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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

Содержание GWB9

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 53: ...53 DETAILED SEQUENCE OF OPERATION...

Страница 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...

Страница 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...

Страница 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...

Страница 57: ...57 TROUBLESHOOTING CHART 2 TROUBLESHOOTING...

Страница 58: ...58 TROUBLESHOOTING CHART 3 TROUBLESHOOTING...

Страница 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...

Страница 60: ...60 TROUBLESHOOTING CHART 5 TROUBLESHOOTING...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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