Lennox International Inc. GWB9-100IH-2 manual

P/N# 240009449, Rev . A [07/2012] RET AIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions must be af fi xed on or adjacent to the boiler . GWB9-050IH-2 GWB9-075IH-2 GWB9-100IH-2 GAS-FIRED , DIREC T VENT , C ONDENSING, HO T W A TER BOILER INST ALLA TION INSTRUCTIONS PRODUCT LITERA TURE Lennox Industries Inc. Dallas, T exas This boiler ca[...]

2 DIMENSIONS 2 2 Figure 1 - Boiler Dimensions[...]

3 INTRODUCTION Introduction • This appliance is a gas- fi red direct vent hot water boiler with cast aluminum boiler sections. • The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger, cooling fl ue gases and causing condensation. • Sealed combustion, premix gas burner, and low fl ame temperature means[...]

4 Installation shall conform to requirements of author- ity having jurisdiction or in absence of such require- ments: • United States • National Fuel Gas Code, ANSI Z223.1/NFPA 54 . • National Electrical Code, NFPA 70. • Canada • Natural Gas and Propane Installation Code, CAN/CSA B149.1. • Canadian Electrical Code, Part I, Safety Standa[...]

5 Table 1 - SEA LEVEL RATINGS – NATURAL AND PROPANE GASES Model Input *(MBH) ++ Heating Capacity *(MBH) Net AHRI Rating *(MBH) Shipping Weight (lbs.) Flue Diameter 90-50 50 45 39 220 2” CPVC & PVC 90-75 75 68 59 220 2” CPVC & PVC 90-100** 100 90 78 220 2” CPVC & PVC * 1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour BOIL[...]

6 Table 2 - 90 - 50/75/100 SERIES 2 NATURAL GAS MODEL 90-50 Stock Factory Btu V alue of Natural Gas++ Settings 750 850 950 1000 1050 Altitude in Ft. 0-5,000 5,000-10,000 Normal Input (MBH) 50 – – – – – Manifold Pressure In W .C. 2.5 4 4 3.5 2.5 2.5 Ori fi ce 43331094 43331094 MODEL 90-75 Stock Factory Btu V alue of Natural Gas++ Settings[...]

7 Table 3 - 90 - 50/75 SERIES 2 PROPANE GAS MODEL 90-50 Stock Factory Btu V alue of Propane Gas++ Settings 2300 2350 2400 2450 2500 Altitude in Ft. 0-5,000 5,000-10,000 Normal Input (MBH) 50 –– – – – Manifold Pressure In W .C. 2.5 3 3 2.5 2.5 2.5 Ori fi ce 43331095 43331095 MODEL 90-75* Stock Factory Btu V alue of Propane Gas++ Settings [...]

8 Boiler Sizing Check to be sure you hav e selected boiler with proper capacity before starting installation. AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. See T able 1, Page 5 . Heat loss calculations shou[...]

9 Table 4 - Required Clearances Unit Combustible Clearance Accessibility , Cleaning, and Servicing T op 1” (26mm) 8” (204mm) Left Side 1 “ (26mm) 24” (610mm) Right Side 1 1” (280mm) - Base 1” (26mm) - Front 1” (26mm) 24” (610mm) Back 1” (26mm) - Intake/V ent Piping 0 (0) - Near Boiler Hot W ater Piping 1” (26mm) - All distances [...]

10 Condensate Drain Requirements • Pitch condensate drain line down to fl oor drain at mini- mum of ¼” per foot. External condensate pump (not furnished) may be used if fl oor drain is not available. • Condensate pump must be designed for fl ue gas con- densate application. • Condensate trap provided with boiler, an additional trap is n[...]

11 Clean the System First Before connecting boiler to heating system, clean and fl ush system thoroughly . V erify system is free of sediment, fl ux and any residual boiler water additiv es. Systems having antifreez e not recommended must be completely fl ushed to insure no old antifreeze remains. In older systems obviously discolored, murky or [...]

12 NEAR BOILER PIPING Figure 2 - Single Zone Boiler Piping[...]

13 Figure 3 - Two Zone Boiler Piping With Zone Valves NEAR BOILER PIPING Multi-Zone Systems Multi-zone systems with two zones are typically piped as shown in fi gures 3 or 4. Multi-zone systems with more than two zones are likely to have small zones with very low heat and fl ow requirements compared to full heating capacity of the boiler. This ca[...]

14 Figure 4 - Two Zone Boiler Piping With Circulators NEAR BOILER PIPING[...]

15 NEAR BOILER PIPING Figure 5 - Primary/Secondary Piping And Wiring With Circulators And Domestic Hot Water[...]

16 NEAR BOILER PIPING Figure 6 - Piping and Wiring Primary/Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water (With Zone Valve)[...]

17 NEAR BOILER PIPING Figure 7 - Piping And Wiring Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator)[...]

18 Safety Relief Valve Installation of safety relief valv e shall conform to ANSI/ ASME Boiler and Pressure V essel Code, Section IV . • Install furnished safety relief valve using 3/4” x 4½” pipe provided with boiler. See Figure 8 . • Install safety relief valve with spindle in vertical position. • Do not install shutoff valve between b[...]

19 Figure 9 - Diaphragm Type Expansion Tank Piping NEAR BOILER PIPING[...]

20 Figure 10 - Conventional (Closed Type) Expansion Tank Piping NEAR BOILER PIPING[...]

21 Condensate Drain Piping Boiler is factory equipped with a condensate trap . An additional trap is not required and should NO T be used. 1. Provide ½” PVC condensate drain and fi ttings. Condensate drain to be pitched down to fl oor drain at a minimum of ¼” per foot. 2. Install ½” PVC tee to over fl ow fi tting as shown in Figure 11 [...]

22 Connections And Termination Provisions for combustion and ventilation air must be in accordance with section, Air For Combustion and V entilation, of the National Fuel Gas Code,ANSI 2223.1/ NFPA54, or Sections 8.2, 8.3 or 8.4 of National Gas and Propane Installation Code, CAN/CGA-B 149.1, or applicable provisions of the local building code. Boil[...]

23 • Under certain conditions, fl ue gas will condense, forming moisture, and may be corrosive. Take steps to prevent building materials at vent from being damaged by exhaust of fl ue gas. • Vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces. 9. Venting system shall terminate at leas[...]

24 Figure 12 - Roof Vent / Intake Terminations COMBUSTION AIR AND VENT PIPE VENT AIR INTAKE[...]

25 Figure 13 - Side Wall Vent / Intake terminations - Less Than 12” Clearance Above Grade Figure 14 - Side Wall Vent/Intake Terminations - 12” Or More Clearance Above Grade COMBUSTION AIR AND VENT PIPE Less Than 12” Clearance 12” Or More Clearance[...]

26 Figure 15 - Concentric Vent Terminations Combustion Air V ent 1" (2.54cm) Maximum Maintain 12" clearance abov e highest anticipated snow level or grade * See Note Below V ent Combustion Air 36"(0.9m) Minimum Maintain 12"(30cm) clearance abov e highest anticipated snow level or grade 12" (30cm) Minimum *Must be less than [...]

27 Figure 18 - Combustion Air and Vent Piping - Boiler Connections COMBUSTION AIR AND VENT PIPE 2” (50.8mm) DIAMETER VENT AND COMBUSTION AIR INTAKE PIPING - 21 feet maximum total equivalent length for 90-100 models -26 feet maximum total equivalent length for 90-50 and -90-75 models - 2 feet minimum total equivalent length for all models TRANSITI[...]

28 Check Gas Supply Gas pipe to your boiler must be correct size for length of run and for total Btu per hour input of all gas utilization equipment connected to it. See T able 7, Page 29 . Boiler and its individual shutoff valv e must be disconnected from gas supply piping system during any system pressure testing at test pressures in excess of ½[...]

29 Table 7 – Gas Pipe Sizes NA TURAL GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour Input Includes Fittings 1/2” 3/4” 1” 1 1/4” 20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000 60 50,000 105,000 195,000 365,000 PROPANE GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour Input Includes Fittings Copper T ubing* I[...]

30 Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. R efer to: • USA- National Electrical Code, ANSI/NFPA 70. • Canada - Canadian Electrical Code, Part I, CSA C22.1: Safety Standard for Electrical Installations. Electric Power Supply Prior to making any line V oltage connections, turn OFf elec[...]

31 Figure 20 - Wiring Schematic ELECTRICAL WIRING NOTICE If any of original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent[...]

32 Figure 21 - Ladder Wiring Diagram ELECTRICAL WIRING[...]

33 Figure 22 - Suggested Wiring Schematic for Domestic Hot Water Priority Two Zone System with Circulators Using Argo AR822II Pump Relay ELECTRICAL WIRING[...]

34 Figure 23 - Ladder Diagram for Figure 22 ELECTRICAL WIRING[...]

35 This section provides a brief description of the key controls and accessories found in this boiler . See Figure 26, Page 41 for detailed sequence of operation. See the Repair P arts Manual for locations of all control components and accessories described. Integrated Boiler Control (IBC) Integrated Boiler Control (IBC) is a microprocessor based c[...]

36 Casting Temperature Safety Switch In event of lack of or loss of water in boiler , Casting T emperature Safety Switch (300 °F setpoint) installed on top of the aluminum boiler section shuts off boiler by shutting off power to Integrated Boiler Control (IBC). This fault requires manual reset of casting temperature safety switch to restart the bo[...]

37 Water Quality, Water Treatment and Freeze Protection - see Appendix A Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks Refer to the appropriate diagr ams, “Near Boiler Piping” on page 11 for more information. 1. Close all zone service valves on the supply and return piping. Open the feed valve and fi[...]

38 Stop! Read Safety information above. 1. Set thermostat to lowest setting. 2. Turn off all electric power to the appliance. 3. This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. 4. Remove the front jacket panel. 5. Turn the gas control knob clockwise to “OFF”. 6. W[...]

39 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS S9381A control has a number of user adjustable parameters as shown in Table 8. Table 8 - User Parameters Adjusting Settings T o discourage unauthorized changing of settings, a procedure to enter the adjustment mode is required. T o enter the adjustment mode, press the UP , DOWN, and I bu[...]

40 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS Table 9 - State Code De fi nitions[...]

41 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS Figure 26 - Sequence of Operation[...]

42 First couple of cold starts may be rough due to gas line not being completely purged of air , causing low fi ring r ate and high excess air levels. Inspect Venting And Air Intake System Operate boiler and v erify all vent/air intake connections are gas-tight and watertight. R epair any leaks immediately . Inspect Condensate Drain V erify all co[...]

43 CHECK OUT PROCEDURE AND ADJUSTMENT F. After adjusting input rate, turn boiler off, remove manometer or pressure gauge, reinstall ⅛ ” plug on gas valve. Turn boiler on. G. Boiler should typically operate between: • 8.5% -10.0% CO2 on Natural Gas • 9.5% -11.0% CO2 on Propane Gas Under all conditions CO level should not exceed 100 ppm. 9. R[...]

44 Following steps and diagr am indicate location of the connection points required to measure manifold pressure. Manifold pressure may be measured using a U- T ube Manometer or Differential Pressure Gauge. Diagram shows connection of both measuring devices. Only ONE DEVICE IS REQUIRED to measure manifold pressure. Remo ve plug. Install appropriate[...]

45 Maintenance As Outlined Below Can Be Performed By Owner Unless Otherwise Noted. • The acidic nature of fl ue gasses condensing on aluminum boiler sections may cause formation of aluminum oxide. This oxide formation is normal, is generally uniform throughout boiler sections, and represents negligible mass of aluminum that is consumed by oxidat[...]

46 K. Reinstall burner and mixer gasket and position mixer assembly over studs. Install fi ve (5) nuts but do not tighten. Reinstall igniter and igniter gasket and fasten with two (2) screws. Use care when installing the igniter. Tighten fi ve (5) nuts holding mixer assembly. L. Connect: • Gas line to gas valve • Condensate drain line to boil[...]

47 Important 1. In reset from lockout condition, all electrical meter readings at the gas control valve (24 vac) must be taken within trial for ignition period. 2. If any component does not function properly, make sure it is correctly installed and wired before replacing it. 3. Static electricity discharge can damage integrated boiler control (IBC)[...]

48 TROUBLESHOOTING Table 10 - Error Codes[...]

49 • Following steps and diagram indicate locations of connection points required to check differential air pressure. • Differential air pressure switch is safety device which prevents boiler from fi ring if there is air intake, boiler heat exchanger or vent blockage. • Turn off service switch, or lower thermostat setting. • Remove vinyl c[...]

50 Aluminum Series High Ef fi cien c y Gas -Fired B o i ler D I ELECTR I C ISOL A T I ON & AN TIFREEZE PR O TECT I ON ADDENDUM APPENDIX A - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION WARNING F ollow these instructions to prevent damage to boiler’s heat ex changer caused by inadequate dielectric isolation, incorrect water treatment [...]

51 System and Operating Precautions Applies to ALL Aluminum High Ef fi ciency Gas-Fired Water Boilers Eliminate System Leaks Continuous addition of make-up water will constantly add oxygen to system. Eliminate all system leaks. All system leaks must be repaired immediately . DO NOT use stop leak compounds. Leaks in threaded connections in aluminum[...]

52 System and Operating Precautions Applies to ALL Aluminum High Ef fi ciency Gas-Fired Water Boilers General Guidelines When Using Antifreeze • Use only antifreeze products recommended for use with aluminum boilers, as listed in this addendum. See Table 11. • Continuous addition of make-up water will dilute power of antifreeze and change buff[...]

53 Compatible Aluminum Antifreeze & Inhibitor Suppliers Noburst AL Antifreeze Noble Company P . O. Box 350 Grand Ha ven, MI 49417 www .noblecompany .com T el: 800-878-5788 F ax: 231-799-8850 Rhogard Antifreeze & Pro-Tek 922 Inhibitor* Rhomar W ater Management, Inc. P . O. Box 229 Spring fi eld, MO 65801 www .rhomarwater .com T el: 800-543-[...]

54 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________  Installation instructions have been followed  Checkout procedure and adjustments performed  Maintenance and Service issues reviewed with owner/ maintenance person  Installation booklet af fi xed on or[...]

55 NOTES[...]

PRODUCT LITERA TURE Lennox Industries Inc. Dallas, T exas Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www .ecrinternational.com[...]