to be installed on carpeting Notes If boiler is not level condensate drain lines will n...

Page 14: ...evices per low water cut off manufacturers specific instructions A Supply And Return Lines The packaged boiler unit is set up to receive 1 NPT supply and return piping from top access The boiler unit...

Page 15: ...15 Near Boiler Piping Figure 2 Single Zone Boiler Piping...

Page 16: ...16 Figure 3 Multi zone Boiler Piping With Zone Valves Near Boiler Piping...

Page 17: ...zone pumps Each stripped end of the electrical wires for the circulator pump inside the junction box should be taped or wire nutted to prevent short circuits Unplug the circulator pump wiring at the...

Page 18: ...er content Boiler contains 2 6 gallons U S Size expansion tank accordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished as show...

Page 19: ...19 Figure 6 Diaphragm Type Expansion Tank Piping Near Boiler Piping...

Page 20: ...20 Figure 7 Conventional closed type Expansion Tank Piping Near Boiler Piping...

Page 21: ...The diameter schedule 40 PVC or CPVC condensate drain and pipe fittings must conform to ANSI standards and ASTM D 1785 or D2846 Schedule 40 PVC or CPVC cement and primer must conform to ASTM D2564 or...

Page 22: ...26 PVC D2661 ABS DWV or F628 schedule 40 ABS Pipe cement and primer must conform to ASTM standards D2564 PVC or D2235 ABS In Canada construct all combustion air and vent pipes for this unit of CSA or...

Page 23: ...ered in ASTM D1784 Deflection Temperatures under Load 264 psi 1819KPa Allowable temperatures based on Classifications covered in ASTM D3965 Deflection Temperatures under Load 264 psi 1819KPa Combustio...

Page 24: ...unted toward the Total Equivalent Length For additional elbows reduce the maximum vent length as shown 2 90 degree elbow 1 feet per additional elbow 3 90 degree elbow 3 feet per additional elbow Combu...

Page 25: ...or snow may cause the boiler to shut down if the vent be comes obstructed Under certain conditions flue gas will condense form ing moisture and may be corrosive In such cases steps should be taken to...

Page 26: ...26 Less Than 12 Clearance 12 Or More Clearance Combustion Air and Vent Pipe Figure 10 Side Wall Vent Intake terminations...

Page 27: ...27 Combustion Air and Vent Pipe Figure 11 Combustion Air and Vent Piping...

Page 28: ...proved cement to end of pipe and fitting socket over primer Apply cement in light uniform coat on the inside of socket to prevent buildup of excess cement Apply second coat While cement is still wet i...

Page 29: ...rols 4 5 Use two pipe wrenches when making the connection to 5 the gas valve to keep it from turning 6 Install a manual shutoff valve in the vertical pipe about 5 6 feet above floor 7 Tighten all join...

Page 30: ...the white neutral lead from the power supply to the white screw on the service switch Connect the green ground lead from the power supply to the ground green screw on the ser vice switch The receptac...

Page 31: ...ed in service switch junc tion box located on outer jacket of boiler See Figure 13 for service switch junction box and thermostat field wiring con nections C Connect Circulator Pump Wiring See Figure...

Page 32: ...32 Electrical Wiring Figure 13 Field Wiring Connections...

Page 33: ...ATOR CN5 CIRCULATOR DRAFT INDUCER CN10 CONTROL TRANSFORMER AT14081297 HOT SURFACE IGNITER IGNITER CN12 IGNITER COLOR DESIGNATION W WHITE BK BLACK Y YELLOW G GREEN R RED V VIOLET BR BROWN PUR PUPPLE 24...

Page 34: ...PPER DIFFERENTIAL AIR P3 9 HIGH LIMIT MANUAL RESET PRESSURE SWITCH 4 5 1 3 VR8205A P12 1 P12 2 LOCATION OF CONNECTOR PLUG BETWEEN SCHEMATIC AND BLK WHT AND THE UNIT RECEPTACLE IS LIVE WHEN CAUTION ON...

Page 35: ...and may be set anywhere between 100 F and 200 F The field setpoint adjustment for each installation depends on heating system requirements The aquastat automatically resets when the boiler water tempe...

Page 36: ...drain the entire system K A S M E Rated Pressure Relief Valve Each boiler must have a properly sized and installed American Society of Mechanical Engineers rated pressure relief valve Water expands a...

Page 37: ...e boiler warranty if evi dence of improper flushing is revealed Consult with your heating professional for recommendations Piping Recommendations System leaks may not always be visible An unseen syste...

Page 38: ...for a list of boiler manufacturer approved products Always clean system prior to using antifreeze refer to the Cleaning the Hydronic System section of this manual for details Only use the antifreeze...

Page 39: ...In these cases it is recommended to flush the system and refill with untreated water and new boiler manufacturer ap proved antifreeze suitable for Aluminum heat exchangers IMPORTANT Regardless of anti...

Page 40: ...agrams in Section VII Near Boiler Piping for more information Close all zone service valves on the supply and return 1 piping and close the expansion tank service valve Drain expansion tank Open the f...

Page 41: ...s control which has been under water STOP Read the safety information above on this label 1 Set thermostat to lowest setting 2 Turn off all electric power to the appliance 3 This appliance is equipped...

Page 42: ...cating 2 Volt power is being supplied to the inte grated control A B C m D m E m Thermostat calls for heat energizing system circulator A l B m C m D m E m Integrated boiler control goes through self...

Page 43: ...minates in dicating the hot surface igniter is powered for the 20 second igniter warm up period The bright yellow orange glow of the hot surface igniter can be observed through the observation port in...

Page 44: ...of the local gas 3 supply from the gas utility At sea level elevation it should be approximately 1000 Btu s per standard cubic foot Operate boiler for 5 minutes 4 Turn off all other gas appliances ext...

Page 45: ...information on correct orifice sizing The specific gravity G and the higher heating value HHV of the local natural gas must be obtained from the local gas utility in order to determine the proper orif...

Page 46: ...ND ADJUSTMENTS in this manual when reading the manifold pressure When measurement is completed disconnect the U Tube Manome ter or Differential Pressure Gauge Be sure to reinstall the plug using appro...

Page 47: ...BTU HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation bo...

Page 48: ...es Check the air baffle located inside 1 x 2 flexible coupling on the mixer clean it if necessary and make sure to put it back Refer to repair parts diagram of mixer and pressure switch assembly for e...

Page 49: ...d to freezing temperatures drain condensate lines Otherwise do not drain system or boiler Annual Examination And Cleaning Of Boiler Components The following service procedures must be performed only b...

Page 50: ...etely Once the condensate trap is emptied of water disconnect B condensate lines from the fittings on the boiler the vent tee and the condensate outlet Remove the condensate trap and run cold water th...

Page 51: ...VALVE LIGHT IS ON GAS VALVE OPENS FOR 5 SEC TRIAL FOR IGNITION BLUE ORANGE GLOW OF THE BURNER CAN BE SEEN THRU OBSERVATION PORT 2 SEC INTO THE 5 SEC IGNITION TRIAL POWER IS TURNED OFF TO THE HOT SURFA...

Page 52: ...or heat or turning the service switch off and back on or b waiting for the control to automatically reset after 15 minutes for loss of combustion airflow or one hour for loss of flame DRAFT INDUCER TE...

Page 53: ...53 DETAILED SEQUENCE OF OPERATION...

Page 54: ...it is being damaged by some other problem an electrical short burning out a transformer for example Initial Service Checks Before troubleshooting 1 Make sure that circuit breaker is on or fuse is ok a...

Page 55: ...FF OFF DURING PURGE CYCLE DRAFT INDUCER IS NOT POWERED OR AIR FLOW IS NOT PROVEN OFF DURING IGNITER AND RUN CYCLE NORMAL OPERATION PURGE CYCLE COMPLETE BLINKING IBC IS LOCKED OUT PROBLEM COULD INDICAT...

Page 56: ...gas supplier s instruction If you can not reach your gas supplier call the fire department Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supp...

Page 57: ...57 TROUBLESHOOTING CHART 2 TROUBLESHOOTING...

Page 58: ...58 TROUBLESHOOTING CHART 3 TROUBLESHOOTING...

Page 59: ...ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON NO NO CHECk FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT NO REPLACE IBC yES REPAI...

Page 60: ...60 TROUBLESHOOTING CHART 5 TROUBLESHOOTING...

Page 61: ...SPECIFIC TOOLS NO yES REPLACE BURNER REPLACE IBC BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT AqUASTAT CONTACTS CLOSED NO BOILER OFF ON HIGH LIMIT IS ACTUAL BOILER WATER TEMP GREATER THA...

Page 62: ...heat Boiler Status Differential Pressure w c Pressure Switch Connects Not Running 0 Normally Open Setpoint 1 00 for Model 100 1 35 for Model 75 1 55 for Model 50 Running Without Blockage Greater Than...

Page 63: ...REPAIR PARTS Model No UB90 50 UB90 75 UB90 100 UB90 50 100 GAS FIRED DIRECT VENT CONDENSING HOT WATER Boiler...

Page 64: ...64 20 3 5 TYP OF 4 6 11 8 9 10 13 15 16 2 12 1 21 17 18 18 4 19 7 A Jacket and Base Assembly Repair Parts...

Page 65: ...14631120 13 RACO 232 4 4 2 BOX 1 14631316 14 15 P S SWITCH 691 I 1 14631319 16 COVER PLATE RACO 902 802 1 14631318 17 419 1AA1 2 PLUG 2 14631174 18 415 1AA1 1 PLUG 2 14631171 19 BPF 3 PLUG 1 14631176...

Page 66: ...59019 IDx1 8 THK VINYL TUBING AS REQUIRED 14631035 2 57134 SNAP GRIP CLAMP 6 14631141 3 62067 ID HOSE TEE 1 14631320 4 62017 NPTx ID TUBE STRAIGHT 1 14631101 5 PVC COUPLING SCH 80 1 14631306 6 4 PVC N...

Page 67: ...DRAFT BLOWER KIT 1 2272065 6 BLOWER GASKET 1 14631026 7 FLUE CONNECTOR 1 12101021 8 RECOVERY COIL GASKET 1 14631027 9 1 4 20 HEX NUT W SERRATED WASHER BLOCK 4 14695810 10 1 8 NPT 1 4 HOSE ID BRASS BAR...

Page 68: ...68 20 21 22 23 24 10 25 3 19 TYP OF 5 12 5 18 14 TYP OF 5 1 14 TYP OF 4 TYP OF 4 TYP OF 4 13 11 2 26 15 8 TYP OF 8 17 15 2 4 16 9 29 30 28 27 6 28 D Boiler Block and Piping Assembly Repair Parts...

Page 69: ...3 16 RH ALH CAP 2 13 14684012 PLASTIC BAG 12 X 9 2 MIL 1 14 14695805 STUD THREADED 1 4 20 X 1 1 4 9 15 1510001 TEE RDCR 1 1 4 X 3 4 X 1 1 4 2 16 14693058 3 4 SQ HD PLUG 1 17 14693056 1 HEX SOCKET PLUG...

Page 70: ...70 13 14 4 11 10 12 5 26 14 14 25 6 7 8 9 19 19 21 21 19 24 22 2 28 3 21 23 18 4 20 17 28 15 16 19 27 1 To Sight Glass Adapter E Mixer and Air Pressure Switch Assembly Repair Parts...

Page 71: ...631308 17 62064 ID TUBE TEE 1 14631104 18 ID TUBE 4 WAY CONNECTOR 1 14631313 19 3 8 HOSE CLAMP HC 6ST 10 14631143 20 PC250 12VINYL CAP 2 14631151 21 59006 IDx3 8 OD VINYL TUBING AS REQUIRED 14631033 2...

Page 72: ...Product Literature Lennox Industries Inc Dallas Texas...

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