Lennox GCWB95W-150-205 Wall-Mount Installation Instructions

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Lennox GCWB95W-150-205 Wall-Mount Installation Instructions | Manualzz

PRODUCT LITERATURE

Lennox Industries Inc.

Dallas, Texas

INSTALLATION

INSTRUCTIONS

GCWB95W-150

GCWB95W-205

CONDENSING

WALL MOUNTED GAS

BOILER

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 could result in death or serious injury. Refer to this manual for assistance. For additional information consult a qualified installer, service agency, or the gas supplier.

WALL MOUNTED GAS-FIRED HOT WATER

BOILERS

These Gas-Fired Water boilers are low pressure, Design

Certified by CSA (Canadian Standards Association) for use with Natural and Propane Gases. They are constructed and hydrostatically tested for a maximum working pressure of 50 psi (pounds per square inch) in accordance with

A.S.M.E. (American Society of Mechanical Engineers)

Boiler and Pressure Vessel Code Section IV Standards for Heating Boilers.

240012994 Rev. B [08/31/2020]

VERIFY CONTENTS RECEIVED

Fully Assembled Boiler

Drain Valve

Metal Wall Bracket w/ 4 ea Wall Screws and Plugs

30 PSI Safety Relief Valve

Temperature Pressure

Gauge

4 ea - 17x24x2 Gaskets

Includes Essential

Documents and Warranty

11x17 Wire Diagrams

*5 GPM Flow Restrictor 205

Combi - Factory Installed

Used for Valve

Connections

Document Package

Wall Mount Template

*Manifold

* Verify proper unit size before use.

Template

For Parts lists see manual 240012996 included with your boiler literature package.

2

240012994 Rev. B [08/31/2020]

Verify Contents Received ...............................................2

Table Of Contents ..........................................................3

Physical Data.................................................................4

1 - Important Information .............................................6

2 - Introduction .............................................................7

2.3 Requirements For Commonwealth Of Massachusetts: .7

2.4 Use Of Carbon Monoxide Monitor ........................... 7

2.5 Designated Use .................................................... 7

2.6 The Unit Must Not ................................................ 7

2.7 Operational Features............................................. 7

4 - Locating Boiler .......................................................10

4.1 Boiler Location Considerations ...............................10

4.2 Clearances .........................................................11

4.3 Wall Mounting .....................................................12

5 - Combustion Air And Vent Piping .............................13

5.1 General ..............................................................13

5.2 Removal Of Existing Boiler From Common Vent System

..............................................................................14

5.3 Definitions ..........................................................14

5.4 Approved Venting Materials .................................15

5.5 Vent Termination .................................................15

5.6 Coaxial Venting Instructions .................................16

5.4 Coaxial Vent Screw Placement - See Figure 5-2 ... 16

5.8 Twin Pipe Systems ...............................................18

5.9 Securing Twin Pipe Polypropylene Venting ........... 19

5.10 (3" / 80 Mm Only) Flexible Vent System ........ 22

5.11 Condensate Piping .............................................24

6 - Hydronic Piping .........................................................25

6.1 General ..............................................................25

6.3 Safety Relief Valve And Air Vent ............................26

6.2 Special Conditions ...............................................26

6.4 Trim Piping .........................................................27

6.5 System Piping .....................................................27

6.6 External Optional Low Water Cut Off ................. 29

6.7 Manufacturer Recommendation - Strainer .......... 30

6.8 Central Heating System ........................................31

6.9 Domestic Hot Water Mode ....................................31

6.10 Frost Protection Mode ........................................31

6.11 Pump Protection ................................................31

7 - Gas Supply Piping ..................................................32

7.1 General ..............................................................32

7.2 Leak Check Gas Piping .........................................33

7.3 Gas Orifice .........................................................33

8 - Electrical Connections ............................................34

8.1 General ..............................................................34

8.2 Install Room Thermostat ......................................34

8.3 Electrical Connections ..........................................34

8.4 Access To Connection Block ..................................35

8.5 Main Supply Connection .......................................35

8.6 Install Room End Switch .......................................36

8.7 Optional Electrical Connections .............................36

8.8 Management Of 0-10v Input .................................37

9 - Start Up Procedure .................................................39

9.1 Central Heating System Connections - Combi ...... 38

9.2 System Start Up .................................................39

9.3 Fill Condensate Trap With Water ............................39

TABLE OF CONTENTS

9.4 Control Panel ......................................................40

9.5 Prior To Commissioning: .......................................41

9.6 Commissioning For The First Time: ........................41

9.7 Automatic Calibration Function ..............................41

9.8 Manual Calibration Function: .................................42

9.9 Deaeration Function.............................................42

9.10 Commission Set Up (Gas) - Changing The Type Of Gas 42

9.11 Chimney Sweep Function (Co2 Adjust) ............. 43

9.12 Combustion Adjustment Function (Co2%) ......... 43

9.13 Check Firing Rate ..............................................43

9.14 Description Of Parameters: Factory Settings ...... 44

9.15 Parameter Settings ............................................44

9.16 Adjusting Maximum Heating Power ......................46

10 - Operating Instructions .........................................47

10.1 T esting For Gas Leaks And Purging The Gas Supply 47

10.2 Boiler Operation ................................................47

10.3 Central Heating Mode .........................................47

10.4 Domestic Hot Water Mode ...................................47

10.5 Frost Protection .................................................47

10.6 Pump ...............................................................47

10.7 Low Water Pressure Sensor (Internal) ............ 47

11 - General Maintenance And Cleaning ......................48

11.1 Beginning Of Each Heating Season .......................48

11.2 Maintenance And Routine Servicing ......................49

11.3 Component Replacement And Cleaning ............. 49

11.4 Draining The Boiler ............................................50

11.5 Draining The Heating Circuit ...............................50

11.6 Hydraulic Unit (Dhw) ..........................................51

11.7 Cleaning The Cold Water Filter .............................51

11.8 Final Commissioning ..........................................51

11.9 Final Assembly ..................................................51

11.10 User Information .............................................52

11.11 Safety Flue Thermostat ....................................52

11.12 Flue Pressure Switch (150 Only) .

................. 52

11.13 Replacement Parts ...........................................52

12 - Ratings And Capacities .........................................53

12.1 Ratings And Capacity .........................................53

12.2 Domestic Hot Water Specifications .......................53

12.3 High Altitude Ratings .........................................54

12.4 High Altitude Chart ............................................54

13 - Trouble Shooting ..................................................55

13.1 Error Messages And Resetting The Boiler .......... 55

13.2 Anomalies Table For The Installer ........................57

14 - Glossary ...............................................................58

Appendix A - Wiring Diagrams .....................................60

Appendix A - Wiring Diagrams .....................................61

3

240012994 Rev. B [08/31/2020]

Dimensions

G

H

I

C

D

A

B

E

F

DIMENSIONS

Height

Width

Depth

Condensate Trap Connection

System Supply

DHW Outlet

Gas Connection

DHW (Cold Water) Inlet

System Return

Boiler Filling Connection

Primary Water Content

SYSTEM

Central Heating (Sealed System)

Heat Exchanger Max Allowable Working

Pressure

Max System Pressure

Min System Pressure

Max System temperature

Pressure Relief Valve Setting

Expansion Tank Minimum Size

(pre-charge press.)

Recommended System Pressure (cold)

Domestic Hot Water (Sealed System)

Max Inlet Water Pressure

Min Inlet Water Pressure

Min DHW Flow Rate

Max DHW Temperature

DHW Water Content

PHYSICAL DATA

150

30" [763 mm]

17 3/4 " [450 mm]

13 9/16 " [345 mm]

13/16" [21 mm] ID Hose

3/4” [19.1 mm]

1/2” [15.9 mm]

205

30 " [763 mm]

17 3/4 " [450 mm]

21 1/2" [571 mm]

3/4" [19.1 mm] NPT

1” [25.4 mm]

3/4” [19.1 mm]

3/4” [19.1 mm]

1/2” [15.9 mm]

3/4” [19.1 mm]

3/4” [19.1 mm]

3/4” [19.1 mm] 1” [25.4 mm]

External to Boiler

1 gal [3.60 L] 1 1/4 gal [4.73 L]

150

50 psi [3.45 bar]

30 .00 psi [2.11 bar]

7.25 psi [ 0.50 bar]

176°F [80°C]

30 .00 psi [2.11 bar]

2.2 gal at 11.6 psi

[10.0 L at 0.8 bar]

21.7 psi [1.5 bar]

205

50 psi [3.45 bar]

30 .00 psi [2.11 bar]

7.25 psi [0.50 bar]

176°F [80°C]

30 .00 psi [2.11 bar]

2.2 gal at 11.6 psi

[10.0 L at 0.8 bar]

21.7 psi [1.5 bar]

150

116 psi [8 bar]

2.9 psi [ 0.2 bar]

0.55 gpm [2.50 L/min]

140°F [60°C]

0.05 gal [0.23 L]

205

116 psi [8 bar]

2.9 psi [0.2 bar]

0.55 gpm [2.50 L/min]

140°F [60° C]

0.10 gal [0.37 L]

When boiler is operating at maximum operating temperature, providing heating with all heat emitters operating, pressure gauge should not indicate more than 26.11 psi / 1.80 bar. If the system pressure increases more than 2 psi at maximum temperature or if continued relief valve operation is witnessed, then a larger expansion tank is needed.

4

240012994 Rev. B [08/31/2020]

A

Front View

All Models

B

PHYSICAL DATA

Top View

All Models

Combustion

Air

Vent

Connector

150 COMBI

Bottom View

Dimensions

D E F G H I

205 COMBI

Bottom View

Dimensions

D E F G H I

C

31/2"

6"

B

9"

6"

31/2"

5"

7"

C

3"

51/2"

B

9 1/2"

7"

41/2"

51/2"

101/2"

5

240012994 Rev. B [08/31/2020]

1 - IMPORTANT INFORMATION

1. Safety Information

Boiler installation shall be completed by qualified agency. See glossary for additional information.

!

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

FOR YOUR SAFETY READ BEFORE OPERATING

!

DANGER

!

WARNING

Do not tamper with or use this boiler for any purpose other than its intended use. Failure to follow these instructions could result in death or serious injury.

Use only manufacturer recommended parts and accessories.

!

CAUTION

Laceration, burn hazard. Metal edges and parts may have sharp edges and/or may be hot. Use appropriate personal protection equipment to include safety glasses and gloves when installing or servicing this boiler. Failure to follow these instructions could result in minor or moderate injury.

!

WARNING

Fire, Explosion, Asphyxiation, Electrical shock hazard!

Flooding will result in damages such as electrical problems, corrosion, inoperative parts, mold and other unforeseen issues which can occur over time. Any equipment determined by a professional as damaged by a flood, defined as excess of water or other liquid, shall be replaced. Failure to follow these directions will result in a Hazardous Situation.

Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

!

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury.

Hot Water Can Scald

!

Water heated to temperature for clothes washing, dish washing and other sanitizing needs can scald and cause permanent injury.

Children, elderly, and infirm or physically handicapped persons are more likely to be permanently injured by hot water. Never leave them unattended in bathtub or shower. Never allow small children to use a hot water tap or draw their own bath.

If anyone using hot water in the building fits the above description, or if state laws or local codes require certain water temperatures at hot water taps, you must take special precautions:

• Use lowest possible temperature setting.

• Install some type of tempering device, such as an automatic mixing valve, at hot water tap or water heater. Automatic mixing valve must be selected and installed according to manufacturer's recommendations and instructions.

• Water passing out of drain valves may be extremely hot. To avoid injury:

• Make sure all connections are tight.

• Direct water flow away from any person.

!

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

!

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

Water

Temperature

Setting

120° F

130° F

140° F

150° F

160° F

1st Degree Burn

Exposure Time For

An Adult

1 minute

5 seconds

2 seconds

1 second

Instantaneous

2nd and 3rd Degree Burn

Exposure Time For An

Adult

5 minutes

30 seconds

5 seconds

1.5 seconds

0.5 seconds

Note: Warning for Infants, Children, and Elderly:

Great care must be taken when exposing the aforementioned groups to warm or hot water as they can be badly burned in exposure times less than half of the time for an adult.

6

240012994 Rev. B [08/31/2020]

2 - Introduction

2.1 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

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 Standard for

Electrical Installations, CSA C22.1

2 - INTRODUCTION

2.5 Designated Use

• GCWB9-150 and GCWB95W-205 provide both central heating and domestic hot water.

• Indoor installation.

• Closet or alcove installation. Direct Vent Boiler does not require air vents when installed in closet or room.

• Direct vent boiler, requires fresh air intake piped from outdoors.

• For use with natural gas or liquefied petroleum gases

(LP/propane).

2.2

Where required by authority having jurisdiction, installation shall conform to Standard for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be required.

2.3 Requirements for Commonwealth of

Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not limited to:

Installation by licensed plumber or gas fitter.

2.6 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).

• Toxic chemicals, such as those used for boiler treatment, shall not be introduced into potable water used for space heating.

• Exceed 43 psig (2.96 bar) maximum system pressure, or drop below minimum system pressure 7.25 psig (.50 bar)

• Exceed 176°F (80°C) system design temperature.

2.4 Manufacturer recommends use of Carbon

Monoxide monitor may be requirement of local jurisdiction.

2.7 Operational Features

• GCWB95W-150 Modulates input to provide CH

Turndown 5.7:1, DHW Turndown 7:1

• GCWB95W-205 Modulates input to provide CH

Turndown 5.5:1, DHW turndown 7:1

• Maximum output available for domestic hot water:

GCWB95W-150 - 136,000 btu/h (40 kW), capable of providing 3.5 (U.S.) gpm (13.2 liters/min) with a temperature rise of 70°F/39°C.

GCWB95W-205 - 180,000 btu/h (53 kW), capable of providing 5.0 (U.S.) gpm (18.9 liters/min) with temperature rise of 70°F/39°C.

• Integral Low Water Pressure Cutoff.

• Optional Outdoor Temperature Reset.

• Heat exchanger over heat protection.

• Boiler operating at maximum operating temperature, providing heat, pressure gauge should not indicate more than 26.11 psi / 1.80 bar. If reading exceeds this figure larger expansion tank is required.

Information and specifications outlined in this manual in effect at the time of printing of this manual. Manufacturer reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.

7

240012994 Rev. B [08/31/2020]

3 - COMPONENT LISTING

LENNOX GCWB95W-150

11

10

16

15

14

13

12

9 8 7 6 5

4

3

Illustrations are a depiction of the boiler for general location of parts and may vary depending on model.

8

17

18

19

20

21

22

23

24

1

2

ITEM

NO.

1 Pump with Air Separator

2 Boiler Drain Tap

3

Flow Sensor with Water Filter and Flow Restrictor

4 DHW Priority Sensor

5 Controlled Fast Fill

6 Gas Valve

7 NTC DHW Sensor

8 Low Water Pressure Cutoff

9 3-Way Valve with Motor

10 Check Valve

11 DHW Heat Exchanger

12 Water Safety Thermostat

13

NTC Heating sensor (Flow/Return)

QTY 2, (1 Shown for clarity)

14 Flue Sensor

15 Pressure Switch

16 Coaxial Connector

17

Heat Exchanger Temperature

Protector

18 Heat Exchanger

19 Burner (not shown)

20 Ignition Electrode

21 Flame Detection Electrode

22 Air/Gas Blend Manifold

23 Venturi

24 Fan

240012994 Rev. B [08/31/2020]

3 - COMPONENT LISTING

LENNOX GCWB95W-205

13

12

11

10

9

8 7 6 5

4 3

2

Illustrations are a depiction of the boiler for general location of parts and may vary depending on model.

9

18

19

20

22

23

24

1

14

15

16

17

21

ITEM

NO.

1 Pump

2 Flow Sensor

3

Flow Sensor with Water Filter and Flow Restrictor

4 DHW Priority Sensor

5 DHW Heat Exchanger

6 Gas Valve

7 NTC DHW Sensor

8 Low Water Pressure Cutoff

9 3-Way Valve with Motor

10

NTC Heating sensor (Flow/Return)

QTY 2, (1 Shown for clarity)

11 Water Safety Thermostat

12 Flue Sensor

13 Coaxial Connector

14

Heat Exchanger Temperature

Protector

15 Heat Exchanger

16

Burner Door Temperature

Sensor

17 Burner (not shown)

18 Ignition Electrode

19 Flame Detection Electrode

20 Air/Gas Manifold

21 Air Purge

22 Venturi

23 Silencer

2 4 Fan

240012994 Rev. B [08/31/2020]

4 - LOCATING BOILER

!

WARNING

Fire Hazard! Do not install on carpeting. Failure to follow these instructions could result in death or serious injury.

4.1 Boiler Location Considerations

• Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate.

• Approved for installation in closets or alcove provided it is correctly designed for that purpose and minimum clearances are met.

• Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Access to outdoors to meet minimum and maximum pipe lengths for combustion air and vent piping. See section 5.

• Disposal of condensate. See section 5.

• Drainage of water (or water - antifreeze solution) during boiler service or from safety relief valve discharge. See section 6.

• Access to system water piping, gas supply, and electrical service. See sections 6, 7 and 8 .

• Clearances to combustible materials and service clearances.

See Table 1 and Figures pg. 11.

• Boiler shall be installed on flat vertical wall which is capable of supporting the weight of the boiler.

• Room-sealed boiler installed in a room containing bath or shower shall be installed so person using bath or shower cannot touch any electrical switch or boiler control utilizing line voltage electricity.

• Multiple Boilers can be wall mounted, placed side by side, or back to back.

• Observe service clearances in all installations.

• For Direct Vent installations, air vents are not required in room boiler is installed in, or when installed in closet or compartment.

• Nécessite une prise d’air frais à l’extérieur.

TABLE 1: BOILER CLEARANCES

Dimension

Combustible

Materials (1)

Manufacturer

Recommended for Service (1)(2)

Top 0" (0 cm) 8-5/8" (220 mm)

Left Side 1-3/4" (45 mm) 1-3/4" (45 mm)

Right Side 1-3/4" (45 mm) 1-3/4" (45 mm)

Front

Back

0" (0 mm)

0" (0 mm)

17-3/4"(450 mm)

0" (0 mm)

Bottom 0" (0 mm)

*9-13/16"

(250 mm)

Combustion Air/

Vent piping

0" (0 mm) 6" (160 mm)

(1) Required distances measured from boiler jacket.

(2) Service, proper operation clearance recommendation.

* Allowance for piping at the bottom of boiler not included.

NOTE: Greater clearances for access should supersede fire protection clearances.

10

240012994 Rev. B [08/31/2020]

4 - LOCATING BOILER

4.2 Clearances

Service Clearances

150

13 9/16 in

[345 mm]

205

211/2 in

[571.5 mm]

Left Side View of Boiler

13.58 in /

345.00 mm

30 in

[763 mm]

1 3/4

Minimum Clearance

17 3/4 in. [450 mm ] in

[45 mm]

8 5/8 in [220 mm]

17 3/4 in

[450 mm]

9 13/16 in [250 mm]

1 3/4 in

Front View of

Boiler

Combustible Clearances

1 3/4 in

0 in

17 3/4 in

[450 mm]

1 3/4 in

[45 mm]

0 in

1 3/4 in

]

Top View

1 3/4 in

0 in

Closet Installation

0 in

Front View of Boiler

11

240012994 Rev. B [08/31/2020]

4 - LOCATING BOILER

FIGURE 4-2 Wall Mount Bracket (Included)

!

WARNING

Fire, explosion, and asphyxiation hazard. Lift boiler using chassis. Do not use front jacket, vent piping, water or gas fittings to lift boiler as it may cause damage to the boiler and/or separation of the exhaust piping. Failure to follow these instructions could result in death or serious injury.

Center brackets. Avoid overhang on sides of wall mount bracket.

!

CAUTION

Boiler weight exceeds 140 pounds (63.5 kg). Do not lift boiler onto wall without assistance.

Note Use two (2) wrenches when tightening and fitting to pipe boiler's threaded fittings. Boiler's internal piping can be damaged if subjected to excessive torque.

4.3 Wall Mounting

1. Decide position of boiler on the wall allowing for all required clearances and flue terminal position.

2.

Tape template to the wall. Ensure template is level and upright. Mark position of holes for boiler mounting bracket and plumbing connections.

3. Rear exit flue - mark position of hole for flue.

4. Side exit flue - mark horizontal center line of flue across the wall to side wall, then along side wall (ensure lines are parallel and sloped properly towards the boiler, refer to section 6. This will give position of center of hole for flue.

5.

Cut hole in wall for coaxial flue. See sizing below:

• 150 - 4 3/8 " [110 mm] diameter

• 205 - 5 5/16 " [135 mm] diameter

6. Pre-pipe supply and return water connections with factory fittings before wall mounting.

7. Mount boiler on wall using wall mounting bracket included with unit.

8.

Adjust the position of the boiler verify it is level and plumb.

Use four (4) predrilled holes for mounting bracket to wall

12

240012994 Rev. B [08/31/2020]

!

WARNING

ABS/PVC venting shall not to be used this product.

Use of DWV plumbing pipes to vent this boiler shall be prohibited.

Use of cellular core PVC (ASTM F891), cellular core

CPVC, or Radel® (polyphenolsulfone) in venting systems shall be prohibited.

Covering non-metallic vent pipe and fittings with thermal insulation shall be prohibited.

Failure to follow these instructions could result in death or serious injury.

Note

!

5 - COMBUSTION AIR AND VENT PIPING

WARNING

Fire, explosion, and asphyxiation hazard. Improper installation could result in death or serious injury. Read these instructions and understand all requirements before beginning installation.

Follow venting manufacturer's equivalent lengths for specialty fittings.

• Venting shall be supported adjacent to each joint using steel strapping or equivalent. See Figure 5-1.

• Support horizontal sections of vent pipe to prevent sags capable of accumulating condensate.

• Assemble vent materials in accordance with venting manufacturer’s instructions.

• Slope exhaust pipe minimum of 1/4” per foot, or vent manufacturer’s recommendation, whichever is greater; back toward the boiler.

• Any "in line" elbows in flue system must be taken into consideration. First elbow on the top of the boiler is included in equivalent length calculations.

• Use U.V. stabilized polypropylene when it will be exposed to sunlight, wind, or prone to freeze ups.

• Check for proper joint construction when joining pipe to fittings.

• Manufacturer requires use of an approved mechanical fastener, which may vary per vent pipe manufacturer, at every push-fit gasket connection when using a single wall polypropylene vent system.

5.1 General

• Installations shall comply with Authority having jurisdiction and in absence of such with:

» U.S. ANSI Z223.1 /NFPA 54 in the United States

» CSA B149.1 in Canada.

• This boiler requires a dedicated direct vent system.

• Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

• Use only manufacturer approved venting materials or venting materials primer and glue approved to: ULC S636 in Canada, or UL 1738 in the U.S.

• Materials used in the U.S. shall comply with Authority having jurisdiction and in absence of such with: ANSI/ASTM

D1785, ANSI/ASTM F441, ANSI/ASTM F493.

• Vent system must have unrestricted movement through walls, ceilings and roof penetrations.

• Check for proper joint construction when joining pipe to fittings.

• If vent is penetrating ceilings and floors, openings must have means of fire stopping in joist areas and proper firestop spacer assemblies installed.

• Standard roof flashing methods must be used to install roof flashing.

• Frame wall and roof openings to provide support for attachment of termination assemblies.

• Support piping in accordance with pipe manufacturer's instruction and authority having jurisdiction. In absence of manufacturer's instruction use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located at intervals of 3 ft (1.m) or less. Allow for expansion/ contraction of pipe.

13

Figure 5-1 - Venting Support

240012994 Rev. B [08/31/2020]

5 - COMBUSTION AIR AND VENT PIPING

5.2 Removal of Existing Boiler From Common Vent

System

When existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.

After removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation:

• Seal any unused openings in common venting system.

• Visually inspect venting system for proper size and horizontal pitch. Determine there is no blockage or restrictions, leakage, corrosion and other deficiencies which could cause an unsafe condition.

• When practical, close all building doors, windows, and all doors between space in which appliances remaining connected to common venting system are located and other spaces of building. Turn on clothes dryer and any appliance not connected to common venting system.

Turn on exhaust fans, such as range hoods and bathroom exhaust so they will operate at maximum speed. Do not operate summer exhaust fan. Close fireplace dampers.

• Turn on appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances will operate continuously.

• Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use flame of match or candle, smoke from cigarette, cigar or pipe.

• Determine each appliance remaining connected to common venting system properly vents when tested as outlined above. Then return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition of use.

• Any improper operation of common venting system should be corrected so installation conforms with National

Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1. When re-sizing any portion of common venting system, common venting system should be re-sized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/ or Natural Gas and Propane Installation Code, CAN/CSA

B149.1.

5.3 Definitions

1. Coaxial piping – Exhaust and air intake pipe have a common axis.

2. Twin Pipe - Exhaust and intake air are separate pipes, can be terminated using single wall terminals from the vent manufacturer or field built configuration using elbows or tees.

14

240012994 Rev. B [08/31/2020]

Manufacturer recommends this condensing boiler be vented with approved polypropylene venting material.

Use only materials listed below for vent pipe, intake air pipe, and fittings. Failure to comply could result in death or serious injury.

!

!

5 - COMBUSTION AIR AND VENT PIPING

WARNING

WARNING

• Covering non-metallic vent pipe and fittings with thermal insulation shall be prohibited.

• Use of cellular core PVC for venting flue gas could result in death, or serious injury.

• Coaxial venting shall be fastened with screws. Dual flue venting is NOT fastened with screws.

1. Venting shall be properly supported.

2. Boiler shall not support any type of vent system.

3. All piping, glue, solvents, cleaners, fittings and components must conform to ASTM and ANSI standards.

In Canada ULC S636 and in the USA UL 1738 schedule 40

CPVC are the only approved vent system to be used as an alternative to polypropylene venting for the exhaust pipe.

4. Manufacturer requires use of a mechanical fastener at every push-fit gasket connection when using a single wall polypropylene vent system.

!

WARNING

Do not use cellular core pipe. Only specified sized pipes are to be used. When using venting material other than boiler manufacturer's venting, note the correct installation procedure. Failure to follow these instructions could result in death, or serious injury.

5.4 Approved Venting Materials

Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

• USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54.

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

5.5 Vent Termination

• Terminate combustion air and vent pipes with fittings or coaxial vent kit.

Use horizontal pipe for vent and 90° elbow for combustion air termination when using fittings.

• Separate vent terminal from air inlet terminal to prevent flue gas recirculation. If T-Terminal is used on flue pipe at sidewall, air inlet terminal shall be at least 36" or more away from vent terminal.

• Locate combustion air termination as far as possible from swimming pool, swimming pool pump house, and other sources of airborne chlorine and other airborne chemicals or pollutants.

• Locate combustion air and vent terminals as required by authority having jurisdiction.

Approved Polypropylene Manufacturers

* Natalini

* DuraVent ®

*Centrotherm

* Z-Flex ®

Note: Maximum equivalent length may vary between manufacturers.

Vent Material Options

150

1 4" / 2" [100 mm / 60 mm] polypropylene coaxial.

205

1 5"/3" [125 mm/80 mm] polypropylene coaxial.

2

3

4

3" [80 mm] polypropylene twin pipe.

Shall be polypropylene on BOTH intake and exhaust.

2" [60 mm] polypropylene twin pipe.

Shall be polypropylene on BOTH intake and exhaust.

3" [80 mm] flexible polypropylene for chimney exhaust vent, shall have rigid 3" [80 mm] polypropylene on air intake.

2

3

4

3" [80 mm] polypropylene twin pipe.

Shall be polypropylene on BOTH intake and exhaust.

2" [60 mm] polypropylene twin pipe.

Shall be polypropylene on BOTH intake and exhaust.

3" [80 mm] flexible polypropylene for chimney exhaust vent, shall have rigid 3" [80 mm] polypropylene on air intake.

5

3" [80 mm] Twin pipe CPVC.

PVC optional on intake ONLY.

5

3" [80 mm] Twin pipe CPVC.

PVC optional on intake ONLY.

* Note: Adapters and fittings used with all vent systems shall be from same manufacturer and compatible with the vent pipe. See list for approved Manufacturers.

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5 - COMBUSTION AIR AND VENT PIPING

5.6 Coaxial Venting Instructions

Maximum equivalent flue lengths for Coaxial venting are:

Coaxial Pipe Vent Lengths

(Includes First Elbow And Termination)

Boiler Size 150 205

Vent Size

4"/2"

[100mm/60mm]

5"/3"

[128mm/80mm]

Maximum

ALL

ALL

Minimum

Natalini

DuraVent

32.8 ft [10m]

27.88 ft [8.5m]

Centrotherm 24.60 ft [7.5m]

32.8 ft [10m]

6 ft.

[1.8m]

!

WARNING

Asphyxiation hazard. Before securing the screws ensure the pipe has been pushed in a minimum of

1-3/4" (45 mm) into the gasketed end of the other pipe. Failure to follow these instructions could result in death or serious injury.

FIGURE 5-3 - Coaxial Venting Horizontal or Vertical

CAN BE USED ON ALL SIZES

2"

Coaxial Elbows - Equivalent length

45°

90°

45°

90°

4"/2" [100 mm/60 mm]

1.64 ft. [0.5 m]

3.28 ft. [1.0 m]

5” / 3” [128 mm/80 mm]

1.64 ft. [0.5 m]

3.28 ft. [1.0 m]

Coaxial Termination - Equivalent length 3 ft (0.9m)

NOTE: Coaxial venting can run horizontal or vertical.

The following instructions are for Natalini pipe, if using another approved manufacturer follow their venting instructions.

• Connect flue elbow to top of boiler and adjust direction of elbow to desired orientation (rear, right or left).

• Measure distance from outside wall face to elbow, this dimension will be known as 'X", add distance "Y" + 2" (60 mm) to "X" this is the total dimension of the vents. See

Figure 5-3.

• Mark dimension from above on outer aluminum intake vent. Measure length of waste material, and transfer dimension to inner grey flue pipe.

• Remove waste from both vents (flue and air). Verify cut ends are square and free from burrs. Insert flue back into intake air vent and pass them through hole in wall.

• Check all measurements before cutting. Clearance to combustible materials is zero when using coaxial vent system.

• After installing venting use calibrated analyzer to verify there is no recirculation of combustion.

• Ensure termination is positioned with slots at the bottom.

WT = Wall Thickness

Note: 2" is insertion depth of straight pipe to elbow.

2"

5.4 Coaxial Vent Screw Placement - See Figure 5-2

Two (2) screws shall be fastened through the outer intake pipe behind the gaskets at equal distances, approximately 180° apart. Note the screws used must be no larger than No. 8-3/4 sheet metal screws and must be zinc coated.

Figure 5-2 - Coaxial Screw Placement

3/4"

(19mm)

1-3/4" (45mm)

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5 - COMBUSTION AIR AND VENT PIPING

FIGURE 5-4 Roof Mount Coaxial Venting

CAN BE USED ON ALL SIZES

FIGURE 5-6 Side Wall Coaxial Venting

CAN BE USED ON ALL SIZES

Anticipated

Snow Line

Maintain 12"(305 mm)

US (18"(457 mm)

Canada) clearance above highest anticipated snow level

24" (610 mm) above roof or ground

18" Vertical

Clearance to ventilated soffit

Min. 8" (181 mm)

Max. 14" (356 mm)

Maintain 12"(305 mm)

US (18"(457 mm)

Canada) clearance above highest anticipated snow level

24" (610 mm) above roof or ground

Anticipated

Snow Line

Ground

FIGURE 5-5 - Coaxial Vertical Exhaust -

CAN BE USED ON ALL SIZES

Multiple

Appliances

12" (305 mm)

Minimum Separation

Manufacturer

Recommends

Greater Separation

FIGURE 5-7 - Coaxial Horizontal Exhaust -

CAN BE USED ON ALL SIZES

Multiple

Appliances

24" (610 mm)

Min. Separation

Manufacturer

Recommends

Greater Separation recommends gr

17

240012994 Rev. B [08/31/2020]

!

5 - COMBUSTION AIR AND VENT PIPING

WARNING

Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe

Installation Instructions completely and understand all requirements before beginning installation.

FIGURE 5-8 - 2"/60 mm & 3"/80 mm Twin Pipe

Separated Horizontal Flue Termination

This Termination can be used on:

2" / 60 mm ON

205

5.8 Twin Pipe Systems

Twin pipe venting allows exhaust flue and intake flue to be separated from each other. Fresh air is drawn in at a different area from the flue terminal location.

3" / 80 mm

ON ALL SIZES vent only

FIGURE 5-9 - 2"/60 mm & 3"/80 mm Twin Pipe

Separated Horizontal Flue Termination

A. Twin Pipe CPVC System

CPVC is approved for boiler exhaust. CPVC or PVC are both approved for air intake.

To transition from Coaxial at the top of the boiler to Twin Pipe

CPVC/PVC a kit is available.

B. Twin Pipe Polypropylene System

Single wall polypropylene is used for both exhaust and air intake piping.

To transition from Coaxial at the top of the boiler to Twin Pipe polypropylene venting an adapter kit is available.

C. Twin Pipe Separated Flue

Exhaust and combustion air intake are not located in same general location.

This Termination can be used on:

2" / 60 mm ON

205

3" / 80 mm

ON ALL SIZES vent only

FIGURE 5-10 - 2"/60 mm & 3"/80 mm Twin Pipe

Separated Horizontal Flue Termination With Tee On

Exhaust - CAN BE USED ON ALL SIZES

D. Twin Pipe - Common Atmospheric Zone

Termination

Exhaust and combustion air intake are located in same general location and are of equal length.

When using charts below

See Vent Material Options - page 15

Twin Pipe Maximum Vent Lengths

(Includes first elbow and termination)

Boiler

Vent Size

3"

[80 mm]

150

2"

[60 mm]

3"

[80 mm]

Maximum

205

2"

[60 mm]

Intake

Vent

Exhaust

Vent

Combined

Vent

L1

L2

L1+L2

49 ft

[15m]

147 ft

[45m]

196 ft

[60m]

85 ft

[25.9m]

170 ft

[51.8m]

100 ft

[30.5m]

200 ft

[60.9m]

85 ft

[25.9m]

170 ft

[51.8m]

All

All

Minimum

6 ft

[1.8 m]

12 ft.

[3.6 m]

This Termination can be used on:

2" / 60 mm

ON ALL SIZES

3" / 80 mm

ON ALL SIZES vent only

Grade, Snow

& Ice

Maintain 12"(305 mm) US, 18"(457 mm) Canada clearance above highest anticipated snow level, 24" (610 mm) above roof.

Avoid locations where snow may drift and block vent and combustion air.

Ice or snow may cause boiler to shut down if vent or combustion air becomes obstructed.

Single Wall Elbows - Equivalent Length

45° bend

3" (80 mm)

0.82 ft [0.25 m]

2" (60 mm)

3 ft [0.91 m]

90° bend 1.64 ft [0.50 m] 5 ft [1.5 m]

NOTE: Two pipe can be installed horizontally or vertically.

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5 - COMBUSTION AIR AND VENT PIPING

Figure 5-11 - Natalini Clamp

!

WARNING

Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe

Installation Instructions completely and understand all requirements before beginning installation.

5.9 Securing Twin Pipe Polypropylene Venting

UP

UP

Note

Venting manufacturer's use a device to secure single wall twin pipe polypropylene vent pieces to each other. Proper application of the securing mechanism is necessary for any use of twin pipe polypropylene venting on exhaust or air intake.

Securing mechanism is for indoor use only and should not be used in outdoor applications.

Follow venting manufacturer’s instructions for applying the securing mechanism on twin pipe polypropylene venting .

UP

Example for Natalini venting system. See Figure 5-11

(For other venting system suppliers see their instructions.)

1. Place clamp so etched "UP" is facing up.

2. Open clamp slightly by separating circular areas from each other.

3. Slide male end of first pipe through open clamp so the shoulder of the female end of the pipe stops the clamp from sliding off the pipe.

4. Insert the male end of the second pipe into the clamp on the

"up" etched side. Force the two pipes together.

5. Verify the two pipes are secure together with clamp in place.

19

240012994 Rev. B [08/31/2020]

Roof

Terminations

5 - COMBUSTION AIR AND VENT PIPING

 12" (305 mm) Min. horizontal separation between combustion air intake and vent of same appliance.

 12" (305 mm) Min. 84" (2.2 m) Max. vertical separation between combustion air intake and vent of different appliances.

15" (381 mm) Max. horizontal length of vent.

 Min. vent/intake between different appliances

12" (305 mm).

 Max. allowable total vertical vent length with outside exposure is 10 ft.(3.05 m).

 Abandoned unused masonry chimney may be used as chase-way for combustion air and vent. Both combustion air and vent pipe must exit above top of chimney with clearances as shown in Figure 5-14.

FIGURE 5-14 - (2"/ 60 mm & 3" / 80 mm) Twin Pipe

Roof Vent CAN BE USED ON ALL SIZES

This Termination can be used on:

2" / 60 mm ON

205

3" / 80 mm

ON ALL SIZES vent only

12" (305 mm) Min.

15"

(381 mm)

Max.

Roof Line

Vent Combustion

Air

FIGURE 5-12 - Twin Pipe on Roof Combustion Air On

Sidewall CAN BE USED ON ALL SIZES

Vent Terminal

12" (305 mm) US,

18" (458 mm) Canada Min.

Above

Anticipated Snow Line

FIGURE 5-15 - (3" / 80 mm ONLY) Single Wall

Exhaust Kit and Air Intake Minimum Distance Center to Center

This Termination can be used on:

3" / 80 mm

ALL SIZES vent pipe only

Combustion Air

Ground

Level

FIGURE 5-13 - Twin Pipe Flue On Sidewall,

Combustion Air On Roof CAN BE USED ON ALL SIZES

Combustion Air

Vent - T Terminal

See Grade,

Snow & Ice

4 3/4"

[120 mm]

FIGURE 5-16 - Horizontal Twin Pipe, Exhaust and

Intake

This Termination can be used on:

2" / 60 mm ON

205

3" / 80 mm

ON ALL SIZES vent only

12" (305 mm)

Minimum Separation

Manufacturer

Recommends

Greater Separation

12" (305 mm)

Anticipated Snow Line

20

See Grade,

Snow & Ice

240012994 Rev. B [08/31/2020]

5 - COMBUSTION AIR AND VENT PIPING

FIGURE 5-17 -Twin Pipe Side Wall Vent (Multiple

Appliances)

This Termination can be used on:

2" / 60 mm ON

205

3" / 80 mm

ON ALL SIZES vent only

Note: 3" shown for clarity. 12" between vent and combustion air of other boilers required in all multiple boiler installations.

12" (305 mm) Min.

Separation

Manufacturer Recommends

Greater Separation

FIGURE 5-20 - (2"/ 60 mm ONLY) Vent Pipe with T

CAN BE USED ON ALL SIZES

3" (80 mm) Min.

24" (610 mm) Max.

Separation

Vent

Combustion Air

See Grade,

Snow & Ice

6" (153 mm) Min.

24" (610 mm) Max.

Separation

FIGURE 5-21 - (2"/ 60 mm ONLY) Vent Pipe with T

CAN BE USED ON ALL SIZES

Vent

Combustion Air

See Grade,

Snow & Ice

Vent

FIGURE 5-18 - (3" / 80 mm ONLY) Twin Pipe Side

Wall with 45° Vent

This Termination can be used on:

2" / 60 mm ON

205

3" / 80 mm

ON ALL SIZES vent only

3" (80 mm) Min.

24" (610 mm) Max.

Separation

Vent

45° Elbow

Upward

12" (305 mm) Min.

24" (610 mm) Max.

Separation

Combustion Air

See Grade,

Snow & Ice

6" (153 mm) Min.

24" (610 mm) Max.

Separation

3" (80 mm) Min.

24" (610 mm) Max.

Separation

FIGURE 5-22 - (2"/ 60 mm ONLY) Twin Pipe Side

Wall Vent CAN BE USED ON ALL SIZES

3" (80 mm) Min.

24" (610 mm) Max.

Separation

Combustion Air, 90°

Elbow Downward Opening

Separation 24"

Min.

See Grade,

Snow & Ice

FIGURE 5-19 - (3" / 80 mm ONLY) Twin Pipe Side

Wall Vent

Combustion Air

Vent

12"(305 mm)Min.

From Overhang

See Grade,

Snow & Ice

3" (80 mm) Min.

24" (610 mm) Max.

Separation

Opening

Separation 24"

Min.

FIGURE 5-23 - (2"/ 60 mm ONLY) Twin Pipe Side

Wall Vent CAN BE USED ON ALL SIZES

See Grade,

Snow & Ice

12" (305 mm) Min.

24" (610 mm) Max.

Separation Between

Bottom Of

Combustion Air Intake

And Bottom Of Vent

Vent

Combustion Air

This Termination can be used on:

2" / 60 mm ON

205

3" / 80 mm

ON ALL SIZES vent only

21

Combustion Air

See Grade,

Snow & Ice

Vent

3" (80 mm) Min.

24" (610 mm) Max.

Separation

240012994 Rev. B [08/31/2020]

5 - COMBUSTION AIR AND VENT PIPING

5.10 (3" / 80 mm Only) Flexible Vent System FIGURE 5-24 - (3" / 80 mm Only) Flexible Venting

System CAN BE USED ON ALL SIZES

Flexible Pipe Minimum & Maximum Vent Lengths

3” [80 mm]

Diameter Pipe

150 205

Natalini

DuraVent ®

Centrotherm

Z-Dens

Exhaust

Intake

Exhaust

Intake

Exhaust

Intake

Exhaust

Intake

Min

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

NA

Max

75 ft

[22.8 m]

50 ft

[15.2 m]

82 ft

[24.9 m]

50 ft

[15.2 m]

52 ft

[15.8 m]

50 ft

[15.2 m]

Min

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

6 ft

[1.8 m]

Max

50 ft

[15.2 m]

50 ft

[15.2 m]

50 ft

[15.2 m]

50 ft

[15.2 m]

50 ft

[15.2 m]

50 ft

[15.2 m]

50 ft

[15.2 m]

Flexible Vent

Vent Terminal

Rigid Vent

Single Wall Elbows - Equivalent Length

45° bend

90° bend

3" [80 mm]

0.82 ft [0.25 m]

1.64 ft [0.50 m]

Note

Flexible vent systems shall only be run vertical.

Horizontal runs before adapting to flexible must be rigid pipe.

Combustion

Air

Condensate Tee

• Maximum vent lengths based on equivalent straight runs only. Include rigid pipe and fittings in overall equivalent length calculations.

• Flexible venting installations use single wall polypropylene to pass flue gasses to base of chimney, then flexible venting to get them to termination at the top.

• Combustion air is not supplied through masonry chimney. Combustion air must be from outside using 3"

[80 mm] single wall polypropylene.

• Position boiler to use minimum of rigid single wall polypropylene venting to the chimney.

• Follow venting manufacturer's instructions on assembly and clearances to maintain.

• Avoid sharp bends in flexible venting.

Note Prime trap before final assembly of vent.

22

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5 - COMBUSTION AIR AND VENT PIPING

FIGURE 5-25 - Flue Terminal Location

All vent pipe and combustion air pipe and fittings shall comply with the following:

Use only manufacturer approved venting materials or venting materials primer and glue approved to: ULC S636 in Canada, or

UL 1738 in the U.S.

Materials used in the U.S. shall comply with Authority having jurisdiction and in absence of such with: ANSI/ASTM D1785, ANSI/

ASTM F441, ANSI/ASTM F493.

INSIDE CORNER

DETAIL

G

V

H

D

A

E

B

L

F

V

C

V

Fixed

Closed

Operable

B

V

VENT TERMINAL

B

B

V

Operable

AIR SUPPLY INLET

V

J

B

Fixed

Closed

V I

M

AREA WHERE TERMINAL IS

NOT PERMITTED

V

K

A Clearance above grade, veranda, porch, deck, or balcony

B Clearance to window or door that may be opened

C Clearance to permanently closed window

D

Vertical Clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (610 mm) from the center line of the terminal

E Clearance to unventilated soffit

F Clearance to outside corner

G Clearance to inside corner

H

Vent Termination Minimum Clearances

US Installations

Clearance to each side of center line extended above meter/ regulator assembly

12" (305 mm)

12" (305 mm)

*12" (305 mm)

18" (457 mm)

18" (457 mm)

9" (229 mm)

36" (456 mm)

3 ft. (0.9 m) within a height of

15 ft. (4.5 m) above the meter/ regulator assembly

3 ft. (0.9 m)

J

I Clearance to service regulator vent outlet

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

K Clearance to mechanical air supply inlet

L

Clearance above paved sidewalk or paved driveway located on public property

M Clearance under veranda, porch, deck or balcony

12" (305 mm)

*3 ft. (0.9 m)

*7 ft. (2.1 m)

*12" (305 mm) ‡

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of one side beneath the floor.

Canadian Installations

12" (305 mm)

3 ft. (0.9 m)

*12" (305 mm)

18" (457 mm)

18" (457 mm)

9" (229 mm)

36" (456 mm)

3 ft. (0.9 m)

3 ft. (0.9 m)

3 ft. (0.9 m)

6 ft. (1.8 m)

7 ft. (2.1 m) †

12" (305 mm)‡

*For clearances not specified in ANSI Z223.1/NFPA 54 or

CSA B149.1, clearance will be in accordance with local installation codes and the requirements of the gas supplier and these installation instructions.

Note: Local Codes or Regulations may require different clearances. Flue terminal must be exposed to external air and position must allow the free passage of air across it at all times. In certain weather conditions the terminal may emit a plume of steam. Avoid positioning terminal where this may cause a nuisance.

23

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5 - COMBUSTION AIR AND VENT PIPING

FIGURE 5-26 - Condensate Drain

Do not glue cap on if used for dust protection.

End must be left open

(field installed) on condensate drain pipe

3/4" PVC (205)

1/2" PVC (150)

5.11 Condensate Piping

• Use materials acceptable to authority having jurisdiction. In absence of such authority:

• USA - PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493.

• Canada - CSA or ULC certified PVC/CPVC pipe, fittings and cement.

• No external trap needed.

• Connect condensate hose, hose clamps, and coupling to boiler drain trap as shown in figure 5-26.

• Connect condensate piping to 3/4" PVC for 205 or 1/2"

PVC for 150 as shown.

• Slope condensate drain pipe minimum 1/4" per foot

(21 mm/m) away from boiler.

• Support condensate pipe to eliminate any sages.

• Use field source condensate pump, designated for use with condensing boiler, if boiler located below disposal point.

• Condensate pump should have overflow switch.

Condensate from Boiler is slightly acidic and may cause property damage if overflow.

• Field source condensate neutralizing kit as required by authority having jurisdiction or for environmentally friendly condensate disposal.

NOTICE

Manufacturer requires an air vent be used to prevent condensate line vacuum lock.

Do not place in environment with temperatures below freezing.

Condensate outlet will block if condensate freezes.

24

240012994 Rev. B [08/31/2020]

Note

Note

Note

6 - HYDRONIC PIPING

Boiler rated at 50 psig (345 kPa) maximum allowable working pressure. Boiler provided with

30 psig (206 kPa) safety relief valve.

When installing safety relief valve it must be installed in a vertical position with spindle at top.

System pressure above 43 psi [2.96 bar] WILL result in boiler shutting down.

FIGURE 6-1 Safety Relief Valve

Safety Relief

Valve

!

WARNING

• Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol.

• Never use automotive or standard glycol antifreeze, even ethylene glycol made for hydronic systems.

• Ethylene glycol can attack gaskets and seals used in hydronic systems.

• Do not use petroleum based cleaning or sealing compounds boiler system.

• Do not fill boiler or boiler system with softened water.

• Use only inhibited propylene glycol solutions certified by fluid manufacturer as acceptable for use with closed water heating system.

• Thoroughly clean and flush any system that used glycol before installing new Boiler.

• Provide user with Material Safety Data Sheet

(MSDS) on fluid used.

6.1 General

• Primary/Secondary piping required.

• Install piping in accordance with authority having jurisdiction.

• Support system piping and safety relief valve discharge piping. Boiler's internal piping and wall mount bracket can be damaged if subjected to excessive weight.

NOTICE

The intended use of the internal heat exchanger pump is a boiler loop. Do not use as a primary system pump.

• Size central heating pump (and domestic hot water pump, if used) for system requirements only. Internal heat exchanger pump compensates for pressure drop through boiler internal piping and heat exchanger.

• Thoroughly clean and flush system before connecting to boiler.

• If oil is present in system water, use approved detergent to wash system.

• It is necessary to semi-annually check the water quality of central heating systems.

• Manufacturer recommends installation of magnetic dirt separator in the hydronic system where there are cast iron or steel components, or where the previous boiler was a cast iron heat exchanger. The abrasive, extremely fine sediment is difficult to remove and can deposit onto heat exchange surfaces and accumulate in pump cavities causing reduced efficiency and premature wear.

• Flush system to remove any solid objects such as metal chips, fibers, or Teflon tape, etc.

• Flush system until water runs clean and piping is free of sediment.

• Use purge valve to flush zoned systems, each zone separately.

If purge valves and isolation valves are not installed, install them to properly clean the system.

• When purging installations that include standing iron radiators and systems with manual vents at high points, start with nearest manual air vent. Open the vent until water flows out, then close vent. Repeat this procedure, working toward furthest air vent.

• Install a basket strainer if large amounts of sediment is present. Keep basket clear of sediment build up.

• Manufacturer recommends a water treatment product be used for sediment removal.

• Ensure piping in the heating system has an oxygen barrier.

25

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6 - HYDRONIC PIPING

FIGURE 6-2 Safety Relief Valve Discharge Piping 6.2 Special Conditions

Note

Do not expose boiler and condensate piping to freezing temperatures.

Safety Relief Valve

Do not use plastic pipe see

Warning below.

Check Local Codes For

Maximum Distance To Floor

• System piping exposed to freezing conditions: Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system.

Do not use automotive or ethylene glycol.

• Boiler installed above radiation level (or as required by authority having jurisdiction). Integral low water pressure switch is provided in boiler.

• Boiler used in connection with refrigeration system.

Install piping in parallel with boiler, with appropriate valves to prevent chilled medium from entering boiler.

• System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation.

Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

!

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

Use pipe suitable for temperatures of 375°F (191°C) or greater. DO NOT use plastic pipe.

!

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

Install discharge piping per these instructions.

6.3 Safety Relief Valve and Air Vent

• Install safety relief valve using pipe fitting provided with boiler. See Figure 6-2.

• Install safety relief valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety relief valve.

• Install discharge piping from safety relief valve. Do not use plastic pipe.

• Use ¾" or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater. Do not use plastic pipe on safety relief valve.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

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6 - HYDRONIC PIPING

6.4 Trim Piping

• Temperature - Pressure Gauge. Install temperature pressure gauge using piping provided with boiler. See

Figure 6-1.

• Some boiler models may have integral drain valve located inside jacket directly underneath pump. Install provided external drain valve as required.

6.5 System Piping

• Ensure plugs are removed from boiler water connections.

• See Figure 6-7 for basic system piping configurations.

• Systems with automatic fill valves require back flow prevention device.

• Single boiler system. See Figures 6-4, 6-5, for general guidance. Additional considerations:

• Boiler control only supports integrated pump. Installer responsible for integration of multiple central heating pumps using field supplied external control.

• Boiler control allows domestic hot water prioritization.

!

WARNING

Burn and scald hazard. Verify all plastic caps are removed from boiler connections. Failure to follow these instructions could result in death or serious injury.

• Thoroughly flush all hydronic piping.

• Secure all valves/fittings to boiler.

• Manufacturer recommends installing an isolation and purge valve to use during commissioning to ensure the boiler does not shut down due to over-temperature. See figure 6-3 and

6-7 for details.

• Do not install isolation valve between boiler and any field installed LWCO.

• Ensure washers supplied are utilized.

• If soldering piping to boiler, avoid over heating and damaging seals and gaskets.

• Connect system valve pipe work to the boiler.

• Route pressure relief valve discharge piping to the floor.

Follow local code with respect to necessary distance to the floor.

See Figure 6-2.

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6 - HYDRONIC PIPING

FIGURE 6-3 - Piping Diagram - LWCO Location

Low Water Cutoff (LWCO)

(See Figure 6-6 for detail)

Position LWCO Above

Top of Boiler

Purge Valve

Air Vent

Supply

Note

Note

Arrange piping to prevent water dripping onto boiler.

Illustrations are meant to show system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction.

Return

Gas

Boiler

1

Purge Valve

Safety Relief

Valve

* Check Local Codes for

Maximum Distance to

Floor.

*To Drain

Note 1 DO NOT PLACE ISOLATION VALVE

BEFORE TEE OR LWCO.

28

1

5 gpm Limiter

Factory Installed

205 Only

Magnetic

Dirt

Separator

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6 - HYDRONIC PIPING

6.6 External Optional Low Water Cut Off

These guidelines are supplied when necessary to install an additional Low Water Cut Off (LWCO), for sensing a low water level condition in a boiler, as required by the Authority Having

Jurisdiction.

FIGURE 6-5 - Low Water Cutoff - Detail

NO

Follow LWCO manufacturer installation instructions for type of

LWCO selected in addition to these instructions.

LWCO shall be 120V/60HZ control and dry contacts sized for load being connected. Wire control to boiler. See Figure 6-4.

Connect LWCO device to the system ground. Ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the

National Electrical Code (NEC) or Canadian Electrical Code

CEC.

• Locate LWCO sensing device in the supply piping, above the minimum height of boiler.

See Figure 6-6, Piping Diagram.

• Position control in HORIZONTAL piping to assure proper boiler protection (upright or 90° rotation).

• For proper operation, sensing element of the LWCO control shall be positioned in the tee to sense the main water stream. Maintain minimum 1/4” spacing from pipe walls. Element shall NOT contact the rear, or side walls of the tee. See Figure 6-5.

• Install an air vent using a tee to avoid nuisance shutdowns.

• Apply small amount of pipe sealant to threaded connections.

• Arrange piping to prevent water dripping onto boiler.

• DO NOT install water shutoff valve between boiler and

LWCO sensing device.

NO

YES

Low Water Cutoff (LWCO)

FIGURE 6-4 - LWCO Wiring Diagram

N.O

Electrical Conduit

L

1

G

J-Box

120 V/60 HZ

Conduit or Power

Supply cord

(Polarized)

BLK

WHT

GND

L

1

N

GND

(Polarized) 120 V/60 HZ

Cord Set From Boiler

120 V/60 HZ Socket

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6 - HYDRONIC PIPING

6.7 Manufacturer Recommendation - Strainer

Potable water

OUT

Potable water

IN

Manufacturer Recommendation

Manufacturer strongly recommends the use of a strainer filtering potable water before entering the boiler. The strainer prevents any sedimentation and debris from your water supply piping from entering the boiler. Debris carried from the water supply will clog DHW water flow sensor, potentially resulting in significant operation issues.

Locate the stainer as close to the boiler as possible and place on DHW (domestic hot water) inlet connection located at bottom of the boiler.

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6 - HYDRONIC PIPING

6.8 Central Heating System

Boiler is designed for use in a sealed central heating system.

Design the system to operate with flow temperatures of up to

176°F (80° C), take pump head, expansion tank size, mean radiator temperature, etc. into account.

Boiler is supplied with the following components: Pressure relief valve - 30.0 psi (2.1 bar). Boiler internal pressure switch will shut boiler off at 43.5 psi /3.0 bar.

Pressure gauge - to indicate system pressure to be maintained.

6.9 Domestic Hot Water Mode

!

WARNING

Burn, Scald Hazard! Water temperature over 125°F

(51°C) can cause severe burns and scalding. See

User's Manual before setting water temperature.

Failure to follow these instructions could result in death or serious injury.

• Flow of water will operate the DHW flow switch which requests the 3 way valve to change position. This will allow the pump to circulate the primary water through the DHW plate heat exchanger.

• Combustion fan will then come on and begin to run at ignition speed.

• Once the fan reaches ignition speed the control board will allow power to flow to the spark generator and gas valve creating ignition in the combustion chamber. The flame sensor will acknowledge the presence of the flame in the combustion chamber and send a signal to the control board.

• Temperature sensors will send a signal to the control board allowing the control board to increase/ decrease the speed of the fan. The combustion fan will in turn modulate the gas rate accordingly.

• When the domestic hot water demand ceases the burner will extinguish, unless there is a demand for central heating.

• Priority is given to the domestic hot water supply.

Demand at tap or shower will override any central heating requirement.

6.10 Frost Protection Mode

Frost protection mode is integrated into the appliance when electricity is connected to the boiler, regardless if power is "on" or "off".

If temperature falls below 41°F / 5° C boiler will fire on its minimum setting until flow temperature of 86°F / 30° C is reached.

FIGURE 6-6

6.11 Pump Protection

Pump will automatically operate for 1 minute in every 24 hours of inactivity to prevent seizing.

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!

DANGER

7 - GAS SUPPLY PIPING

Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source.

Failure to comply will result in death or serious injury.

7.1 General

• Use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements:

• USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

!

WARNING

Fire, explosion, asphyxiation and burn hazard. Boiler piping and gas connections shall be leak tested before placing boiler in operation. Failure to follow these instructions and or improper installation could result in death or serious injury.

• Install manual main shutoff valve before the gas valve accordance with state and local requirements.

• Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure.

• Boiler and its individual shutoff valve shall be disconnected from gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.40 kPa - 34.47 mbar).

!

WARNING

If overheating occurs or gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Shut off gas supply at a location external to the appliance.

Do not use this boiler if any part has been under water.

Call a qualified service technician before use.

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

NOTICE

If overheating occurs or gas supply fails to shut off, do not turn off or disconnect electrical supply to pump.

Shut off gas supply at location external to the boiler.

NOTICE

Use of CSA approved corrugated, semi-rigid stainless steel tubing with polyethylene jacketing is approved for use with boilers following tubing manufacturer's instructions.

Use of flexible " appliance whip" gas tubing is not allowed per NFPA 54.

MODEL

GCWB95W-150

GCWB95W-205

GAS SUPPLY REQUIRED:

NATURAL GAS

(A)

LIQUID PROPANE

(E)

143 ft

3

/h

(4.00 m

3

/h)

191 ft

3

/h

(5.40 m

3

/h)

61.15 ft

3

/h

(1.72 m

3

/h)

82 ft

3

/h

(2.30 m

3

/h)

• Boiler shall be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

• Install boiler so that gas ignition system components are protected from water (dripping, spraying,rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Gas meter and supply pipes must be capable of delivering the listed quantity of gas in addition to demand from any other appliances in the house. Boiler requires a 3/4” (19.5 mm) gas supply pipe.

• Support piping with hooks straps, bands, brackets, hangers, or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection. Boiler will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for liquefied petroleum gas.

• Install external field sourced manual main gas shutoff valve, ground joint union, and sediment trap upstream of gas controls.

• Install boiler so gas ignition system components are protected from water dripping, spraying,rain, etc. During appliance operation and service.

• Leak test boiler and gas line connections before placing boiler into operation.

REQUIRED GAS SUPPLY PRESSURE

NATURAL GAS LIQUID PROPANE

Min.

Max.

Min.

Max.

3.5" w.c.

10.5" w.c.

8.0" w.c. 13.0" w.c.

(0.7 kPa) 2.61 (kPa) 1.99 (kPa) 3.23 (kPa)

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7 - GAS SUPPLY PIPING

NOTICE

Sediment trap shall be located upstream of gas controls.

FIGURE 7-1

7.2 Leak Check Gas Piping

Pressure test boiler and gas connection before placing boiler in operation.

• Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

• Pressure test at 1/2 psig (3.5 kPa) or less.

Isolate boiler from gas supply system by closing manual gas shutoff valve.

• Locate leakage using gas detector, noncorrosive detection fluid, or other leak detection method acceptable to authority having jurisdiction. Do not use matches, candles, open flames, or other methods that can provide ignition source.

• Correct leaks immediately and retest.

7.3 Gas Orifice - See Figure 7-2

• Models 150 = 5.8 mm ( Natural & LP)

• Models 205 = 9.0 mm ( Natural & LP)

FIGURE 7-2 Gas Orifice Location

Gas Orifice -205 shown

Green Side Down - Toward gas valve

Gas Valve

Gas Orifice

150

Gas Orifice

205

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!

DANGER

Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz).

Before making connections, verify appliance is disconnected from power supply. Respect the input polarity on terminal block M1: L (LINE) - N (NEUTRAL).

Failure to follow these instructions WILL result in death or serious injury.

Model Size

Power Supply

Power Consumption

150 205

142 W

120V - 60Hz

182 W

Internal Fuse (Qty. 2) F3.15 A

Electrode Spark Gap 1/8" to 3/16" [3.1 mm to 4.7 mm]

Note

Wiring diagrams can be found in Appendix A of this Manual.

!

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

8.1 General

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to:

• USA- National Electrical Code, ANSI/NFPA 70.

• Canada - Canadian Electrical Code, Part I, CSA C22.1:

Safety Standard for Electrical Installations.

• Install all wiring in accordance with requirements of

National Electrical Code and any additional national, state, or local code requirements having jurisdiction.

• In Canada, installation must conform to CSA C22.1

Canadian Electrical Code Part 1 and any local codes.

• All wiring shall be N.E.C. Class 1.

• Boiler shall be electrically grounded in accordance with the

National Electrical Code, ANSI/NFPA No. 70-latest edition.

• Boiler requires a 120V 60Hz power supply. Ensure electrical supply is polarized.

• There shall only be one common isolator, providing complete electrical isolation, for boiler and any external controls. Using PVC insulated cable 12 AWGx3C 221°F

(105 ºC).

FIGURE 8-1 Electric Knockouts Bottom Of Boiler -

Illustration shown (size 150), illustration is for location purposes, wiring knockouts found same general location on all sizes.

Electric

Knockouts

8.2 Install Room Thermostat

Install room thermostat on inside wall. Do not install where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, sun rays or near a fireplace.

8.3 Electrical Connections

• Boiler requires 120V 60Hz power supply. Verify electrical supply is polarized.

• Boiler shall be grounded and on dedicated circuit.

• Shall be one common isolator, providing electrical isolation for boiler and any external controls. Using PVC insulated cable 18 AWGx3C 221°F (105°C).

• All wiring must be installed in accordance with requirements of the National Electrical Code and any additional national, state, or local code requirements having jurisdiction. All wiring must be N.E.C. Class 1.

• Canada, installation must conform to CSA C22.1 Canadian

Electrical Code Part 1 and any local codes.

• If replacing original boiler wiring use only TEW 105°C or equivalent.

• If appliance is connected to in floor system, install limit thermostat to prevent latter from overheating.

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8 - ELECTRICAL CONNECTIONS

FIGURE 8-2 Terminal Block Locations

!

DANGER

Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz).

Before making connections, verify appliance is disconnected from power supply. Respect the input polarity on terminal block M1: L (LINE) - N (NEUTRAL).

Failure to follow these instructions WILL result in death or serious injury.

8.4 Access To Connection Block

1. Ensure there is no line voltage at boiler.

2. Unscrew two screws located under front panel. Remove front cover.

3. Guide controller or thermostat wire through round grommet(s) on right side of boiler's bottom plate.

4. Tilt control box forward by opening holding clip located on left side of control housing.

5. Expose M1 and M2 terminal blocks by removing screw from plastic cover on left. See Figure 8-3.

6. Remove plastic from channel in plastic cover. Run wires through new opening.

7. Connect wires to appropriate terminals on connection block.

8.

Reinstall electrical cover plate.

9. Tilt control box back to original position. Ensure clip on left side is fully engaged.

10. Replace front cover and screws under front panel.

11. Turn power to boiler on.

Fuse Holders (2)

FIGURE 8-3 Terminal Plastic Cover with Knockouts

Remove

Dry contact end switches from various manufacturers can be attached to boiler control PCB.

New Opening

8.5 Main Supply Connection

Main supply is connected to terminal block M1 which is high voltage (120V / 60Hz).

Fuses, 3.15 A, 250 V, Fast Acting, are incorporated in the power supply terminal block. To check or replace fuse pull out black fuse carrier.

TERMINAL BLOCK M1

(L) = Live (brown)

(N) = Neutral (light blue).

= Ground (yellow-green).

(1) (2) = contact for 120V Room Thermostat.

Place jumper back on terminals 1-2 of boiler terminal block

M1 if room thermostat is not used or if Remote Control is not installed.

TERMINAL BLOCK M2

Terminals 1 - 2 : Bus connection for Argo communicating thermostat (supplied as an accessory)

Terminal 4 - 5: outdoor temperature sensor connection

(supplied as an accessory)

Terminals 6 - 7 - 8: Dry Contact End Switch

Terminals 9 - 10: 0 - 10V connection

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8 - ELECTRICAL CONNECTIONS

FIGURE 8-4 Thermostat Connections

8.6 Install Room Thermostat

Install room thermostat on inside wall. Do not install where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, sun rays or near a fireplace.

Dry contact only - do not apply 24 volts between 6 and 7.

A. Connect Room End Switch

• turn power off to boiler;

• access terminal block M2 ;

• connect room end switch to terminals 6(R)-7(W)-

8(C) ; Do not apply voltage between 2 terminals. Dry contact only.

• turn boiler power on;

• verify room end switch operates per end switch manufacturer instructions.

NOTE: maximum load allowed is 10 mA

Dry contact end switches from various manufacturers can be attached to boiler control PCB.

8.7 Optional Electrical Connections

A. 1K Ohm (1K Ω) Outdoor Temperature Sensor

To connect this accessory, see figure 8-5, terminals 4-5, and instructions supplied with 1K Ω sensor.

A

Room End

Switch

FIGURE 8-5 Outdoor Sensor Connections

1K Ω

B. Setting "Kt" Climate Curve

When external 1K Ω sensor is connected to boiler, the electronic board adjusts the flow temperature calculated according to set Kt coefficient.

Select required curve by pressing as indicated in chart below for selecting the appropriate curve (00 to 90).

Flow temp Outside temp

Sensors used for this boiler are proprietary to the manufacturer. Use of after market sensors will diminish boiler performance.

FIGURE 8-6 Kt Climate Curves

Note

80 Is Default.

NOTE:

Temperatures below -40 °F (-40 °C), maximum heating flow temperature set point no longer increases, curves shown on graph become horizontal.

Boiler set-point will override sensor set-point.

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8 - ELECTRICAL CONNECTIONS

8.8 Management of 0-10V Input

The functions with 0...10V regulator are activated by means of their parameters. When the function is enabled ( P82=3) and P78 =1, the input manages the heating set point temperature directly; when P78 =2, the input manages the heating power input directly. Demand is activated above 3V and the heating setpoint is calculated in proportion to deviation from 3 to 10 V DC, to give a setpoint that goes from minimum to maximum.

0-10V DC Electrical Signal Input

(V)

0...3

3

9

10

7

8

4

5

6

P78=1

Heating Flow Setpoint Temperature

(°F) (°C)

77

95

108

124

140

154

167

176

25

60

68

75

80

35

42

51

P78 = 2

Central Heating - Heat Input (Gross)

150 205

(kW) (Btu/h) (kW) (Btu/h)

OFF

6.4

22,000 8.6

29,500

10.8

15.1

19.4

36,700 14.2

51,400 19.9

66,100 25.5

48,620

67,740

86,860

23.7

28.0

80,800 31.1

105,980

95,500 36.7

125,100

32.3

110,200 42.3

144,220

36.6

125,000 48.1

164,000

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9.1 Central Heating System Connections - Combi

GCWB95W-150 COMBI

GCWB95W-205 COMBI

F

K

K

H

A

B

I

MANIFOLD

G

E

D

GCWB95W-150/205

H

G

C

A

B

I

D

E

C

E

F

A

B

C

D

G

H

I

K

LEGEND

Pressure Gauge

Pressure Relief Valve

Heating return connection

Cold DHW inlet tap / system filling connection for Combi

Gas shutoff connection

150 205

-

30.00 psi [2.11 bar]

3/4" [22.2 mm] 1" [25.4 mm]

1/2"

[15.9 mm]

3/4" NPT

3/4" [22.2 mm]

Boiler Fast Fill External to Boiler NA

DHW outlet

Drain connection for condensate

Heating supply connection

5 gpm DHW flow restrictor

(Factory installed) (205 only)

1/2"

[15.9 mm]

13/16" [21 mm] ID

Hose

3/4" NPT

3/4 NPT

3/4" [22.2 mm] 1" [25.4 mm] na

3/4"

[22.2 mm]

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9.2 System Start Up

Follow all codes and regulations when filling the boiler.

Use drain taps to allow system to completely drain.

Thoroughly flush the heating system before boiler is connected and again after first heating season.

FIGURE 9-1 Condensate Drain Assembly

Model 205 shown (location similar in all sizes)

Pour approximately

1 cup of water into flue way of boiler.

HTEX Air Vent

Air Vent

• Boiler is fitted with automatic air vent positioned on pump

Vent and is fitted with adjustable sealing cap. See Figure

9-1.

• Open central heating flow and return valves. Spindle is flat in-line with valve.

• Open fill point valve on filling system until water begins to flow. To aid venting boiler drain may be open until water flows out. Close drain as soon as water appears.

• During initial system air purge open valve connected to top left of heat exchanger, see figure 9-1. Open 4 full turns counter clockwise until steady stream of water is witnessed. Close fully by turning clockwise with no tools required.

• Systems using radiators to remove air - Vent each radiator in turn, starting with lowest in the system.

• It is IMPORTANT the pump is properly vented to avoid running it dry and damaging its bearings. Unscrew and remove cap from center of pump. Use screwdriver. Rotate exposed spindle about half turn, replace cap.

• Check operation of heating pressure relief valve. Pull lever on top of valve upwards lifting the seat. This will allow water to escape from system. Check water is escaping from the system.

• Open cold water supply inlet valve. Turn on all hot water taps. Allow water to flow until no air is present. Turn off taps. See page 4- Physical Data and section 2.7

Operational Features.

9.3 Fill Condensate Trap with Water

!

WARNING

Asphyxiation hazard! Fill condensate trap before starting boiler to avoid combustion products escaping boiler. Failure to follow these instructions could result in death or serious injury.

• To fill the condensate trap pour water into exhaust vent until water begins to flow through the siphon.

• Visually inspect the siphon to ensure it is full with clean water.

• During operation check condensate (trap) to ensure it draining properly.

Note

Condensate trap must be manually filled with water at initial start up.

39

Condensate Drain

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9 - START UP PROCEDURE

9.4 Control Panel

Press and hold for 1 second, to display information as shown in the table below.

Press to exit.

00

01

02

03

04

05

06

07

08

DESCRIPTION

Secondary fault internal code

Heating flow temperature (°F/°C)

Outdoor temperature (°F/°C)

Indirect Tank DHW temperature (boiler CH only)

Domestic hot water temperature (boiler with plate exchanger)

Water pressure in heating system (PSI/bar)

Heating return temperature (°F/°C)

Thermo fuse status (000/001)

Not used

BUTTONS Key

DHW temperature adjustment

(+ to increase the temperature and – to decrease it)

Heating water temperature adjustment

(+ to increase the temperature and – to decrease it)

Boiler operating information

Operating mode:

DHW – DHW & Heating – Heating Only

ON/Off – Reset – Exit menu/functions

DESCRIPTION

09 Setpoint Central Heating (°F/°C)

10/11 Manufacturing information

12 Flue sensor temperature (°F/°C)

13 Manufacturing information

14 Identification Open Therm communication

15

16

17

18

Manufacturing information

Manufacturing information

Fan speed (“i17”x100)

Manufacturing information

SYMBOL Key

Off: heating and DHW disabled (only boiler frost protection is active)

Ignition fault

Boiler/system water pressure low

Call a qualified service technician

Manually re-settable fault (

Fault in progress

)

Burner lit

DHW operating mode enabled

Heating mode enabled

Programming menu

Boiler information menu

Set unit of measurement (SI/US)

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9 - START UP PROCEDURE

NOTICE

All connections shall be made and water added before performing this function.

NOTICE

First ignitions immediately after installation, system will implement a self-learning procedure to reach correct ignition level.

9.5 Prior to Commissioning:

• Check system pressure is correct;

• Power boiler;

• Open gas tap (positioned under boiler);

• Select required heating mode. See section 10.4

Operating Modes.

9.6 Commissioning For The First Time:

1. Turn power to boiler on. Code "000" appears on the display. Appliance is ready for "commissioning" procedure.

2. Press at the same time. Hold for 6 seconds. "On" appears on the display for 2 seconds followed by code

"312 " indicating " de-aeration" function is active. This function lasts 10 minutes.

3. Boiler will turn on after deaeration function is complete.

Display will show code "000 " alternating with % of ignition power and temperature value (°F / °C).

• During this gas recognition function phase which lasts about 7 minutes, type of gas being used is analyzed.

• During this function, ensure maximum heat exchange out to the system with all zones and circulators running. maintain system temperature below 176°F for the duration of the process until NG or LPG are seen on the display.

• If boiler operates on Gas A (Natural Gas), display shows NG (Natural Gas) for about 10 seconds. Boiler is now ready for normal operation.

Note

9.7 Automatic Calibration Function

Before performing this function verify there are no heat demands in progress.

During this function ensure there is maximum heat exchange to the system in Heating or DHW mode (DHW request) to avoid boiler shutting off due to overheating.

Press and together and hold for about 6 seconds.

When display indicates "On" press within 3 seconds after pressing previous buttons.

NOTICE

Important: If display indicates "303" Automatic

Calibration function has not been activated. Disconnect boiler from main power supply for few seconds and repeat procedure.

1.

4.

5.

Boiler must not shutoff during calibration.

Open all heating zones in heating or DHW mode to ensure boiler does not shutoff.

When function is enabled, and display.

NOTICE

NOTICE

will flash on the

2. After ignition sequence, which can also take place after few attempts, boiler performs three operations.

Each operation lasts about 2 minutes:

• maximum power

• ignition power

• minimum power

3.

Before moving to the next combustion point, the and appear on the display as the control is setting values.

During this phase, power level reached by boiler and delivery temperature alternate on the display.

When , and flash together on the display, automatic calibration function has completed.

• If boiler operates on Gas E (LPG) display shows LPG

(Gas E). Press for at least 6 seconds to confirm gas used.

• If display shows LPG (Gas E), press and together and hold down for at least 4 seconds to exit without changing factory setting. Boiler will stay set to

Natural Gas.

• If display shows NG (Gas A) and does not recognize the type of gas used, press and together and hold down for at least 4 seconds to exit the function. Change parameter P02=01 as described in section 9.12 Parameter Settings of boiler Installation,

Operation and Maintenance Manual. Perform Automatic

Calibration Function. Manual Calibration may be necessary if combustion is not within specified range.

• After furel type is detected, confirm P02 is set for the desired fuel type by checking the parameter in following section 9.12.

41

6. Press to exit the function. Display will show ESC.

7.

Verify combustion is within specified range. If not, perform Automatic and then Manual Calibration. (See

Section 9.8)

IMPORTANT: If Calibration function does not complete, verify unit did not shut down for overtemperature. Repeat Automatic Calibration. Replace

KEY if Automatic calibration does not complete after second try.

During initial ignition, burner may not ignite. This may cause boiler to shut down until any air in gas pipes is vented. Repeat ignition procedure until gas reaches the burner. To reset boiler operation, press for at least

2 seconds.

240012994 Rev. B [08/31/2020]

9 - START UP PROCEDURE

9.8 Manual Calibration Function:

Manual Calibration phase starts at the end of the Automatic

Calibration.

The Display shows the boiler power and adjustment of the

CO2 value (parameter setting) during Manual Calibration sequence.

The process begins at minimum power.

A. After Automatic Calibration sequence with flashing together on the display, you can adjust minimum power combustion by pressing to lower %

CO

2

, and to raise % CO

2

.

B. When minimum power combustion is in the specified range, press and then to reach ignition power.

C. Press to adjust ignition power combustion. Press to lower % CO

2

, and to raise % CO

2

.

D. When ignition power combustion is in the specified range, press and then to reach maximum power.

E. Press to adjust maximum power combustion. Press

to lower % CO

2

, and to raise % CO

2

.

F. When maximum power combustion is in the specified range, press to exit Manual Calibration Function. ESC is displayed on the screen.

9.9 Deaeration Function

Used to eliminate air inside the heating circuit when boiler is installed or after maintenance when water is drained from primary circuit.

1. Press buttons program row 312.

together and hold for 6 seconds.

On appears on display for a few seconds, followed by

2. The electronic board will activate pump on/off cycle for

10 minutes. Function will automatically stop at end of the cycle.

3. To manually exit this function, press together and hold for 6 seconds.

FIGURE 9-3 - Gas Inlet Tap - Pi buttons

IMPORTANT INFORMATION

A. If venting or gas recognition function is interrupted by power blackout, start function again when power is restored. Press and together and hold at same time for at least 6 seconds.

B. If display shows fault E118 (low pressure in hydraulic circuit) during venting function, open filling tap on appliance and restore correct pressure.

C. If gas recognition function is interrupted due to fault (e.g.: E133 no gas) press to reset. Then press and (for at least

6 seconds) to restart the function again.

If gas recognition function is interrupted due to overheating, restart function by pressing and holding down together for at least 6 seconds.

D. If gas recognition is interrupted for E125 or E110 see pump air removal section 9.6.

E. Combustion of this appliance has been factory controlled, calibrated and set for operation with Gas A (Natural

Gas).

F. During Gas Type Control Function, combustion ratio will increase for a short period of time while gas type is being established.

PI = Gas Supply Inlet Pressure Tap

9.10 Commission Set Up (Gas) - Changing The Type

Of Gas

During the first installation boiler carries out an automatic commissioning function.

The system is able to detect (gas recognition function) the gas type present in the network.

Correct gas type setting, is made by pressing two buttons at the same time, see section 9.6 Commissioning.

Change of gas type is made after

• Change parameter P02. See section 9.7 Commissioning and section 9.13 Parameter Settings.

• Check minimum gas pressure is suitable for selected gas: minimum gas pressure is determined with boiler operating at high fire and any other appliances connected to same fuel source operational as well (whole house load).

• Gas A (NG) = 3.5" (8.7 mbar)

the first installation:

Gas E (LPG) = 8.0" (19.9 mbar)

• Place supplied label with indication of gas type close to the data plate of boiler replacing the original.

• Perform Automatic Calibration Function - Section 9.7.

• Manufacturer recommends verification of CO on the flue.

2 concentration

42

240012994 Rev. B [08/31/2020]

9 - START UP PROCEDURE

9.11 Chimney Sweep Function (CO

2

Adjust)

For correct boiler operation, content of (CO

2

- O

2

) in the combustion flue must be within tolerances indicated in table below.

COMBUSTION TABLE

Maximum power (100%)

Nominal value

Gas A

(Natural Gas)

150

CO2 %

9.0

O2 %

4.9

Gas A

(Natural Gas)

CO2 %

9.0

205

O2 %

4.9

Gas E (LPG)

CO2 %

10.0

O2 %

6.0

Permitted value 8.5 – 9.5 5.7 – 4.0 8.7 – 9.3

5.4 – 4.3

9.5 – 10.5 6.8 – 5.2

Ignition power

(*)

Nominal value 8.7

5.4

8.7

5.4

10.8

4.8

Permitted value 8.2 – 9.3 6.3 – 4.3 8.2 – 9.3

6.3 – 4.3 10.3 – 11.3 5.5 – 4.1

Minimum power (0%)

Nominal value 8.8

5.2

9.0

4.9

10.0

6.0

Permitted value 8.2 – 9.3 6.3 – 4.3 8.7 – 9.3

5.4 – 4.3

9.5 – 10.5 6.8 – 5.2

(*) Automatically calculated from the PCB

Chimney Sweep Function enables boiler to generate maximum heating power.

After activation, boiler power % can be adjusted from minimum (0%) to maximum (100%) in DHW mode.

A. Press and hold and at the same time for 6 seconds. When the function is enabled, displays shows

On ” for few seconds followed by program row “ 303” alternating with % of boiler power.

B. Press

1%).

to gradually adjust power (increments of

C. To exit press both buttons together for at least 6 seconds.

If value of CO

2

-O

2 is different, check the electrodes and their relative distances. See Figure 11-1.

If necessary, replace electrodes and position them correctly. f problem persists, use "COMBUSTION ADJUSTMENT

FUNCTION (CO

2

% )". See Section 11 General Maintenance,

Figure 11-1 Electrodes. If problem persists, use Section 9.8

Automatic Calibration Function, and Section 9.9 Manual

Calibration Function.

2. After burner is lit, boiler reverts to maximum DHW power

(100). When display shows "100" it is possible to partially adjust value of CO

2

%;

3. Press and . Display shows "00 " alternating with function number "304" ( flashes);

4. Press to raise or lower the amount of CO

2

(from -0.3% to + 0.3%);

5. Press to save new value. Power value " 100" will show on display again. Boiler continues operating at maximum

DHW power.

This procedure can be used to adjust CO

2

to ignition power and minimum power by pressing after performing step

5 above.

NOTICE

• Press to display instantaneous flow temperature for

15 seconds.

• Use a regularly calibrated combustion analyzer for combustion analysis.

• During normal operation boiler performs combustion control cycles. In this phase CO values higher than 400 ppm can occur for brief periods of time.

6. After saving the new value (step 5 above), press to set boiler to ignition power. Wait for value of CO

2 to stabilize. Adjust as described in step 4 of procedure

(power value is a number <> 100 and <> 0). Repeat step

5 to save.

7. Press to adjust boiler to minimum power. Wait for value of CO

2 value = 00);

to stabilize. Go to step 4 to adjust (power

8. Exit function by pressing and together for at least

6 seconds, see step 1.

If proper combustion cannot be reached see Automatic

and Manual Calibration sections 9.7 and 9.8.

9.12 Combustion Adjustment Function (CO

2

%)

This function sets out to partially adjust the value of CO

2

%.

Use the following procedure:

1.

Press buttons and together for at least 6 seconds.

When the function is enabled, displays shows “On” for a few seconds followed by program row “ 304” alternated with the % of boiler power;

43

9.13 Check Firing Rate

1. Measure input, if a gas meter is installed in the system.

• Turn off gas to all other appliances.

• Activate some heating zones to dissipate heat.

• Set boiler on high fire using Chimney Sweep Function.

• Use ½, 1 or 2 cu ft dial on gas meter. Measure time required for two or more complete revolutions. Measure time for one or more minutes.

• Calculate input.

240012994 Rev. B [08/31/2020]

For Natural Gas :

Input (MBH) =

3600 x cu ft

seconds

Example: Natural Gas - Gas flow from

Meter = 2 cu ft

Measured time = 72 seconds

=

3600 x 2 cu ft

72 seconds

For Propane (LP):

Input (MBH) =

9160 x cu ft

seconds

Input Rate (MBH)

For Metric formulas- See Glossary

= 100 MBH

2.

9 - START UP PROCEDURE

Compare measured input to table below. If calculated input is not in range given in Table 9-2 check firing rate again after setting the combustion following steps in section 9.12.

Table 9-2 Input Rate @ High Fire (MBH)

Approximate Rate @

100% Fire (MBH)

Size

150

205

150

205

9.14 Parameter Settings

Program boiler electronic board parameters as follows:

• Press and together, hold them down for 6 seconds until program “ P01” appears on the display alternated with the set value;

• Press or to scroll the list of parameters;

• Press , value of selected parameter begins flashing, press to change the value;

• Press to confirm the value or press without saving.

to exit

Further information in regards to parameters listed in the following table are supplied together with required accessories if necessary.

FACTORY SETTINGS

150-205

01

00

P01

P02

P03

P04

P05

9.15 Description Of Parameters: Factory Settings

Manufacturer information

Gas used

00 = Gas A (Natural Gas)

01 = Gas E (LPG Gas)

Hydraulic system

00 = instantaneous appliance

03 = instantaneous appliance with pre-heat function

04 = heating only appliance with DHW thermostat

05 = appliance with external storage indirect tank

08 = heating only appliance

13 = instantaneous appliance with pre-heat function for solar application

Programmable relay 1 setting (optional):

00 = no function is associated

01 = close contact with a room thermostat request (other than ECR thermostat)

02 = close contact with a ECR room thermostat request

03 = relay for indicating low water pressure

04 = relay for error code display

05 = relay for kitchen fan function

07 = relay for post circulation pump

09 = DHW relay on with DHW program setting

10 = DHW relay on with DHW request; if P64 = 1 relay on with CH and DHW request

13 = relay for Cooling function

14 = close contact with room thermostat request (120V~) with post circulation

15 = close contact with open therm remote control request with post circulation

Programmable relay 2 setting (optional):

(Same configurations as Relay 1P04)

00

02

04 parameters continued on next page

44

240012994 Rev. B [08/31/2020]

9 - START UP PROCEDURE

9.15 Description Of Parameters: Factory Settings conti.

P06

P07

Outdoor temperature sensor input configuration

00 = with outdoor temperature sensor connected, external temperature value has influence to calculate heating flow temperature set-point

01 = with outdoor temperature sensor connected, display shows external temperature value (no influence)

02…05 = no function is associated

00..02 = No function is associated

03 = This is an input contact for CH request (e.g. trigger phone).

When contact CN2 is closed and Room Thermostat (RT) requiring heat switches burner on.

Note: verify heating mode is enabled (winter or heat only mode)

04 = This is an input contact for Low Temperature Thermostat (e.g. floor heating system).

When Low Temperature Thermostat connected on CN2 cuts out, burner switches off and display shows

E178 anomaly.

Note: verify heating mode is enabled (winter or heat only mode)

05 = This is an input contact for external DHW recirculation pump. When contact CN2 is closed the pump runs for a specific period.

To enable input it is necessary to set parameter P04 or P05 = 08 and P69 = 05.

Pump will run at P19 minutes (Summer/Winter mode or Only Winter mode) or P19/2 minutes (only

Summer mode).

P09 Manufacturer information

P10

P44

Heating set-point setting OT / RT (Open Therm / Room Thermostat 120V~)

00 = with Remote Control (RC) connected, temperature request is RC set-point

01 = Temperature Request is highest set point between RC and PCB

02 = Temperature request is RU setpoint. The RT enable the gas boiler operates

P11..P12

Manufacturer information

P13 Max. heating output (0-100%)

P14 DHW max. output (0-100%)

P15

P16

Min. heating output (0-100%)

Maximum CH set-point (°C)

00 = 176°F (80°C)

01 = 113°F (45°C)

Pump overrun time in heating mode (01-240 minutes) P17

P18

P19

P20

P21

P22

Burner ignition delay in CH mode (00-10 minutes) - 00=10 seconds

Manufacturer information

Pump overrun time in DHW mode (seconds)

Anti-legionellosis function

00 = Disabled -

01 = Enabled

Manufacturer information

(set “22” to display parameters 42 and above)

Maximum DHW set-point temperature 113°-140°F (45°-60°C), Default 49 = 120°F P23

P24 Manufacturer information

P25 No water safety device

P26..P31

Manufacturer information

P32..P41

Diagnostics (See SERVICE Instructions)

Temperature unit setting

00 = °C

01 = °F

Model

P71*

P72*

Maximum Fan Speed

Minimum Fan Speed

To calculate fan speeds

Setting

RPM

FACTORY SETTINGS

150-205

80

150

220

7200

00

00

--

00

--

100

00

00

03

03

07

30

00

00

49

35

00

--

--

01

Setting

RPM

40

1150

(P71 x 10) + 5000

(P72 x 10) + 750

75

205

225

7250

40

1150

P78

0-10V Input

0= Disabled

1 = Temperature Setpoint (3V = minimum setpoint, 10V = maximum setpoint

2 = Power Setpoint (3V = minimum power, 10V = maximum power)

0

NOTE : To scroll to parameter 42 and above it is necessary to set P22 to 22 before scrolling up to the parameter.

45

240012994 Rev. B [08/31/2020]

9 - START UP PROCEDURE

9.16 Adjusting Maximum Heating Power

Maximum boiler heating power can be reduced to suit requirements of heating system it serves.

Table showing parameter P13 values according to desired maximum power model is shown for each single boiler.

To access and edit P13 values, proceed as described in

Section 9.15 Parameter Settings.

Boiler Model - PARAMETER P13 (%)/ Heating Output

KW

18.0

20.0

22.0

24.0

26.0

28.0

30.0

32.0

33.0

10.0

12.0

14.0

16.0

6.0

7.0

8.0

9.0

Btu/h

61,400

68,200

75,100

81,900

88,700

95,500

102,300

109,200

112,600

20,400

23,800

27,200

30,700

34,100

40,900

47,700

54,500

150

59

65

71

75

80

35

41

47

53

12

18

24

29

6

9

0

3 kW

24.4

27.0

29.9

32.2

34.8

37.2

40.1

42.6

44.4

8.0

9.2

10.5

12.1

13.6

16.4

19.3

21.8

Btu/h

83,200

92,300

101,900

110,000

118,000

127,000

136,900

145,300

151,700

27,400

31,300

35,800

41,300

46,500

55,900

65,700

74,500

205

59

65

71

75

80

35

41

47

53

12

18

24

29

6

9

0

3

46

240012994 Rev. B [08/31/2020]

10 - OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

!

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to light this burner by hand.

• Before operating smell all around appliance area for gas. Be sure to smell next to floor because some gas is heavier than air and will settle to the floor.

• Use only your hand to turn the gas shutoff

valve. Never use tools. If valve will not turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in fire or explosion.

• Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

10.1 Testing For Gas Leaks And Purging The Gas

Supply

• With boiler gas service cock closed (spindle flats at right angles to valve). Pressure test gas supply and inlet pipe work connection to boiler gas service cock for soundness.

• Loosen screw of pressure inlet gas test port on gas valve.

See section 13.4 Gas Valve. Verify gas supply is ON.

Open boiler service cock to purge.

• Retighten test port screw and test for gas leaks. Close boiler gas shutoff device.

10.2 Boiler Operation

Domestic hot water supply always takes priority over central heating.

Demand for hot water required during central heating period, boiler automatically switches to hot water mode until demand is satisfied.

This interruption in central heating is only when demand for hot water is present and should not be noticed by the user.

47

10.3 Central Heating Mode

1. With demand for heating, pump circulates water through the primary circuit.

2. After a 3 minute anti-short cycling stage the combustion fan comes on at ignition speed, closing the air pressure switch, allowing power to spark generator and gas valve, creating ignition in the combustion chamber.

3. Flame sensor acknowledges presence of flame in combustion chamber sending a signal to the control board.

4. After initial stabilization period the control board monitors supply and return temperatures and modulates fan speed and gas rate accordingly.

5. Once boiler satisfies CH call for heat, the unit will shutdown and enter 3 minute anti-cycling mode. The boiler pump will operate for 3 minutes to dissipate any residual heat.

If there is a subsequent CH call for heat, boiler will wait 3 minutes to operate.

10.4 Domestic Hot Water Mode

• When a tap is opened and water flow is sensed by DHW flow switch, domestic hot water call for heat is initiated .

• Water in the boiler is diverted from central heating system to domestic hot water heat exchanger to heat incoming domestic water.

• Combustion fan will come on at ignition speed, closing the air pressure switch (150 model only), allowing power to flow to spark generator and gas valve, creating ignition in the combustion chamber.

• Flame sensor will acknowledge presence of flame in combustion chamber and send a signal to the control board.

• After initial stabilization period, the control board monitors supply and return temperatures and modulates fan speed and gas rate accordingly.

• Domestic call for heat ends when tap is closed and DHW flow switch does not see water flow.

• There is no anti-cycling mode after a DHW call for heat.

10.5 Frost Protection

Boiler monitors supply and return water temperatures to enable frost protection which automatically turns boiler and pump on.

If water in boiler falls below 41°F (5°C), providing boiler is connected to power, boiler will operate until water temperature in the system reaches approximately 86°F (30°C).

Frost protection is for boiler only and not for complete Central

Heating System.

10.6 Pump

If electricity is connected to the boiler, regardless if power is

"On" or "Off" and has not operated for 24 hours for heating or hot water, boiler pump will operate automatically for one minute every 24 hours.

10.7 Low Water Pressure Sensor (Internal)

Device protects primary exchanger from damage. It will not allow boiler to run in a LOW water pressure situation. Low water condition occurs when water pressure drops below 7.0 psi (0.5 bar).

240012994 Rev. B [08/31/2020]

Note

Note

Note

!

11 - GENERAL MAINTENANCE AND CLEANING

DANGER

Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury.

!

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

V erify proper operation after servicing.

Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe, trouble free operation and maximum efficiency.

A Heat Exchanger cleaning kit is available for annual service of the boiler. See repair parts manual for part number.

• Circulator pump and combustion air blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication. Lubricate field sourced pumps and/or motors according to pump and/or motor manufacturer’s instruction.

• Check following components are operating properly and are free of blockages or obstructions:

• air vent;

• check venturi air inlet for blockage and clean as required;

• verify pressure test port cap and combustion test port caps are in place

• verify supply and return sensors are properly clipped to pipes as close to heat exchanger as possible;

• Check boiler for any sign of leaks.

• Check external low water cutoff operation (if installed).

• Check operation by pressing test button on low water cutoff.

• "Low Water" LED on the external LWCO should illuminate and boiler should shut down.

• Every 5 years remove low water cutoff. Reinstall after cleaning.

• Every 10 years replace low water cutoff.

• Visual inspection of flame through sight glass. Burner should be fully illuminated.

• Check heating system expansion tank.

11.1 Beginning of Each Heating Season

• Check boiler area is free from combustible materials, gasoline, and other flammable vapors and corrosive liquids.

• Visually inspect combustion air and vent piping for proper operation. Check for and remove any obstruction to flow of combustion air or vent gases. Immediately repair or replace pipe showing deterioration or leakage. Reassemble per instructions in section 6. Ensure proper reassembly and resealing of system.

• Visually inspect condensate drain line for proper operation.

Checking for deteriorated or plugged condensate drain line.

Verify condensate trap drains freely and clean as required.

• Test safety relief valve for proper operation. Refer to valve manufacturer's instructions packaged with relief valve.

• Examine heat exchanger, burner, condensate lines, and clean (if necessary) by following instructions in section 11.3

- Component Replacement And Cleaning.

48

240012994 Rev. B [08/31/2020]

11 - GENERAL MAINTENANCE AND CLEANING

!

WARNING

Following service procedures must be performed by qualified service agent. Boiler owner shall not attempt these steps. Failure to do so could result in death or serious injury.

!

WARNING

Combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans

(Group1). Avoid breathing dust and contact with skin and eyes. Use NIOSH certified dust respirator

(N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current

NIOSH recommendations can be found on the NIOSH website http://www.cdc.gov/niosh/homepage.html.

NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website. Wear long-sleeved, loose fitting clothing, gloves, and eye protection. Apply enough water to the combustion chamber lining to prevent dust. Wash potentially contaminated clothes separately from other clothing.

Rinse clothes washer thoroughly.

NIOSH stated First Aid. Eye: Irrigate immediately.

Breathing: Fresh air.

11.2 Maintenance And Routine Servicing

Check and service boiler as necessary.

Frequency of servicing will depend upon installation conditions and usage, manufacturer recommends annually.

• Check flue terminal outside and ensure it is not blocked.

• Operate boiler. Check operation of boiler's controls.

• Ensure all system connections and fittings are sound.

Correct any joints and fittings that maybe leaking.

• Follow safety valve manufacturer recommendations for service.

To ensure boiler operates at peak efficiency, following checks must be performed every year:

• check appearance and tightness of gas and combustion circuit gaskets

• check condition and position of ignition and flame sensing electrodes

• check condition of burner and its connection to aluminum front plate

• check for dirt in combustion chamber.

• Brush down with hard bristle nylon brush. Vacuum and flush deposits out of heat exchanger through condensate trap

• check gas valve is calibrated correctly using combustion analyzer

• check there is no dirt in condensate trap

• check central heating system pressure

• check expansion tank pressure

• check vent system, clean if necessary

!

WARNING

Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Test for gas leaks on any gas carrying components after servicing. Service not complete until appliance operation verified per

Installation, Operation & Maintenance Manual provided with boiler.

!

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Failure to follow these instructions could result in minor or moderate injury.

Record details and maintain service history.

11.3 Component Replacement And Cleaning

1. Remove any deposits from heat exchanger using suitable soft brush. Do not use brush with metallic bristles.

2. Check condition of the combustion chamber insulation panels. Any damaged panels must be replaced.

3. Check condition of burner. Clean burner with soft brush and check flame ports are clear. Blockages may be removed with stiffer brush. Do not use a brush with metallic bristles this might damage the burner.

4. Remove any fallen deposits from bottom of inner case.

5. Check condition of electrodes.

6. Check spark gap, positioning and height of electrodes,

See Figure 11-1.

7. Check fan impeller is clean and free to rotate.

NOTICE

Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe, trouble free operation and maximum efficiency.

49

240012994 Rev. B [08/31/2020]

11 - GENERAL MAINTENANCE AND CLEANING

!

DANGER

Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury.

11.4 Draining the Boiler

• turn boiler off

• isolate electrical supply

• close boiler gas service cock

• allow boiler to cool

• drain boiler through onboard drain if available or external drain valve.

11.5 Draining the Heating Circuit

• Follow all steps in 11.4.

• Close central heating flow and return valves.

• Connect suitable pipe to drain point.

• Route it to suitable container.

• Open drain tap.

11-1 ELECTRODES

50

240012994 Rev. B [08/31/2020]

11 - GENERAL MAINTENANCE AND CLEANING

11.6 Hydraulic Unit (DHW)

For special areas, where water is harder than 200 ppm or 12 grains/ gallon, install polyphosphate dispenser or equivalent treatment system, compliant with current regulations.

Model 150 Shown

11.7 Cleaning The Cold Water Filter

Boiler is fitted with cold water filter located on DHW hydraulic assembly (B). To clean:

• Drain domestic hot water system.

• Remove nut on DHW priority sensor unit using 18 mm wrench. (B)

• Pull out flow sensor and its filter.

• Remove any impurities.

• Soak in white vinegar or replace as necessary.

NOTICE

When replacing and/or cleaning “O-rings” on hydraulic assembly (DHW), use only Molykote 111 as a lubricant, not oil or grease.

Model 205 Shown

11.8 Final Commissioning

• Allow heating system to heat. Balance the system to achieve temperature difference across heating supply and return pipes at the boiler.

• Check system for proper volume and pressure. See page 4 for acceptable volume and pressure.

• Turn off boiler.

• Thoroughly flush water pipe work. Clean filters in heating return and supply water isolating valves.

• Repressurize the system.

11.9 Final Assembly

• Place front jacket in position over boiler. Secure in position at top using screws previously removed.

• If boiler is to be left in service with the User, set controls and room thermostat.

• If boiler is not to be handed over immediately, close boiler gas service valve and turn off electrical supply.

• If there is possibility of boiler being left during frost conditions drain boiler and system. See section

11: Component Replacement Or Periodic Cleaning.

Manufacturer recommends attaching a label to the boiler drawing attention to the fact that the system has been drained.

F E B A

LEGEND

Hydraulic Assembly (B)

A DHW exchanger fixing screw

B DHW priority sensor with filter

(C-1 & C-2: access to tap C - bottom of boiler)

D Boiler / system filling tap (150 unit only)

E DHW temperature NTC probe

F Low water cutoff

51

240012994 Rev. B [08/31/2020]

11 - GENERAL MAINTENANCE AND CLEANING

11.10 User Information

Advise and demonstrated to User the following important information:

A. How to light and turn off boiler. How to operate system controls.

B. Importance of annual servicing of boiler to ensure safe and efficient operation.

C. Servicing or replacement of parts shall be carried out by a qualified personnel.

D. Ensure boiler controls and room thermostat, if fitted, are set to User's requirements.

E. Tell User about sealed system pressure.

F. Tell User if display is active and boiler has not operated for 24 hours for heating or hot water, the pump and three way valve will automatically operate for 1 minute.

G. Explain to User an internal frost thermostat is fitted in boiler, and electrical supply to boiler must be left on for thermostat to operate.

H. Show User position of pressure relief valve discharge pipe.

I. Leave this Installation, Operation and Maintenance

Manual with User for use on future calls.

11.11 Safety Flue Thermostat - DO NOT disable this safety device.

Safety Flue Thermostat found on the flue inside the boiler, interrupts flow of gas to the burner if the temperature overheats.

After verifying the cause of the trip, press seconds.

for about 2

11.12 Flue Pressure Switch (150 Only)

DO NOT disable this safety device.

This device, positioned inside the sealed chamber, interrupts flow of gas to the burner if flue pressure exceeds 1.6 in w.c. (4 mbar).

Verify if vent is blocked before resetting the boiler.

NOTICE

When servicing the appliance, check the condition and position of flame sensing electrode and replace it if necessary.

11.13 Replacement Parts

Perform Automatic Calibration procedure described in section

9.8 if one or more of the following components are replaced.

Check and adjust CO2% value as indicated in the Combustion

Table.

Components replaced:

• Primary heat exchanger

• Fan

• Gas valve

• Gas orifice

• Burner

• Flame sensing electrode

• Spark electrode

52

240012994 Rev. B [08/31/2020]

12 - RATINGS AND CAPACITIES

12 TECHNICAL DATA

12.1 Ratings and Capacity

Model Number

GCWB95W-150

GCWB95W-205

Maximum

CH Input, MBH (1)

Minimum

125

164

22

29.5

(1)(2) CH Heating

Capacity, MBH *

113

153

(1)(3) Net AHRI

Rating Water, MBH

98

133

(2) AFUE%

95.0

95.0

(1) 1000 Btu/hr (British Thermal Units Per Hour)

(2) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.

(3) Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

*Max CH Supply temp 176° F (80°C)

12.2 Domestic Hot Water Specifications

Item

Input Ratings (MBH)

Output Ratings (MBH)

Domestic Water Pressure

Minimum Flow Rate

Maximum Flow Rate

Flow Rate 77°F (43°C) Temp. Rise

DHW Supply Connection Size

Cold Water Input Connection Size

Min

Max

Min

Max

*Max DHW temp 140° F (60° C)

Factory set at 120° F (40° C)

GCWB95W-150

22

153

GCWB95W-205

29.5

205

19

136

26

180

2.9 psi (0.2 bar) - 116 psi (8.0 bar)

0.50 GPM

3.50 gpm 5.00 gpm

3.25 gpm

1/2"NPT

1/2"NPT

4.65 gpm

3/4"NPT

3/4"NPT

53

240012994 Rev. B [08/31/2020]

12 - RATINGS AND CAPACITIES

12.3 High Altitude Ratings

For elevations between 2000 ft (600 m) and 10,000 ft (3048 m), use the following information:

Input, MBH (KW)

Altitude

2,000-4,500 ft

(600m-1350m)

Model Number

GCWB95W-150

GCWB95W-205

Maximum

113

147

Minimum

22

26.5

Heating

Capacity,

MBH*

101

137

AFUE, %

95.0

95.0

4,501-6,500 ft

(1372 m -1981 m)

GCWB95W-205 135 24.1

126 95.0

Domestic Hot Water (DHW) Circuit

Max Input,

MBH

Min Input,

MBH

Max Output,

MBH

**

Min Output,

MBH

137

184.5

22

26.5

122

157

19

23

168 24.1

143 20

6,501-10,000 ft

(1982 m -3048 m)

*

*

GCWB95W-205 113

Max CH Supply temp 176° F (80° C) for GCWB9-150

Max DHW temp 140° F (60° C)

20.3

105 95.0

141 20.3

120 17

**GCWB9-150 Max DHW Flow rate 3.5 gpm (13.2 l/min)

** GCWB9-205 Max DHW flow rate 5.0 gpm (18.9 L/min)

12.4 High Altitude Chart

GAS

Model

GCWB95W-150

Parameter

P71

High Fire

Fan Speed

GCWB95W-205

Parameter

P72

Low Fire

Fan Speed

GCWB95W-150

GCWB95W-205

Setting

RPM

Setting

RPM

Setting

RPM

0-2,000 ft.

[0-610 m]

220

7200

Natural

2,000- 10,000 ft

[610-3,048 m]

170

6700

Altitude

0-2,000 ft.

[0-610 m]

170

6700

225

7250

40

1150

Setting

RPM

40

1150

CO Limit < 200 ppm

60

1350

45

1200

LP

220

7200

25

1000

2,000- 10,000 ft

[610-3,048 m]

150

6500

60

1350

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240012994 Rev. B [08/31/2020]

13 - TROUBLE SHOOTING

13.1 Error Messages and Resetting the Boiler

09

10

Error Description

Gas valve connection fault

Outdoor sensor fault

15

20

28

40

50

53

55

E72/E92

Gas valve command fault

Central Heating NTC sensor fault

Flue NTC heat exchanger sensor fault

Return NTC sensor fault

Domestic Hot Water NTC sensor fault

Obstruction in flue pipe, Recirculation, Out of

Calibration, Poor gas quality

PCB not programmed

Combustion test alarm during commissioning / calibration

E83 OT Communication Failure

Operation

Check cable PCB/gas valve and gas valve plug

Check sensor and cable

Verify all cables. Replace PCB .

Call authorized SERVICE center

Check sensor and cable

Check sensor and cable

Check sensor and cable

Check sensor and cable

Check for obstruction in flue pipe. Check gas pressure, check gas orifice. Check for recirculation, recalibrate, check gas quality.

Call authorized SERVICE center

Check flame sensor, check for obstruction in flue pipe, check for recirculation, check gas pressure, check gas orifice, check gas quality. Perform calibration function.

Check OT connection, remove power, reconnect OT connections, if problem persists replace service key.

84-85

86-87

109

110

118

117

125

128

130

131

133

134

135

160

Communication problem between boiler board and control unit

Pre-circulation alarm (temporary fault)

Safety thermostat tripped due to over temperature

(pump probably blocked or air in heating circuit)

Probable short circuit on wiring.

Check cable between control unit and boiler

Check correct circulation of water and pump. Check supply and return wiring is correct.

Check safety thermostat and cable; check correct circulation of water and pump

Hydraulic pressure too low.

Hydraulic pressure too high.

No circulation of water

(control performed via temperature sensor).

Loss of flame

NTC flue sensor tripped due to over temperature

Thermo fuse tripped due to over temperature or wire harness disconnected from thermo fuse, off the board, or wire harness may be cut.

Ignition failure

Gas supply valve blocked

Internal error

Fan fault

Refill heating system by opening cold water tap

Relieve pressure via relief valve or drain. Ensure water feed is operating correctly.

Check correct circulation of water and pump.

Check correct connection of NTC sensor on pipe

Check sensing electrode and cable, flue recirculation, electrical continuity between burner and ground, gas pressure, gas orifice. Enable automatic calibration.

Call authorized SERVICE center.

Check thermostat, correct circulation of water and pump.

Check status of primary exchanger.

Check thermo fuse, correct circulation of water and pump. Check status of primary exchanger. Replace heat exchanger. Call authorized SERVICE center.

Verify wire harness installation and continuity.

Check correct operation of condensate trap. Check sensing electrode, spark electrode and cable. Check flue recirculation, electrical continuity between burner and ground. Check gas orifice and gas pressure.

Enable automatic calibration function.

Call authorized SERVICE center

Check gas pressure, sensing electrode, spark electrode and cable, replace PCB if it necessary.

Call authorized SERVICE center

Verify all cables. Replace PCB .

Call authorized SERVICE center

Check fan and cable

To RESET boiler press button for at least 2 seconds.

For other error codes not described in table please contact manufacturer at 1-888-9boiler (926-4537)

55

240012994 Rev. B [08/31/2020]

13 - TROUBLE SHOOTING

13.1 Error Messages and Resetting the Boiler - continued

162/317

Error Description

Incorrect power supply frequency.

169 Flue pressure switch (contact open)

Operation

Incorrect power supply frequency.

Check pressure switch and cable.

Check obstruction on flue pipe

164/384

165/385

E178

Fault flame (parasitic flame).

Input voltage too low.

Low return water temperature / anti-freeze function active

Check correct operation of T. gas valve.

Check power supply

Check the return water sensor, check the circulator, check the correct circulation of the water. Boiler will exit status when condition is resolved.

Anomalies Only Displayed in the Fault History

E62

Anti-wind activation with increase of the minimum fan speed

E63/E65

E65

E67

E69

E70

E73

Check the position of the terminal of the flue duct.

Combustion level out of range Check flue recirculation and combustion levels.

Maximum value of the speed reached / correction of the flame signal

Anti-wind activation at maximum power

Combustion level out of range

Flame signal problem/micro interruption of the flame signal

Check flue recirculation on the flue duct.

Check the position of the terminal of the flue duct.

Check flue recirculation and the combustion levels.

Check cable and integrity of the sensing electrode, verify the continuity between burner and earth.

Combustion adjustment / modified during operation Review and monitor other codes such as E53 and E92

56

240012994 Rev. B [08/31/2020]

13 - TROUBLE SHOOTING

13.2 Anomalies Table for the Installer - Use this table to report the anomaly values.

SYSTEM STATUS CODES

0 STANDBY

1 DHW "ON"

2 CHIMNEY SWEEP ACTIVE

3 CH "ON"

4 PREHEAT "ON"

5 CH NO FROST "ON"

6 DHW NO FROST "ON"

8 THERMOSTATIC POST- CIRCULATION

NO RESET

ANOMALY

RESET

ANOMALY

Anomaly

Number

P32

P33

P34

P35

P36

P37

P38

P39

P40

P41

C00: LAST FAILURE

C06: FIRST FAILURE

C07: LAST LOCKOUT

C09: FIRST LOCKOUT

C00

C01

C02

C03

C04

C05

C06

C07

C08

C09

FAILURE

CODE

Anomaly

Code

NUMBER

OF TIMES

OCCURRED

Consecutive

Counter for the Same

Anomaly

Number of

Days Elapsed

From the

Anomaly

Event

System

Status

Phase

Status

TEMPERATURE

CH Flow

Temperature

Value

During the

Anomaly vent

PHASE STATUS CODES

0: STANDBY

1: PRE-PURGE

3: INTER-PURGE

4: SAFETY TIME

5: RUNNING

6: LOCKOUT

11: INTER-PURGE

15: POST VENTILATION

16: THERMOSTATIC POST

VENTILATION

57

240012994 Rev. B [08/31/2020]

14 - GLOSSARY

• APPLIANCE - Device to convert gas into energy; term includes any component, control, wiring, piping or tubing required to be part of the device.

• DIRECT VENT BOILER - Boiler constructed and installed so all combustion air is derived directly from outdoors and all vent gases are discharged to outdoors.

• ANSI - American National Standards Institute, Inc. over see's creation and maintenance of voluntary consensus standards, including ANSI Z21.13/CSA 4.9: Gas-Fired Low

Pressure Steam and Hot Water Boilers.

• DOMESTIC - Relating to household usage as opposed to commercial usage.

• DOMESTIC WATER - Potable drinking water - tap water.

• DRAFT - Pressure difference causes gases or air to flow through a chimney, vent, flue or appliance.

• ASME Association of Mechanical Engineers

Establishes rules of safety governing the design, fabrication, and inspection of boilers and pressure vessels, determining the MAWP of such vessels.

• ASTM - American Society for Testing and Materials.

ASTM International is one of largest voluntary standards development organizations in world trusted source for technical standards for materials, products, systems, and services. Known for their high technical quality and market relevancy, ASTM International standards have important role in information infrastructure that guides design, manufacturing and trade in the global economy.

• FLA - Full load amps.

• FLUE - Enclosed passageway for conveying combustion gases.

• FLUE GASES - Products of combustion plus excess air in appliance flues or heat exchanger.

• GAS SUPPLIER - Party that sells commodity of Natural Gas

(Gas A) or LPG (Gas E).

• HIGH-VOLTAGE - Circuit involving potential of not more than 600 volts and having circuit characteristics in excess of those of low-voltage circuit.

• AUTHORITY HAVING JURISDICTION - Individual or organization adopting and enforcing codes, rules, and bylaws governing various concerns of community. Commonly referred to as "final authority" for any matters relating to LIFE SAFETY and BUILDING CONSTRUCTION within a community.

• BOILER - Appliance intended to supply hot liquid for spaceheating, processing or power purposes.

• BTU - Abbreviation for British Thermal Unit. Quantity of heat required to raise temperature of 1 pound of water 1°F.

• BURNER - Device for final conveyance of gas or mixture of gas and air, to combustion zone.

• CALIBRATE - Make fine adjustments or divide into marked intervals for optimal measuring.

• COAXIAL VENTING Sharing the same center.

• COMBUSTION - Rapid oxidation of fuel gases accompanied by production of heat or heat and light. Complete combustion of fuel is possible only in presence of adequate supply of

Oxygen.

• COMBUSTIBLE MATERIAL - Materials made of or surfaced with wood, compressed paper, plant fibers, or other materials capable of being ignited and burned. Such material shall be considered combustible even though flameproofed, fire-retardant treated, or plastered.

• COMBUSTION AIR - Air that is drawn into an appliance to mix with fuel and support combustion.

• CONDENSATE - Liquid separated from flue gas due to reduction in temperature.

• HYSTERESIS (DIFFERENTIAL) difference between the temperature at which the thermostat switches off - and the temperature at which it switches on again.

• IGNITER - Device utilizing electrical energy to ignite gas at main burner.

• LEAK CHECK - Operation performed on gas piping system to verify system does not leak.

• LICENSED QUALIFIED INSTALLER / SERVICE

TECHNICIAN any individual, firm, corporation or company that either directly or through a representative is engaged in the installation, replacement, repair or servicing of gas piping, venting systems, appliances, components, accessories, or equipment, and whose representative is experienced and trained, in such work and has complied with the requirements of the authority having jurisdiction.

• LOW WATER CUTOFF - Device constructed to automatically cut off fuel supply when surface of water in boiler falls to lowest safe water level.

• LOW-VOLTAGE - Circuit involving potential of not more than 30 volts.

58

240012994 Rev. B [08/31/2020]

14 - GLOSSARY

• METRIC GAS METERS

Natural Gas

127,116 x cu meters

MBH =

Seconds

For example: Gas Meter measures 0.1 cubic Meters in 100

seconds

127,116 x 0.1

MBH =

100

Propane Gas (LP)

= 127 MBH

383,482 x cu meters

MBH =

Seconds

• TWO PIPE SYSTEM - Type of venting that allows for exhaust flue and intake air piping to be separated from each other. Fresh air may be drawn in at a different area from where flue terminal is located.

• VENT - Passageway used to convey flue gases from appliance vent connector to outdoors.

• VENTING SYSTEM - Continuous open passageway from of appliance vent connector to outdoors for purpose of removing flue or vent gases.

• NATIONAL BOARD OF BOILER AND PRESSURE VESSEL

INSPECTORS - Group composed of boiler and pressure vessel inspectors representing states, cities and provinces enforcing pressure equipment laws and regulations.

• PRESSURE TEST - Operation performed to verify gas tight integrity of gas piping following its installation or modification.

• PURGE - To free gas conduit of air or gas, or mixture of gas and air.

• PURGE TIME - Period of time intended to allow for dissipation of any unburned gas or residual products of combustion.

• QUALIFIED AGENCY - Any individual, firm, corporation, or company engaged in and responsible for:

• Installation, testing, or replacement of gas piping, or connection, installation, testing, repair or servicing of appliances and equipment.

• Experienced in such work.

• Familiar with all precautions required.

• Complies with all requirements of authority having jurisdiction.

• SAFETY RELIEF VALVE - Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment.

• SAFETY SHUTOFF DEVICE - Device that will shut off gas supply to controlled burner in event source of ignition fails.

• SEDIMENT TRAP - Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve.

• SERVICE -Supply, installation, or maintenance of goods carried out by a Qualified Installer / Service Technician.

59

240012994 Rev. B [08/31/2020]

A-3 MODEL 150 - Combi

APPENDIX A - WIRING DIAGRAMS

60

240012994 Rev. B [08/31/2020]

A-4 MODEL 205 - Combi

APPENDIX A - WIRING DIAGRAMS

61

240012994 Rev. B [08/31/2020]

NOTES

62

240012994 Rev. B [08/31/2020]

INSTALLATION AND CHECK-OUT CERTIFICATE

Date Installed___________ Boiler Model Serial #

Measured BTU/HR input____________

Installer (Company)

Address

Phone

Installer’s Name

Signature

63

240012994 Rev. B [08/31/2020]

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases.

This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of

300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

PRODUCT LITERATURE

Lennox Industries Inc.

Dallas, Texas

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