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model gx series installation, operating and maintenance manual

1. 7 24V Prepurge IGNITION MODULE 24 V Manifold amp Stack Limit 150 amp 200 Manifold Limit amp Flow Power to ignitor 120v from S1 S1 L1 L2 S2 W MV GND TTTITI Igniter warm up 5 seconds Three retries for flame Flame Probe Power to Gas valve Signal 1 microA Less than Sentry 2100 1 0 microA Modulates fan based upon setpoint and programming Call for flame ends Greater than 1 0 microA GX INSTALLATION AND OPERATION INSTRUCTIONS Page 32 FOR YOUR SAFETY READ BEFORE OPERATING f you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that
2. Page 1 GX INSTALLATION AND OPERATION INSTRUCTIONS REPLACEMENT PARTS LIST Replacement parts are available from your stocking wholesaler Homeowners must contact their local installer or wholesaler Figure 48 Replacement Parts Exploded View Models GX150 and GX200 Description Blower gasket 200 Only Inlet Pipe assembly Condensate nylon Y Siphon Condensate Trap Cast aluminum Burner door Ceramic burner door disc Burner door gasket Igniter gasket Extended air tube Complete Control panel amp Harness PCB Optocoupler CVI Venturi 01 150 200 Only CVI Venturi Gasket Air metering Elbow Sentry 2100 10k Outdoor Air Sensor 1 8NPT Water Pressure Switch after 5 1 06 1 4NPT Water Pressure Switch 150 ASME Divider Plate Insulation c w washer and screw Stainless steel Top Electrical box cover Stainless steel Left side Stainless steel Right side Stainless steel Front Door Galvanized Right Side Galvanized Bottom base Bottom Base support Galvanized Back Part Number GX 82719 GX 82622 1 GX 82127 GX 82913 GX 82767 GX 82769 GX 82770 GX 82768 GX 82771 GX 82754 GX 82754 1 GX 82054 1 GX 82054 2 GX 82104 1 GX 81027 1 GX 83223 GX 83223 1 GX 83112 GX 82976 A GX 82976 B GX 82976 C GX 82976 D GX 82976 E GX 82976 F GX 82976 G GX 82976 H 82976 1 16 17 18 18 19 19 19B 20 22 27 27A 28 28A
3. page 4 Horizontal Direct Vent Systems page 5 Vertical Direct Vent Systems page 9 Condensate Drain page 10 General Plumbing Guidelines page 11 Primary Loop Plumbing page 13 Multiple Boiler Primary Loop Plumbing page 13 Secondary Loop Plumbing page 13 Gas Supply Piping page 18 Electrical Wiring inet eto page 19 Sentry 2100 page 26 Boller Set page 29 Operating Instructions page 29 Boiler Checking amp Adjusting page 33 Gas Pressure Adjustment page 33 Boiler Maintenance 0806 4 Wall Hung Conversion page 35 Trouble 36 Replacement Parts page 41 BEFORE YOU START WARNING This manual must be read and fully understood before installing operation or servicing this boiler Failure to follow these instructions could result fire explosion causing extensive property damage personal injury or death These instructions cover the GX Series gas fired direct vent low pressure hot water boiler GX boi
4. ACT 0 Q 180 1 60 15 AMP FUSED PDWER SUPPLY Thermostat 1 Thermostat 2 Thermostat 5 Thermostat 4 Page 3 Once the room thermostat is satisfied it breaks power to the TT terminal of the pump controller de energizing the XX contacts The circuit between terminals T and C opens shutting down the pumps and the burner GX INSTALLATION AND OPERATION INSTRUCTIONS Multiple Zone Pump Controller Models Taco SR504 Argo ARM 861 Series Figure 32 shows the basic multiple zoned system using circulating pumps This wiring system is used with the piping as shown in Figures 25 When there is a call for heat the room thermostat closes the circuit between the TT terminals on the pump controller The controller energizes the appropriate circulating pump and closes the circuit between terminals T and C on the Sentry 2100 control The Sentry 2100 provides power to the primary pump via terminal C1 Once these pumps are on the burner fires Figure 32 Multiple Zone Pump Controller Models Taco SR504 Argo ARM 861 Series CB Blue White lt 2 Black 120 1 60 15 FUSED
5. SUPPLY Pump 1 2 120 V Circulators Pump 3 INDIRECT hermostat 1 THERMOSTAT OR COMBI Thermostat 2 EpL FLOW SWITCH Thermostat 3 Thermostat 4 LEGEND P1 PRIMARY PUMP P3 SECONDARY PUMP P2 INDIRECT PUMP OR CB CONTROL BOX fr 3 WAY ON COMBI EH Burner On EH Heating Pump Aux Pump EH Coll for Heat 1 EH Water Bic BRE f L1 L T Page 4 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 33 Boiler Ladder Diagram POWER SUPPLY 120 60 HZ 1 PHASE BLOWER BARE 5 4 e 3 BK 2 LR 5 PIN CONN 0 GND HI PRESSURE 3 PIN CONN R Ain SWITCH w SWITCH MODEL 400 OTO 020 e 24vac 2 8 8 PIN CONN c N OG 8 PIN CONN GND BOILER BK PROBE MODEL 150 200 6 OUTDOOR SENSOR 2 SENTRY RESET MODE 3 2100 ONLY SHIELDED 3 CABLE 1 INDIRECT O A AQUASTAT THERMOSTAT 6 PIN CONN PRIMARY PUMP T Iw LOW WATER STACK LIMIT W PRESS SWITC
6. GX INSTALLATION AND OPERATION INSTRUCTIONS Detected Problem Excessive noise current or voltage spikes in the 120V power supply No power to control or control failure Typically an imbalance in the air to gas ratio Slight vibration can cause noise in the residence This is not a warranty issue Making a rubbing noise This is not a warranty issue Problem Sentry Controller Locks up Display Goes Blank Boiler Lights rough or pulsates Fan appears to be creating a noise in the housing Page 40 GX INSTALLATION AND OPERATION INSTRUCTIONS The following are the thermister curves for diagnosing the water and outdoor air sensors 1 Measure the resistance of the thermister when disconnected 2 Using the appropriate chart find the resistance and move vertically for the water probe or horizontally for the air probe until the line is intersected 3 Move 90 degrees to the corresponding temperature 4 fthe temperature is plus or minus 10 F 12 C then the probe is operating correctly Outside 10K probe Temperature Thermistor Resistance Chart 1 Mohm Water Probe Low Temp Resistance Mega Ohms 50 60 70 380 90 100 110 120 130 140 Water Temperature F Thermistor Resistance Chart 1 Mohm Water Probe Hi Temp E 120 e 100 80 gt 60 2 40 20 0 160 170 180 190 200 210 2200 0 Water Temperature
7. Reset Curve for Res 70 40 50 60 70 80 90 Outdoor Temperature deg F Bl 28 Determining Reset Temperature Once the Sentry 2100T control identifies the presence of a good outdoor sensor the control will automatically reduce the HI setting based upon the outdoor temperature For example if Hi 200 F 93 C RES 70 F 21 and the Air Temperature 32 F 0 C the HI setpoint Hlcac would be calculated as follows RESET RATIO High Setting RES RES 200 F 93 C 70 F 21 C 70 F 21 C 1 85 RESET TEMPERATURE RES Outdoor Air x Reset Ratio RES 70 F 21 C 32 F 0 C x 1 85 70 F 21 70 6 F 21 70 F 27 C 140 6 F 42 C Figures 39 Reset Curve For Res 85 F 29 C Reset Curve for Res 85 Hi Setting amp Water Temp F Outdoor Temperature deg F Figures 40 Reset Curve For Res 70 F 27 C 20041 120 1004 Hi Setting amp Water Temp F 1 0 10 20 30 L o Page 9 Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water NOTE The GX was tested with Natural Gas having a heating value of 1020 BTU per cubic foot For areas
8. 5 lt SIOM 151 Item Part Number Description 1 GX 82657 Premix burner 135 8 150 Only 1 GX 82658 Premix burner 200 6 200 Only 1A GX 82761 Premix Burner Gasket 2 GX 82457 Transformer 24V 3 GX 82013 Sentry 2100 4 GX 82052 Blower 400130 150 Only 4 GX 82661 Blower RG148 1200 200 Only 5 GX 82054 Gas Valve CVI VK8115F1134B 5A GX 82065 Gas Valve 1 2 npt elbow 5B GX 82600 Gas Valve Vent connection 6 GX 82662 Air switch Huba 15 wc 7 GX 82671 Thermister 7335 2016 1 Mohm 150 200 7 GX 83035 Thermister NTC 1 4 NPT 1 Mohm 150ASME 8 GX 82058 Ignition Moduel Fenwal 2465 9 GX 82708 IGNITER 601 c w SS Heat shield 10 GX 82762 Rauscchert Flame Rod 11 GX 82763 Composit Flue Box 11A GX 82764 Composit Flue Box Gasket 11B GX 82765 Composit Flue Outlet Gasket 110 GX 83291 1 Flue Adapter Assembly 12 GX 82659 Manifold Limit 1 8BSP Brass 150 200 12 GX 82992 Manifold Limit 1 4NPT Brass 150 ASME 13 GX 82596 150 non ASME Heat Exchanger 13 GX 83012 150 ASME Heat Exchanger 13 GX 82647 200 Heat Exchanger 14 GX 82650 LP orifice 5 20mm 150 200 Only 15 GX 82660 Stack Limit 1 4BSP SS 190F Dif 30 16 GX 82766 Blower gasket 150 Only Page 2 GX INSTALLATION AND OPERATION INSTRUCTI
9. Figure 48 Gas Supply Piping BOILER pen cas RO VALVE GAS COCK SHUT OFF VALVE TO BE T HANDLE TYPE c IT IS HIGHLY RECOMMENDED TO i USE FLEXIBLE GAS PIPE THE GAS VALVE AND BLOWER CANNOT SUPPORT THE WEIGHTOF PIPING IF PIPING IS USED ENSURE THAT THE VALVE SUPPORTS NO WEIGHT GX INSTALLATION AND OPERATION INSTRUCTIONS Aquastat High Limit The aquastat high limit controls the maximum water temperature in the boiler If the water temperature reaches the set temperature before the demand for heat has been met the aquastat high limit should shut the burners off The outlet water temperature should never exceed 220 F 104 C If the aquastat high limit fails to function properly replace it WALL HUNG CONVERSION This boiler is certified to be either mounted on the floor as supplied or mounted on a wall For wall mounting perform the following steps 1 Ensure that the desired location provides adequate room for the clearance see Table 1 venting and servicing 2 Remove the right stainless steel panel and discard 3 Youwill see that underneath the panel the boiler frame has mounting holes designed for wall attachment 4 The boiler must be mounted so the lag bolts enter the studs of the wall If this is not possible use a 3 4 thick of plywood approximately 24 in 610 mm wide by 36 in 914 mm high 5 Install two 14 3 lag bolts three quarters of the way into the surfa
10. with lower heating values a combustion test is required to obtain optimum operation WARNING The input Screw MUST NEVER ADJUSTED without verifying proper combustion with a calibrated combustion analyzer Failure to comply with this warning can result in excessive levels of carbon monoxide which can cause severe personal injury or death Table 7 contains the range for the CO CO2 and NOx that should be in a flue gas sample of a properly operating boiler at maximum input Table 7 Normal Flue Gas Composition Natural Gas Propane Carbon Dioxide CO2 8 9 5 9 10 5 Carbon Monoxide CO ppm 25 175 25 175 NOX ppm 10 50 10 50 Note At maximum fan speed of 240 on the Sentry display GX INSTALLATION AND OPERATION INSTRUCTIONS BOILER SET UP NOTE Before starting the boiler turn off the electrical supply going to it Make sure that gas is available at the gas valve inlet Open the valves in the hot water return and supply piping Failure to take these precautions will prevent the boiler from operation properly Fill the boiler and all of the radiation with water Make sure that the system is completely purged of air see GENERAL PLUMBING GUIDELINES Review these instructions and make sure that the boiler installation complies with ALL of the instructions up to this point OPERATING INSTRUCTIONS The GX boiler employs a pneumatic modulation system This modulation system increases or decreases the speed of the blower to
11. 64 0010 45 25 PL 36 UP 26 99 0011 57 45 PL 36 UP 26 99 0011 Minimum Restriction Flow Model Head Loss GPM L s GX 150 7 ft at 6 GPM 2 7 m at 0 4 L s 6 0 4 GX 200 10 ft at 8 GPM 3 m at 0 5 L s 8 0 5 GX 400 10 ft at 20 GPM 3 m at 1 25 L s 13 0 8 Page 4 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 23 Single Boiler with Indirect Hot Water Heater MAX 12 SEE b NOTE 3 b gt COLD HOT WATER WATER 5 SEE X EXPANSION 4 SEE 6 BACKFLOW Z 11 PREVENTION H DEVICE N L ORNE e SE Y A 4 optional NOTE 53 COLD INDIRECT HOT 0 WATER WATER HEATER SEE y MAKE UP SEE NOTE NOTE 15 10 SEE NOTE 1 SEE x NOTE 7 bM SEE SIOM 90 REV 1 NOTE 2 NOTES 1 All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger To make boiler service easy use Unions or flexible Vibration Isolation Kit 2 This boiler is provided with a 1 8 vent that is not intended for continuous system venting 3 For continuous system venting use a cast iron air scoop for excessive air conditions use a Spirovent Do not fire boiler until all air is purged from the system piping Heat exchanger damage caused by air is not covered by warranty See Table 3 for boiler p
12. IV to prevent scalding of persons with hot liquid or vapor in the event of a discharge see Figure 20 Support the relief valve discharge piping to prevent strain on the valve body Leave the open end of the relief valve discharge pipe visible for periodic inspection NOTE The discharge pipe diameter must be the same at the relief valve output diameter Never restrict the outlet relief valve WARNING Never install any type of valve between the boiler and the relief valve or an 2 causing extensive property damage severe personal injury or death may occur Figure 20 Relief Valve Piping All ASME Models Non ASME Model 150 Page 12 Understand and follow the plumbing requirements provided in this section Keep serviceability in mind when installing plumbing around the boiler cabinetry Install fittings that will allow the system to be flushed if needed during annual check ups Add an inhibitor to the system water to prevent lime and magnetite deposits from forming and to protect the boiler from galvanic corrosion A minimum clearance of 1 in 25 mm must be maintained between heating system pipes and all combustible construction All heating system piping must be supported by suitable hangers not the boiler The thermal expansion of the system must be considered when supporting the system A minimum system pressure of 12 psig 84 kPa must be maintained Hot water boilers are designed
13. and the burner should light If the burner fails to light the system will make three more ignition attempts If the burner has not lit after the last ignition try the gas valve will close and the system will go into lock out DO NOT attempt to reset the system until the ignition system has been inspected and the problem resolved Once the problem has been resolved and 5 minutes have passed since the last ignition attempt reset the system by turning the thermostat to it s lowest setting and then back to where it was or by momentarily interrupting the electrical power to the boiler With the burner in operation close the manual shutoff valve in the gas supply line As soon as the burner flame goes out open the manual shutoff valve A normal ignition sequence should take place With the burner in operation interrupt the power to the control circuit by lowering and raising the thermostat A normal ignition sequence should follow To test the ignition safety shutoff device close the manual shutoff valve in the gas supply line Within 6 seconds of main burner flame extinction the main gas valve solenoid should close with an audible noise The igniter should glow and make three attempts at ignition After unsuccessfully attempting to light the burner the ignition module should lock out A Page 30 The gas supply pressure to the boiler while running at maximum rate must be between 4 to 9 in 102 to 229 mm W C for natural gas inst
14. burner out of the unit 8 Inspect the burner for damage or signs of deterioration Use a brush or vacuum cleaner to remove any debris from the burner ports 9 DO NOT install a damaged or badly corroded burner replace it 10 Inspect the ceramic burner disc for signs of damage or deterioration and replace it if necessary 11 Inspect the burner door gasket for signs of damage or deterioration and replace it if necessary 12 Inspect the ignition components for signs of damage or deterioration and replace them if necessary 13 Reassemble the unit following the removal steps in reverse order 14 All gas connections MUST be leak tested before putting the boiler into operation WARNING Never use an open flame to test for gas leaks Always use an approved leak detection method Failure to comply with this WARNING could result in an explosion 15 Confirm proper operation of the boiler and replace the jacket panels Condensate System Ensure that the condensate removal system is clean sound and working properly Vent System The entire vent system must be thoroughly inspected for any signs of blockage damage or leaks Immediately replace any unsound vent system piping Remove any foreign matter in or near the vent and air inlet terminals that might obstruct them Low Water Cutoff If the system has been equipped with a low water cut off device follow the manufacturer s instructions for cleaning and to confirm proper op
15. draw of output C1 and Ap max 3 Amp Check the Amp draw of control on start up max 6 Amps Contact Hydrotherm Check for 120V between terminals L1 and L2 at Sentry If 120V exists turn power off and remove line voltage harness from Sentry Then check for resistance between L1 and L2 of control if the circuit is open O L the internal fuse has blown Check for shorts in wires leading to circulators prior to replacing controller If 120V not present check wiring and for 120V at source Ensure that the venting lengths are in compliance with the venting sections above Ensure that the line pressure during operation does not drop more than 20 from the static line pressure Momentarily remove the intake vent from the boiler during ignition if unit lights smoothly with intake vent disconnected reconnect and check for proper combustion if unit maintains smooth operation after ignition Calibrate for proper combustion If problem persists contact Hydrotherm Use flexible gas line to insolate the vibration noises between the gas valve and the line Don t hang gas lines from floor joists Use rubber insulators with gas line supports If gas valve is not held when the gas nipple is connected the force of tightening the fitting can damage the valve and warp the fan housing If pipe is used the gas line must not create any forces to the valve either vertically weight of line or horizontally misaligned connection
16. gas tight and watertight All horizontal vent piping must be sloped back to the boiler a minimum of 1 4 27mm m of vent NOTE Steps must be taken to ensure that condensate does not collect in the venting system or the boiler will not operate properly This boiler may be vented using the following materials but local codes must be followed GX150 amp 200 3 in 76 mm PVC Sch 40 solid core pipe CPVC Sch 40 pipe AL29 4C Flex Stainless Vent or AL29 4C Rigid Stainless Vent GX 400 4 in 102 6 in 152 mm PVC Sch 40 solid core pipe CPVC Sch 40 pipe AL29 4C Flex Stainless Vent or AL29 4C Rigid Stainless Vent CAUTION All vent systems must be fully supported by the building structure The vent connection and vent piping MUST be perfectly aligned to the boiler connection Figure 3 It MUST NOT APPLY ANY WEIGHT OR LATERAL FORCE TO THE FLUE BOX or the flue box will be damaged voiding the warranty Appropriate adapters must be used to increase the 2 in 51 mm vent collar to 3 in 76 mm at the boiler GX 150 amp 200 Figure 3 On the GX 400 the 4 in 102 mm long 4 inch diameter ABS pipe provided with the boiler must be inserted into the exhaust connection on the top of the boiler and tightened in place with the supplied clamp Figure 3 Vent Pipe To Boiler Attachment Ss The maximum combined equivalent vent and intake pipe lengths are listed in Table 2 The length specified is the equivalent vent length added
17. has been under water C 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 does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not tough any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions Remove control access panel Turn the manual gas supply shut off valve clock wise w to the full OFF position Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn the manual gas supply shut off valve counter clockwise to ON Replace control access panel Turn on all electric power to the appliance Set thermostat to desired setting 12 If the appliance will not operate follow the instruct tions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier 5 6 10 11 STOP Read t
18. lower then 1 2 micro amps see Boiler will not stay lit below Check combustion properties If the Burner light on the Sentry is going out go to Burner shutting off Check condensate drain for blockage and check the inlet piping for ingested snow or water if the flame rod gets wet it may need to be replaced Check for resistance from flame rod to ground must be an open circuit O L Check for proper polarity of line and neutral wiring to the boiler Ensure the plumbing is as shown in manual Check to see if pumps are faulty or end switches are stuck This problem can lead to boiler overheating Detected Problem Stack Safety Limit Trips Automatic Reset Located on the front of the flue box The Fenwal controller thinks that there is a flame prior to ignition Indicates Ignition Lockout Indicates lack of a good flame signal In order to stay running the flame signal must be at least 0 7 micro Amps Bangs or sounds like a kettle while burner is running indicating insufficient flow Page 38 Problem Ignition Sequence not activated when burner light is on Fan is on and Fenwal not flashing continued Two Flashes on Fenwal Three Flashes on Fenwal Boiler will not stay lit Boiler bangs or hisses Page 9 Solution Check for voltage at the wires going to the A C T terminals of the Boiler Check the magnitude of the line voltage power supply Check the Amp
19. protected If the test pressure is equal to or less than 1 2 psi 3 5 kPa isolate the boiler by closing it s manual shut off valve see Figure 27 If the test pressure is greater than 1 2 psi 3 5 kPa disconnect the boiler and it s individual shut off valve from the gas supply piping WARNING Failure to protect the gas valve from excessive pressure can damage the gas valve which can cause a fire or explosion Page 18 GAS SUPPLY PIPING The GX hot water boiler comes from the factory ready to be piped to the gas supply The National Fuel Gas Code ANSI Z223 1 NFPA 54 and local codes for gas piping requirements and sizing must be followed If for any reason the boiler is not for the type of gas available at the installation site call the nearest Hydrotherm distributor to resolve the problem Figure 27 depicts the proper way to connect the boiler to the gas supply piping The manual shut off valve MUST be installed in the supply piping It should be approximately 5 ft 1 5 m above the floor Provide a sediment trap drip leg at the bottom of the vertical section of the gas supply pipe A ground joint union should be installed between the boiler gas controls and the supply piping Each of these items is needed to ensure long life and ease of servicing Always use a pipe sealant that is suitable for use with LP gas Flexible gas piping is recommended if accepted by the local codes Make sure the gas piping doesn t hinder boiler acc
20. shaped structure including walls and fences Under normal operating conditions this appliance will produce a plume of water vapor and should be taken into consideration when selecting an adequate vent terminal location A 3 ft 0 9 m diameter stainless plastic or vinyl shield can be used to flash the exterior of the residence to protect is from damage e e e Separate Air Intake and Vent Terminals It is highly recommended that the air intake and vent terminals not be located where they will be exposed to normal prevailing winds Both terminals must be on the same wall The vent terminal must be a minimum of 18 in 457 mmabove the air inlet terminal The air inlet terminal must always be a minimum of 12 in 305 mm plus the snow allowance above any surface that will support snow however a snow allowance of two feet is highly recommended Figure 5 6 7 amp 8 Page 7 For installations that have to exit the foundation below grade excavate the site as shown in Figure 8 to a point below where the pipes exit the building Maintain the proper vent clearances as outlined above Attach the vent and air intake pipes to the outside of the building using special bracket 82075 Ensure that the wall penetrations are properly sealed before backfilling the site Figure 8 Below Grade Installation IN MIN PLUS SNOW ALLOWANCE vov o viv vov ov ow wy vow ow SUPPORT ATTACHED TO PLUS SNOW BUILDING ALL
21. terminal must be a minimum of 18 in 457 mm above the air inlet terminal The vent terminal must also be 24 in 670 mm above any roof surface within a horizontal distance of 10 ft 3 m The air inlet terminal must always be a minimum of 12 in 305 mm plus the snow allowance above any surface that will support snow however a snow allowance of 24 in 610 mm is highly recommended Figures 15 amp 16 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 18 Multiple Concentric Through the Roof EXHAUST i 1 1 1 1 1 1 arn V TEIN MINIMUM 265 6o paese 90009502 m 24 IN MINIMUM AIR INLET CONDENSATE DRAIN WARNING The condensate siphon must be connected to the boiler per the followin instructions or combustion gases will enter the room This can result in excessive levels of carbon monoxide which cause severe personal injury or death This unit produces water as a byproduct of combustion Much of this water condenses on the heat exchanger and in the venting system Condensate must be drained from the boiler into a household drain as shown in Figure 19 Figure 19 Condensate Piping ONDENSATE FROM BOILER CONDENSATE SIPHON CONDENSATE DRAIN PIPE MUST NOT BE SEALED DRAIN MUST NOT EXCEED HEIGHT OF HOLE IN CABINET CONDENSATE TRAP AND DRAIN BACK PANEL NOTE Check
22. to be greater then 36 in 914 mm A dormant chimney can be used as a chase through which the air intake and vent pipes can be run Figure 16 The chimney must not be connected to a fireplace water heater or any other heating appliance Figure 16 Two Pipe Using Dormant Chimney 18 IN MINIMUM ABOVE AIR INLET 12 IN PLUS SNOW ALLOWANCE GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 13 Wall Penetration Detail SUPPORT BRACKET ES EI INLET AIR d 4 3 EXHAUST gt MUST BE ve 1 FROM WALL The debris screen provided with the boiler must be installed in the concentric terminal as shown in Figure 14 Figure 14 Debris Screen Installation 2 VERTICAL DIRECT VENT SYSTEMS Read the information in the GENERAL VENTING GUIDELINES section before proceeding The GX can be vented vertically directly through the building s roof or through a dormant chimney used as a chase Figures 15 8 16 All roof penetrations must be properly flashed and sealed WARNING Under no conditions shall this boiler vent gases directly into a masonry chimney nor can an active chimney be used as a chase Failure to comply with this warning can result in excessive levels of carbon monoxide which can cause severe personal injury or death Separate Air Intake and Vent Terminals The discharge of the vent terminal must point away from the pitch of the roof The vent
23. 4 NPT Gas Valve Connector O ring Gas Valve Harness Air switch Huba 0 2 wc Air Vent Thermister NTC 1 4 NPT 1Mohm Ignition Module Fenwal IGNITER 601 c w SS Heat shield Flame Rod Rauschert Air Switch 604 E421180 set 6 3 wc Limit Switch 1 4 NPT Manifold 400 Heat Exchanger ASME Gas Valve Orifice 8 0mm NG Gas Valve Orifice 6 2mm LP Flow Switch FS 10C Blower Gasket Part Number GX 83173 GX 82761 GX 82457 GX 83171 GX 82994 GX 82989 GX 82991 GX 83194 GX 83016 GX 82662 GX 82539 GX 83035 GX 82058 GX 82708 GX 82762 GX 82906 GX 82992 GX 82926 GX 82993 GX 83017 GX 81887 GX 82766 Item 5A 5B 6C 10 11 12 13 14 14A 15 16 Advanced Thermal Hydronics IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONTARIO 15 114 905 672 2991 FAX 905 672 2883
24. D BOILER MANIFOLD CABLE PROBE SENSOR TYPICAL STACK LIMIT SWITCH MODEL 150 200 R CONTROL PANEL FLAME SENSE MODULE FENWAL BK IGNITOR CONTROL 35 655006 011 120v W FAULT FLAME TRANSFORMER SENSOR 1 L1 L2 2 W CND 20VA CIRCUIT BOARD NM CONN TYPICAL 8 7 SENTRY 6 2100 C 1 c1 TERMINAL AIR 2 DISPLAY L2 STRIP SWITCH nag mee 6 8 COO Wor ax Ap 7 Jgjr mwosur 1 6 A X L1 5 WATER AR GAS DHW TER due wer 3 2 ACT L HI PRESS AIR SWITCH BK X 0 6 PIN CONN MODEL 400 c 6 tH 0 BLOCK 2 2 6 1 MODEL 150 200 6 BLOWER GAS BARE VALVE 2 BR BK 1 BK W 2 BL 6 5 1 5 5 CONN 5 PIN CONN MOLDED COLOR CODE BR BROWN BK BLACK FACTORY WIRING BL BLUE R RED FIELD WIRING Y YELLOW WHITE PR PURPLE G GREEN DWG 82 1050 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 37 2100T Display Screen BURNER BRULEUR THERMOSTAT DEMAND WATER RUN EF EAU TIME EN MARCHE Burner Bruleur Indicates that the ignition system is activated Circ Indicates that the heating pump is
25. GX2 707 HydroTherm MODEL GX SERIES INSTALLATION OPERATING AND MAINTENANCE MANUAL Modulating Direct Vent Gas Fired Condensing Boilers Natural Or Propane 150 000 to 399 000 Btuh Input see note WARNING If the information this manual is followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 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 e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING Installation and service must be performed by a qualified installer service agency or the gas supplier in accordance with all local and national codes Failure to comply with this warning can result in a fire or explosion causing property damage personal injury or loss of life WARNING It is the responsibility of the homeowner to keep the vent terminal clear of snow and ice Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death INSTALLER THESE INSTRUC
26. H SWITCH MODEL 150 200 MODEL 150 200 INDIRECT PUMP Bu PR FLOW SWITCH er ODEL 460 CIRCUIT MODEL 400 BOARD oy ON CONTROL PANEL 0 TERMINAL STRIP BL MANIFOLD SENSOR R w FLAME 4 BR 24V COM V 24V COM if FLAME SENSE MODULE FENWAL 35 655006 011 51 CONTROL L1 FAULT Lis 8 FLAME BK SENSOR 52 w BK MV 120V TRANSFORMER 20VA GND 0 GAS VALVE 24 24V COM Y 24V COM COLOR CODE BR BROWN BLACK FACTORY WIRING BL BLUE R RED FIELD WIRING Y YELLOW W WHITE PR PURPLE G GREEN DWG 82 1050 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Figure 34 Boiler Connection Diagram E 5 OUTDOOR Q SENSOR 8 z RESET MODE ONLY NDIREGT BUME 6 120VAC 3 AMPS 2 FUME 120VAC 3 AMPS Sz POWER SUPPLY 120V 60 HZ 1 PHASE DRY CONTACTS HHAH LOW WATER PRESSURE SWITCH TERMINAL STRIP 4 c o o ON TOP COVER wopEL 150 200 ELECTRICAL 1 FLOW SWITCH Box BARE Bk RIR MODEL 400 R SHIELDE
27. NING This boiler must be supplied with combustion air in accordance with Section 5 3 Air for Combustion amp Ventilation of the latest revision of the National Fuel Gas Code ANSI 2223 1 54 all applicable local building codes Failure to provide adequate combustion air for this boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death WARNING Never operate this boiler unless the air intake is connected to the outdoors Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death WARNING Each boiler must have it s own intake air system Common intake air systems are not to be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death To operate properly and safely this boiler requires a continuous supply of air for combustion NEVER store objects around the air inlet Use appropriate adapters to increase the 1 in 38 mm air inlet collar to 3 in 76 mm at the boiler GX 150 8 200 Figure 2 Use a 2 in 51 mm to 4 in 102 mm adapter on the GX 400 Terminate the air inlet system per the instructions found in the venting sections that follow Figure 2 Air Inlet System Attachment Page 5 Table 2 Vent amp Air Intake System Sizing Model Equivalent Vent amp Air Intake Number System Length see note GX 150 105 f
28. ONS REPLACEMENT PARTS LIST Replacement parts are available from your stocking wholesaler Homeowners must contact their local installer or wholesaler Figure 49 Replacement Parts Exploded View Model GX400 SIOM 152 Page 3 Description TEE NYLON 3 4 to 3 4 ADAPTER NYLON 3 4 x 1 4 SIPHON CONDENSATE TRAP Burner Door Ceramic Disc Burner Door Viton Gasket Igniter Gasket Exhaust Test Plug Extended Air Tube Control Panel Complete CVI Venturi O ring Venturi to Blower Test Port Retaining Clamp PCB Optocoupler Air Metering Assembly Sentry 2100 10K Outdoor Probe Vent Screen 4 Vent Screen 6 Nipple 1 1 4 x 8 Brass 1 1 4 1 1 4 3 4 Tee Brass RELIEF VALVE 3 4 4335 30 PSI PRESSURE GAUGE 0 30 PSI Divider Insul c w washer amp screw Part Number GX 83037 GX 83038 GX 82913 GX 82769 GX 82770 GX 82768 GX 83034 GX 83195 GX 83141 GX 82990 GX 83106 GX 83001 GX 82754 1 GX 83170 1 GX 81027 1 GX 83018 GX 83019 GX 83013 GX 83005 GX 13701 GX 82148 GX 83112 Item 17 17A 18 19A 19B 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 GX INSTALLATION AND OPERATION INSTRUCTIONS Description Premix Burner For 400 Premix Burner Gasket Transformer 24V Sentry 2100 Assembly EBM BLOWER RG148 E Gas Valve VR8615VB 1044B Gas Valve Adapter 3
29. OWANCE If required the air intake and vent systems may be run along an outside wall Figure 9 providing the following conditions are met 1 The maximum length on the outside of the building is not more than 20 ft 6 7 m 2 All normal termination clearances are maintained 3 The entire vent system external to the building is insulated using closed cell foamed polyolefin tubing having a minimum wall thickness of 1 2 in 13 mm 4 The air intake and vent systems are supported every 24 in 610 mm 5 The air intake and vent systems are sloped 1 4 in ft 21mm m back toward the boiler GX INSTALLATION AND OPERATION INSTRUCTIONS When penetrating an outside wall the air intake and vent pipes must be constrained as shown in Figure 6 The openings through which the air intake and vent pipes pass must be properly sealed to prevent products of combustion from entering the building WARNING Failure to properly install and seal the air intake and vent system can result in excessive levels of carbon monoxide which can cause severe personal injury or death Figure 6 Wall Penetration Detail THE VERTICAL PORTION OF THE EXHAUST TERMINATION DOES NOT REQUIRE INSULATION IF LESS THAN 5 FEET IN TOTAL 12 PLUS SNOW ALLOWANCE 18 IN MIN COUPLING AND ELBOW TO BE AGAINST WALL 1 2 IN PLAY IS ACCEPTABLE In some cases it may be necessary to attach the air intake and vent pipes to the outside wall
30. TIONS MUST BE AFFIXED ADJACENT TO THE BOILER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES Note For LP gas use conversion kit GX82650 1 on GX 150 amp 200 GX83017 1 on GX 400 Advanced Thermal Hydronics IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONTARIO 15 1L4 905 672 2991 FAX 905 672 2883 GX INSTALLATION AND OPERATION INSTRUCTIONS To obtain the safe dependable efficient operation and long life for which this boiler was designed these instructions must be read understood and followed Direct all questions to your Hydrotherm distributor or to the Customer Service Department 260 North Elm Street Westfield MA 01085 Always include the model and serial numbers from the rating plate of the boiler in question The owner should maintain a record of all service work performed with the date and a description of the work done Include the name of the service organization for future reference Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 latest revision In Canada the installation must be in accordance w
31. W PREVENTION SEE DEVICE nc Z SE NOTE 1 T 7 COLD WATER j MAKE UP 2 SIOM 92 REV 1 NOTES 1 All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger To make boiler service easy use Unions or flexible Vibration Isolation Kit 2 This boiler is provided with a 1 8 vent that is not intended for continuous system venting 3 For continuous system venting use a cast iron air scoop for excessive air conditions use a Spirovent Do not fire boiler until all air is purged from the system piping Heat exchanger damage caused by air is not covered by warranty See Table 3 for boiler pump flow requirements This pump is wired to terminals C1 L2 Indirect Water Heater pump is wired to terminals AP L2 Set pressure reducing valve to 12 PSI Use 30 psi relief valve max Locate where discharge will not cause injury or damage Follow local codes Add an inhibitor to protect system CHP from Fernox Boiler circuit piping must be sized large enough to handle maximum flow through unit Do not operate boiler with service valves closed isolating the boiler from the expansion tank Failure to follow these instructions will result in heat exchanger damage All flux and contaminants must be flushed from piping before connecting boiler Do not connect this boiler to older systems with cast iron r
32. a the condensate drain This process may warrant removing the insulation disc from the back of the heat exchanger Heat Exchanger Flushing Listen for water flow noises that indicate a drop in the boiler water flow rate The boiler and hydronic system may need to be flushed to eliminate hard water scale A de scalar such as Fernox DS 40 is recommend Burner Removal amp Replacement WARNING The ceramic door disc on the rear of the burner contains crystalline silica Wear proper respiration protection when servicing the burner and gently handle the burner and its disc to prevent inhalation of airborne fibers Crystalline silica fibers have been identified as carcinogenic or possibly carcinogenic when inhaled CAUTION The burner should not be removed unless there is a problem with it Careless handling can damage the burner Page 5 Figure 46 Gas Valve Rotation NEW LOCATIONS FOR SCREWS REMOVE SCREWS AND ROTATE 90 RE INSTALL SCREWS N NEW LOCATIONS 1 2 IN THREADED CONNECTION 10 Reattach the gas valve venturi assembly to the side of the blower making sure the gasket is correctly orientated 11 Re install the Air Inlet Pipe assembly and Metering elbow from the gas valve venturi assembly in the vertical position Figure 47 Figure 47 Air Inlet Pipe Installation 12 Install the gas line as per Figure 48 and follow the instructions in the GAS PIPING section of this manual
33. adiation without installing a fine particulate separator TYP Spirotrap Junior Model TDN 125 FT Do Not use non oxygen barrier radiant tubing ovoo mudocoxs k ak Notice This drawings show suggested piping configuration and valving Check with local codes and ordinances for specific requirements 6 dE NIA Zone Ball Check Valve Automatic Heating Drain Valve Differential Pressure Spirotrap Expansion Val Air Vent Bypass Valve Fine Particulate Tank Ld Load Typ 6 Separator GX INSTALLATION AND OPERATION INSTRUCTIONS Page 17 Figure 26 Multiple Zones Valves with Bypass Valve AP SEE NOTE 4 4 O3 pw pow pow Xe 4 ej MAX 12 Q gt Dx 6 3 EXPANSIO TANK C Note Velocity noise may be NOTE co SZ problem when the entire 4 0 output of the system pump is DEVICE zt flowing through the zone with WE the highest pressure drop X a Adjust the differential bypass E valve to eliminate noise 7 4 COLD may WATER SEE MAKE UP NOTE 2 SIOM 93 REV 1 NOTES 1 All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger To make boiler service easy use Unions or flexible Vibration Isolation Kit 2 This boiler
34. allations 9 to 12 in 229 to 305 mm W C for propane installations This pressure can be measured on the gas valve using a manometer Figure 41 or 42 Ensure that the regulator is capable of maintaining this pressure under all operating conditions The gas valve is also equipped with a manifold pressure port Figure 41 or 42 Gas Valve Layout GX 150 amp 200 B LINE PRESSURE Gas Valve Layout GX 400 Manifold Pressure Line Pressure Figure 41 A Gyr 9 MANIFOLD PRESSURE Figure 42 Input Screw GX INSTALLATION AND OPERATION INSTRUCTIONS Page 31 Figure 43 Operational Flow Chart Displays version Boiler in t2 0 or t4 0 standby Mode Indirect thermostat or flow Switch closes A C Call for Domestic 120v Power Applied Combi model Thermostat End switch or relay closes T C Call for Heat Combi or indirect Energizes 3 way diverter valve Indirect Water Heater Energizes Primary Pump C1 Energizes Indirect Pump Ap turns off C1 nergizes Prima Pump C1 Air Closed Switches Qo eq Sentry 2100 Call for Ignition 7 Open 0 Sentry 0 24 Volt signal gt Sentry 2100 to blower O Sentry 2100 Fan to SFS 75 1 Closed 9 en EEEE E 2 no Y4 Cod Switch 1 Hi pressure 1T Closed 400 N C switchon E 400 only
35. amage to the electrical system components caused by improper wiring will void the warranty Thermostat Installation ALWAYS follow the instructions included with the thermostat to be used to control the boiler Proper location of the thermostat will ensure efficient trouble free operation of the boiler Mount the thermostat to an inside wall at a height approximately five feet above the floor Avoid placing the thermostat in areas that will not provide an accurate measurement of the room temperature Locating the thermostat behind a door in an alcove close to a source of thermal radiation or in a drafty area will cause poor or sporadic heating CAUTION CONTACTS THAT ENERGIZE THESE INPUTS MUST BE DRY CONTACTS ONLY THERMOSTAT V WIRING ELECTRICAL WIRING CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Install a separate 120 volt 15 amp circuit for the boiler Figures 28 and 29 A properly rated shut off switch should be located at the boiler The boiler must be grounded in accordance with the authority having jurisdiction or if none the latest revision of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of any contro
36. ble 6 Recommend System Temperatures Hi Dif RES System F F C F C Finned Tube Baseboard 190 88 20 11 7 85 29 Cast Iron Radiators 150 66 20 11 7 85 29 Radiant 130 54 20 11 7 85 29 Outdoor Sensor 10K The outdoor sensor should be installed to take advantage of the energy saving features of the Sentry Controller Install the sensor on the north or coldest side of the building out of direct sun It must be at least 10 ft 3 from the vent terminal or other source of heat Display Data Input conversion chart LED Display GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 38 Input Conversion Chart 400 350 BTU 000 s Setting Sentry 2100T control Programming is accomplished by a series of three push buttons located on the bottom side of the control To enter the programming mode press the function key once RUN should be displayed on the screen To scroll through the various menu options depress 1 To alter the value of a menu option press Function once while the menu option is displayed and the current value will be displayed then use for up and for down until the desired value is obtained To enter the selected value press Function which will return to the menu and store the new setting When all desired values are set scroll to the RUN menu option and press Function which exits the Programming Mode and initiates normal operation If the control is left in the Pro
37. ce to the height you desire for mounting 6 Lift the boiler onto the wall and tighten the top lag bolts 7 Once the unit is level install the bottom two 14 3 lag bolts 8 Remove the Air Inlet Pipe assembly and Metering elbow from the gas valve venturi assembly Figure 45 Figure 45 Air Inlet Pipe Removal 9 Remove the two screws attaching the gas valve venturi assembly to the side of the blower and rotate the valve 90 so the 1 2 threaded connection is pointing down Figure 46 Pay close attention to how the cork gasket is aligned Page 6 GX INSTALLATION AND OPERATION INSTRUCTIONS TROUBLE SHOOTING This section is intended to assist the service technician in detecting and correcting common errors The Sentry 2100 is equipped with an internal diagnostic system that verifies control operation The following series of error codes has been developed to aid in diagnosing control problems Solution 1 Check to see if water is dripping on the sensor 2 Reduce the Hi setting and or ensure that there is proper water circulation in the system Check wiring Check wiring Note ER3 will be displayed if temperature sensed is less then 32 F 0 Note If problem is corrected by resetting power Sentry control had locked up contact Hydrotherm 1 Not enough flow to keep boiler from tripping on limit Verify that a min of 6 GPM 0 4 L s flow is going through boiler amp indirec
38. cked This will cause condensate to fill the combustion chamber resulting in a no heat condition and damage to the boiler 6 NEVER use copper steel or galvanized piping in the construction of the condensate system 7 When a condensate pump is used or required select a pump that is designed for residential furnaces GENERAL PLUMBING GUIDELINES If connecting this boiler to a system containing cast iron radiation be sure to add a strainer to the system to trap any sediment that may dislodge Failure to do this could harm the heat exchanger and void the warranty The use of non oxygen barrier radiant tubing is acceptable provided that non ferrous pipe valves and fittings are used throughout the entire hydronic system CAUTION All heating system piping must be installed in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section IV All applicable local codes and ordinances must also be followed If the boiler is installed above any radiation elements it must be fitted with a low water cutoff device installed above the normal boiler water level CAUTION This boiler must have adequate water flowing through it whenever the burner is on Failure to do this will damage the unit and void the warranty GX INSTALLATION AND OPERATION INSTRUCTIONS Pressure Relief Valve Each boiler is equipped with a 30 psi pressure relief valve that must be piped in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section
39. e Spirotrap Reducin Relief Val Air Vent Device Bypass Valve Fine Particulate Valve Long yp Separator Fine Particulate GX INSTALLATION AND OPERATION INSTRUCTIONS Page 15 Figure 24 Multiple Boiler Installation orr eae Y 9 EXPANSION TANK A SEE NOTE 3 SEE NOTE S SEE Y 6 Sy 668 BACKFLOW PREVENTION dee 2 9 DEVICE NOTE 11 C C Ez sEE StE A en NOTE 1 NOTE 7 4 COLD Zs WAER SEE MAKE UP NOTE 2 SIOM 91 REV 1 NOTES 1 All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger To make boiler service easy use Unions or flexible Vibration Isolation Kit 2 This boiler is provided with a 1 8 vent that is not intended for continuous system venting 3 For continuous system venting use a cast iron air scoop for excessive air conditions use a Spirovent Do not fire boiler until all air is purged from system piping Heat exchanger damage caused by air is not covered by warranty See Table 3 for boiler pump flow requirements This pump is wired to terminals C1 L2 Indirect Water Heater pump is wired to terminals AP L2 Set pressure reducing valve to 12 PSI Use 30 psi relief valve max Locate where discharge will not cause
40. eath NOT install this boiler in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or servicing The boiler location ambient temperature must be no less than 50 F 10 C including the condensate line BOILER LOCATION WARNING The clearances to combustible construction listed in Table 1 must be maintained 4 NEVER store objects on or around the boiler Failure to comply with this warning can result in a extensive property damage severe personal injury or death 5 This boiler may be wall mounted See the Wall Hung Conversion section listed in the table of contents CAUTION This boiler is designed to operate only in residential and commercial heating systems It is not intended for WARNING Never store combustible materials gasoline product containing flammable vapors or liquids in the vicinity of the boiler Failure to comply with this warning can result in extensive property damage severe personal 1 Outdoor installations or unheated spaces which can cause freezing 2 Process heating of potable water or any other irt fluids injury or death 3 Un pressurized and gravity feed heatin 3 WARNING Liquefied Petroleum LP gas is 4 Heating systems with very low pressures or heavier than air it is imperative that your boiler is not installed in a pit or simila
41. eed of the installation Contractor modifications to these instructions may be required based upon the existing piping and system design GX INSTALLATION AND OPERATION INSTRUCTIONS Low Water Cut Off LWCO If a LWCO is used ensure that the water line of the Low Water Cutoff is at least 6 in 152 above the top of the boiler Figure 21 It is recommended that the LWCO be situated so that it can be tested without removing water from the boiler Tri cocks and a gauge glass are highly recommended Valves shall not be installed between the LWCO and the boiler Use an air vent if installed as per our diagram to be used as a vacuum breaker and to eliminate air upon filling Figure 21 LWCO amp Air Vent Piping SYSTEM AIR VENT OW WATER CUTOFF WATER LINE 6 IN H MINIMUM EXPANSION TANK SECONDARY LOOP PRIMARY LOOP PLUMBING This low mass boiler requires a continuous minimum water flow for proper operation The heat exchanger in this boiler is more restrictive than a conventional boiler The system pump must be sized to overcome the head loss of the boiler Figure 22 Greater consideration must be given to the capabilities of the circulating pump s in the primary loop This includes the pump used for an indirect tank Table 3 Recommended Primary and Indirect Loop Circulators Max Temp Minimum Primary amp Rise Indirect Pump Size F C B amp G Grundfos Taco 45 25 NRF 33 UP 26
42. een 896 and 9 5 with a CO reading of less than 175 ppm air free For LP gas the CO reading should fall between 9 and 10 5 with a CO reading of less than 175 ppm air free Main Burner Flame A properly adjusted main burner flame will produce a tight blue flame pattern about 1 2 in 73 mm tall from the burner s surface Figure 44 A yellow floating or tall stringy flame is not normal and must be corrected WARNING Yellow floating flames indicate a lack of combustion air DO NOT operate the boiler until the problem is solved or severe personal injury or death may occur Figure 44 Burner Flame Thermostat Adjustment Set the heat anticipator to 1 1 amps when controlling the boiler directly For zoned systems set the heat anticipator to match the amp draw of the zone valves or pump relays GX INSTALLATION AND OPERATION INSTRUCTIONS BOILER CHECKING amp ADJUSTMENT Input Rate Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 ft 610 m At elevations above 2000 ft 670 m input ratings should be reduced by 4 for each 1000 ft 305 m above sea level Check the input rate as follows NATURAL GAS 1 Turn off all other gas appliances that use the same gas meter as the boiler 2 Call the gas company for the gas heating value 3 Start the boiler and let it run for 15 minutes 4 Usingthe gas meter and a stopwatch clock the time that it takes to burn 10 cub
43. en T C Closed amp A C open T C Closed amp A C Closed T C Open amp A C Closed Condition Standby Heating Only Domestic Only Domestic Only Set Point HI LO LO Burner On HI cac DIF LO 10 LO 10 Burner Off HI cate 10 200 F 200 F Heat Circ C1 Off On Off Off Aux Circ Ap Off Off On On Page 7 200 115 90 65 48 40 Recommended Settings When programming the Sentry 2100T determine what the hottest boiler temperature required for the coldest day will be This will be the HI SETTING If an indirect tank is used for domestic hot water DHW determine the minimum boiler temperature required to ensure an adequate supply of hot water This is the LO SETTING The LO SETTING is only used during a call for DHW when A and C terminals are closed Set the LO to the temperature required for the Indirect Water Heater 140 F 60 C or at least 30 F 1 C higher than the indirect Aquastat is recommend WARNING Proper control settings must be used to prevent water supplied for domestic use from exceeding 130 F 54 C or a scald injury will occur When higher water temperatures are required for appliances such as a dishwasher a mixing valve or some other tempering means must be installed Households with small children may require water temperatures less than 120 F 49 C Local codes must be complied with Ta
44. energized Circ Aux Indicates a call for DHW and Indirect pump or 3 way valve is activated Thermostat Demand Indicates that terminals T C are closed iniating a call for heat The LED screen will display one of four values A light will illuminate above the function to indicate what information is being displayed Water Temp Indicates that the display is showing the boiler water temperature Air if the air sensor is used When illuminated indicates that the display is showing outdoor air temperature Gas Input Value Indicates the current input level Figure 38 must be used to determine the actual input GX 150 use 46 to 240 GX 200 use 40 to 240 and GX 400 use 35 to 195 DHW Temp indicates that there is a call for domestic hot water Page 26 SENTRY 2100T CONTROLLER CAUTION The T4 0 controller can only be used on the GX 400 and the T2 0 on the GX 150 amp 200 Misapplication of the controller will result in improper boiler operation The Sentry 2100T controller is the central controller for the GX boiler The Sentry handles all of the combustion logic along with the energy management functions The Sentry 2100T operates in two different modes Conventional or Reset see Figures 35 amp 36 The mode is automatically determined by the presence of the outdoor sensor When the Sentry 2100T detects the presence of the outdoor sensor the controller will operate in the Reset Mode If the outdoor sensor is not
45. ens the circuit between terminals T and C shutting down the pumps and the burner GX INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Figure 30 Multiple 4 Wire Zone Valves Blue Burner On Heating Pump Aux Pump Coll for Heat voter BRE END SWITCH END SWITCH END SWITCH MOTOR MOTOR MOTOR 5 THERMOSTAT Zone 1 THERMOSTAT Zone 2 THERMOSTAT Zone 120 1 60 15 FUSED PDWER SUPPLY 2 wire valve no end Switch 3 wire Zone valve 4 wire Valve valve Power open self close SOY P1 P2 AUN D00 539 N 46 9 22 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 31 Multiple Zones w Taco Valve Controller Models ZVC403 to ZVC 406 Zone 2 Blue White Purple Black 9o T Main End switch CB Burner On Heating Pump Aux Pump EB Coll for Heat Voter BRE f
46. ent installation must be in accordance with Part 7 Venting of Equipment of the latest revision of the National Fuel Gas Code ANSI 2223 1 54 applicable provisions of local building codes Improper venting result in excessive levels of carbon monoxide which can result in severe personal injury or death NOTE Compliance with code requirements doesn t insure a satisfactory installation good common sense must also be applied WARNING Each boiler must have it s own vent system Common positive pressure vent systems are not be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death WARNING Field supplied piping and fittings are required to complete installation The combustion air and vent pipe and fittings must conform to ANSI and ASTM standard D1785 for schedule 40 02665 for PVC DWV 02661 for ABS DWV Pipe cement and primer must conform to ASTM standard 02564 for PVC or D2235 for ABS Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death Page 4 Table 1 Clearances Combustible Service Clearance Clearance Surface in mm in mm Front 0 0 24 610 0 0 0 0 Sides 0 0 12 305 Top 0 0 12 305 Bottom 150 amp 200 0 0 12 305 Bottom 400 0 0 0 0 Flue Pipe enclosed 2 51 n a n a Flue Pipe in free air 0 0 n a n a COMBUSTION AIR WAR
47. eration Relief Valve The relief valve should vent water when the test lever is lifted It should not weep or discharge water at normal system pressure NEVER try to clean or repair the relief valve If the valve fails replace it Page 34 BOILER MAINTENANCE The boiler should be cleaned and inspected once a year before each heating season CAUTION Servicing inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes Improper servicing or adjustment could damage the boiler Controls Use a soft brush and or a vacuum cleaner to ensure that the electrical components are free from dust or deposits that would impair the boilers performance Heat Exchanger Cleaning Natural Gas once every two years Propane once per year The burner door should be removed so the combustion chamber can be inspected for flue gas blockage see BURNER REMOVAL amp REPLACEMENT below Once the burner has been removed remove the heat exchanger baffle Blockage of the heat exchanger will reduce the boiler s capacity firing rate and can negatively impact on how smooth and efficiently the burner lights Vacuum out any loose build up and clean the heat exchanger surface with an appropriate cleaner for combustion chambers such as Sotin 300 Use a nylon or other non metallic brush to loosen the sulfate incrustations and any other contaminates Rinse with water allowing the solution to exit vi
48. ess CAUTION Always use a wrench on the gas valve body when making gas connections to it Never over tighten the piping entering the gas valve body or the gas valve will be damaged voiding the warranty CAUTION The gas piping must be properly supported by the building structure and not by the boiler or the gas valve will be damaged voiding the warranty Figure 27 Gas Supply Piping GAS COCK SHUT OFF VALVE TO BE T TYPE TPN BOILER GAS VALVE FLEXIBLE GAS PIPE Table 4 should be used to ensure that the gas supply piping is sized properly If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand Do not neglect the pressure drop due to pipe fittings Table 5 should be used in conjunction with Table 4 to ensure that the gas supply piping is sized properly GX INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Before supplying 120 volts to the boiler do a continuity check between all the wires and the ground to make sure that there are no electrical shorts that could damage the Sentry 2100 board Never use magnetic tip screwdriver near the Sentry 2100 Verify that the wires connected to the Sentry TC and AC terminals are not grounded or have any voltage applied to them or voltage to ground dry contact closure only Ensure that the probe wire is not damaged CAUTION D
49. for added rigidity Figure 7 If this is the case special bracket GX 82075 must be ordered for each pipe Proper clearances must be maintained Figure 7 Air Intake amp Vent Pipe Attachment r IN MIN r 12 IN MIN PLUS SNOW PLUS SNOW ALLOWANCE ALLOWANCE GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 11 Horizontal Concentric Terminal Location 36 IN MIN 4 IN OR GREATER THAN 24 IN vov ow ow ow vov v wow ov ov ws vov ow cw V ow ov v wv vov ow cw ov vov ov v vov ov ow vw vov ow 9 9 9 vov ov ow ow 9 v v v c9 c9 vov ov 9 v Y 9 vw vow ow o v ov v we c9 vow ow v vov vov ov ow vov v jw 9 9 9 c9 ov ov ow ow v v MINIMUM 12 IN PLUS SNOW ALLOWANCE Figure 12 Vertical Concentric Terminal Location 36 IN MINIMUM vow ow vov ow vow ow v ov vow wy V ow 9 9 MINIMUM 12 IN PLUS SNOW ALLOWANCE vow ov ow v v v vow ov ow ov ow vow ov ow ov vow v v v ow v ov ow vow ov ow v 9 v 9 vow ow vow vov ov vl 7 vov v
50. g system is used with the piping as shown in Figure 26 When there is a call for heat the room thermostat closes the circuit between the TT terminals on the Taco zone controller The controller energizes the appropriate zone valve and closes the circuit between terminals T and C on the Sentry 2100 control The Sentry 2100 provides power to the primary and secondary pumps via terminal C Once these pumps are on the burner fires Once the room thermostat is satisfied it breaks power to the zone valve motor The end switch opens the circuit between terminals T and C shutting down the pumps and the burner 7 INDIRECT DG L1 2 120 1 60 15 FUSED 120V WIRING e 2 GREEN NL WHITE PURPLE 7 ELECTRICAL BOX POWER SUPPLY Multiple 4 Wire Zone Valves Figure 30 shows the basic multiple zoned system uses normally closed four 4 wire zone valves This wiring system is used with the piping shown in Figure 26 When there is a call for heat the room thermostat closes the circuit to the zone valve motor thus opening the zone valve When the zone valve is opened the end switch closes the circuit between terminals T and C on the Sentry 2100 control The Sentry 2100 provides power to the primary and secondary pumps via terminal Once these pumps are on the burner fires Once the room thermostat is satisfied it breaks power to the zone valve motor The end switch op
51. gram Mode longer than 30 seconds without receiving any input the unit will turn off Press Function once to continue programming or to restart boiler operation Below is a list of functions and a description of what they control RUN Stores Values amp initiates LO Boiler Setpoint for DHW 80 200 F 27 93 C HI Boiler Setpoint for Heating 80 200 F 27 93 C DIF Differential 1 40 F 17 C 4 C RES Sets Outdoor Reset Curve Slope 70 F 27 C to HI SFS Sets Starting Gas Input Value 60 to 100 GX150 amp 200 is 60 to 100 GX 400 is 45 to 90 HFS Sets Highest Gas Input Value 100 to 240 GX 150 amp 200 is 100 to 240 GX 400 is 90 to 195 LFS Sets Lowest Gas Input Value 40 to 100 GX 150 amp 200 is 40 to 100 see note GX 400 is 35 to 90 NOTE LFS must not be set below 48 on the GX150 model To start the control operation return to RUN on the menu and press Function Normal operation will begin GX INSTALLATION AND OPERATION INSTRUCTIONS NOTE The design temperature is 0 F 18 C outside air so at O F 78 or less the hi setting is used and not surpassed Figures 39 amp 40 are examples of reset temperatures based upon different set points and outdoor air temper atures The vertical axis is the water temperature that the boiler will maintain and is also the Hi setting of the Sentry 2100T control The Horizontal axis is the outdoor air temperature
52. he safety information above Turn off all electric power to the appliance Set the thermostat to lowest setting This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand LINE PRESSURE MANIFOLD PRESSURE 1 gt 1 Turn off all electric power the appliance 4 Turn the manual gas supply shut off valve clock wise lt w to the full OFF position 5 Replace control access panel 2 Set the thermostat to lowest setting 3 Remove control access panel Page 3 Gas Pressure Adjustment Optimum results are obtained when the boiler is operated at its full input rating If adjustment is necessary the following steps must be followed 1 Connect a flue gas analyzer to the vent pipe 2 Rotate the input adjustment screw clockwise to decrease the manifold pressure counterclockwise to increase it Figure 41 or 42 The input screw on the GX 150 amp 200 is a multi turn needle valve From fully open to fully closed is approximately 17 turns A typical adjustment is O to 1 turn for natural gas 0 to 3 turns for LP The input screw on the GX 400 turns a geared ball valve with a 4 to 1 ratio Two turns will take the valve from fully open to fully closed 0 to 1 4 turn is a typical adjustment Never force the input adjustment screw or the gas valve will be damaged 3 For natural gas the CO reading should fall betw
53. here but not at B1 indicates faulty relay inside Sentry contact NTI replace control 2 If 24V is not present check for 24V at transformer 3 If 24V exists at transformer check wiring and safety limits If 24V not present at transformer check wiring and replace transformer if necessary May be caused by an error in the reading of the water temperature by the Sentry control Watch cycle and ensure the Sentry is displaying the correct water temperature and is modulating This device protects the boiler from overheating due to a lack of flow passing through the unit when the burner is on FLOW MUST NEVER BE BLOCKED BY ANY VALVES INCLUDING MIXING OR ZONE VALVES Install unit as described in this manual GX INSTALLATION AND OPERATION INSTRUCTIONS Detected Problem This is displayed when the boiler is expecting the air switch to be closed by a differential pressure generated when the combustion blower turns on It can occur momentarily during normal operation A problem is indicated when ASO is displayed continuously This is displayed when the boiler has turned the blower off and is expecting the air switch to be open It can occur momentarily during normal operation A problem is indicated when ASC is displayed continuously Check for 24 Volts between terminal B1 on Sentry amp Ground Check for 24 Volts between terminal F1 on Sentry amp Ground Water Safety Limit trips Automatic reset Located i
54. hold the boiler fittings when installing the heating system piping Failure to do so can seriously damage the boiler voiding warranty The GX hot water boiler comes from the factory ready to be piped to the heating system The boiler must be used only in a Primary Secondary pumping system to avoid cycling problems in systems that have poor flow or heating zones with very small capacities CAUTION A 1 in 32 mm primary loop system must be used for GX 150 amp 200 models regardless of the configuration of the secondary system design 1 in 38 mm primary loop system must be used for the GX 400 Failure to properly plumb the boiler may void the warranty GX INSTALLATION AND OPERATION INSTRUCTIONS The following are important rules that must be followed when constructing the condensate system 1 Connect the condensate trap to the drain using 1 2 in 13 mm silicone rubber reinforced nylon or PEX tubing Long runs must be properly pitched and supported to prevent blockage 2 Donotuse nylon tubing as it will collapse blocking drainage This could damage the boiler 3 not seal the opening between the condensate pipe and the condensate drain pipe Figure 19 In the event of a blocked drain the opening will allow the condensate to overflow and prevent the boiler from flooding 4 Never have the drain pipe higher than the hole in the back cabinet this will flood the boiler 5 Never allow the drain to freeze or become blo
55. ic feet of gas and divide the time by 10 5 Insert the heating value and the time in seconds into the formula below Input Rate Heating Value Btu ft 3600 s hr Flow Rate s ft EXAMPLE If the heating value 1000 Btu ft and the flowrate 18 s f Input Rate 1000 Btu ft 3600 s hr 18 s ft Input Rate 200 000 Btu hr If the computed rate deviates by more than 5 from the rated input value of the unit adjust the gas valve pressure according to the GAS PRESSURE ADJUSTMENT instructions that follow PROPANE GAS The input rate for LP units is factory set based on the orifice size Use the factory supplied kit to convert the boiler to LP A combusiton analyzer must be used to ensure that the CO reading falls between 9 and 10 5 with a CO reading of less than 175 ppm air free CAUTION Never increase the input to the boiler above that for which it is rated Doing so can cause premature failure of the boiler GX INSTALLATION AND OPERATION INSTRUCTIONS 1 Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler 2 Remove the front and left jacket panels 3 Disconnect the wires going to the igniter flame rod ground rod blower and gas valve 4 Carefully disconnect the gas piping at the union Figure 27 5 Carefully disconnect the air inlet piping at the valve Figure 2 6 Remove the nuts used to attach the burner to the heat exchanger 7 Carefully slide the
56. il power is reset or the indirect call is interrupted Flame Lock Out Sentry has sensed a lack of 24V to the gas valve during operation or a Fenwal ignition lockout Reset calculation being used to lower HI setting Thermostat is satisfied Problem ER1 On Display ER2 On Display On Display ER5 On Display DHW Problem ER6 Burner shuts off before set point temperature is reached and burner light goes out 806 7 Solution 1 Are the vinyl tubes connected between the air switch and the ports on the inlet pipe Negative side of switch connects to the port on the 1 1 2 in 38 mm ABS elbow 2 Check for blockage on the intake and exhaust vents 3 If fan is running air switch may be faulty ensure that it s set for 0 2 in 5 1 mm WC The GX 400 condensate drain switch must be set at 3 in 76 mm WC 4 If fan is not running check 120V wiring to blower if ok remove low voltage harness from blower if blower fails to start replace blower if blower does start problem may be with blower or Sentry control 1 Is the fan running If so check for 24V between C and D terminals see wiring diagrams If 24V is not present replace transformer 2 Check venting termination with required venting described in manual If there is 24V indicates faulty wiring between BI and W1 on Fenwal or faulty Fenwal 2 If 24V is not present proceed to next step I 24V exists
57. injury or damage Follow local codes Add an inhibitor to protect system CHP from Fernox Boiler circuit piping must be sized large enough to handle maximum flow through unit Do not operate boiler with service valves closed isolating the boiler from the expansion tank Failure to follow these instructions will result in heat exchanger damage All flux and contaminants must be flushed from piping before connecting boiler Do not connect this boiler to older systems with cast iron radiation without installing a fine particulate separator TYP Spirotrap Junior Model TDN 125 FT Do not use non oxygen barrier radiant tubing au Notice This drawings show suggested piping configuration and valving Check with local codes and ordinances for specific requirements 5 LHe N 8 1 dili ASR Gate Valve Ball Valve Pressure Check Valve Pressure Thermometer Union Automatic Heating Drain Valve Backflow Prevention Differential Pressure Reducin i Air Vent Device Bypass Valve in g Relief Valve Load Typ Separator Spirotrap Page 6 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 25 Multiple Zones Using Circulators 4 4 4 E HHO HHO y 66 5 Y 0 BACKFLO
58. installed the controller will operate in the Conventional Mode NOTE If the outdoor sensor is connected after the boiler has been started power to the boiler must be shut off and then turned back on Boiler Modulation The GX boiler employs a pneumatic modulation system This modulation system increases or decreases the speed of the blower to meet the heating demand The gas valve pressure regulator senses the air pressure and adjusts the gas flow to ensure correct combustion The term 561 Point is used to indicate the desired temperature that the GX will maintain by increasing or decreasing the input Indirect Water Heaters The Sentry 2100 comes with an input and output for a 120 volt indirect pump When the A and C terminals are closed dry contact the boiler will go immediately to indirect domestic mode whereby the indirect pump is activated and the boiler will modulate to the LO setpoint Sentry Display The Sentry 2100T contains four green lights that illuminate to indicate the boilers state of operation Figure 37 Figure 35 Conventional Mode Operation Chart T C amp A C Open T C Closed amp A C open T C Closed amp A C Closed T C Open amp A C Closed Condition Standby Heating Only Domestic Only Domestic Only Set Point HI LO LO Burner On HI DIF LO 10 LO 10 Burner Off HI 10 200 200 Heat Circ Off On Off Off Aux Circ Off Off On On Figure 36 Reset Mode Operation Chart T C amp A C Op
59. is provided with a 1 8 vent that is not intended for continuous system venting 3 For continuous system venting use a cast iron air scoop for excessive air conditions use a Spirovent Do not fire boiler until all air is purged from system piping Heat exchanger damage caused by air is not covered by warranty See Table 3 for boiler pump flow requirements This pump is wired to terminals C1 L2 Indirect Water Heater pump is wired to terminals AP L2 Set pressure reducing valve to 12 PSI Use 30 psi relief valve max Locate where discharge will not cause injury or damage Follow local codes Add an inhibitor to protect system CHP from Fernox Boiler circuit piping must be sized large enough to handle maximum flow through unit Do not operate boiler with service valves closed isolating the boiler from the expansion tank Failure to follow these instructions will result in heat exchanger damage All flux and contaminants must be flushed from piping before connecting boiler Do not connect this boiler to older systems with cast iron radiation without installing a fine particulate separator TYP Spirotrap Junior Model TDN 125 FT Do not use non oxygen barrier radiant tubing 6 0 4 ak ak Notice This drawings show suggested piping configuration and valving Check with local codes and ordinances for specific requirements 9 5 1 IHN 2 Ball Check Valve Auto
60. it a common wall the following conditions must apply 1 If limited to two terminals the horizontal centerline distance must be 4 in 102 mm or greater than 24 in 610 mm to prevent flue gas recirculation For more than two terminals located along a horizontal plane the centerline distance between them must be 24 in 610 mm Figure 11 2 If the terminals are located in a vertical plane the centerline distance between them must be at least 48 in 1220 mm Figure 12 Page 9 Consult your weather office for the maximum typical snowfall for your region For example in Boston MA the maximum typical snowfall is 12 in 305 mm Therefore the inlet must be 24 in 610 mm above any surface that will support snow The exhaust must be 42 in 1067 mm above this surface Figure 15 Two Pipe Through the Roof EXHAUST 18 IN MINIMUM 12 IN MINUMUM PLUS SNOW ALLOWANCE 4 IN MINIMUM N AIR INLET The horizontal centerline distance between the inlet and exhaust terminals must be a minimum of 4 in 102 mm f the horizontal distance between the inlet and exhaust is more than 12 in 305 mm increase the vertical separation by the same amount For example if the horizontal separation is 24 in 610 mm a minimum vertical separationof 30 in 762 mm is required 18 in 457 mm 12 in 305 mm 30 in 762 mm f the horizontal distance is greater then 6 ft 1 8 m no additional vertical spacing is required The vertical separation is never required
61. ith the requirements of CSA B149 1 or B149 2 Installation Code for Gas Burning Appliances and Equipment If installed in the Commonwealth of Massachusetts you MUST FOLLOW the additional instructions contained in Hydrotherm s instruction sheet MA IOM If you don t have a copy call your Hydrotherm distributor or Hydrotherm BOILER RATINGS amp CAPACITIES Before undertaking the installation of the GX check the boiler rating plate to ensure that the boiler is the proper size for the job Also ensure that the boiler has been set up for the type of gas available at the installation site Other important considerations are the availability of an adequate electrical supply fresh air for combustion and proximity a suitable outside wall High Altitude Operation The GX boiler is designed to operate to capacity in installations with 2000 ft 670 m of elevation or less At elevations higher than 2000 ft 610 mthe unit will de rate due to the lower air density see Figure 1 NOTE It is the nstallers responsibility to check the combustion and to adjust the combustion in accordance to Operating Instructions Section Page 2 CONTENTS Before YOU reete tuis page 2 Boiler Ratings amp Capacities page 2 Boiler EOCatlOr tio crm retta etes page 3 Clearances to Combustible Construction page 3 Combustion All 4 General Venting Guidelines
62. lers have been design certified by CSA for use with natural and propane gas under the latest edition of ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers Each unit has been constructed and hydrostatically tested for a maximum working pressure of 30 psi 207 kPa in accordance with Section IV of the ASME Boiler and Pressure Vessel Code Each boiler has been equipped with a 30 psi 207 kPa pressure relief valve This manual covers the application installation operation and maintenance of a GX Series low pressure hot water boiler GX INSTALLATION AND OPERATION INSTRUCTIONS Page 3 Figure 1 Input vs Elevation Graph 400 A 300 Input Mbh N e o 100 0 T T T T T T T P 0 2000 3000 4000 5000 6000 7000 8000 9000 10000 Elevation ft 50 200 400 WARNING At elevations greater than 2000 ft 660 m the combustion of the GX must be checked with a calibrated combustion analyzer to ensure safe reliable operation Consult the Operating 2 An optimum site will be level central to the hot water piping system and close to an outside wall NOTE This boiler is designed for direct placement on a combustible floor Never install this boiler on carpeting Instructions Section for instructions adjusting the input to provide proper operation Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or d
63. line distance must be 4 in 102 mm or greater than 24 in 610 mm to prevent flue gas recirculation For more than two terminals located along a given plane the centerline distance between them must be 24 in 610 mm Figure 18 Figure 17 Concentric Through the Roof EXHAUST Page 1 CAUTION All systems must be flushed to remove sediment flux filings and other foreign matter Use products such as Fernox Superfloc for new installations and CHR Central Heating Restorer for retrofits Also add an inhibitor to the system water to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion An inhibitor such as CHP Central Heating Protector from Fernox is recomended If connecting this boiler to a system containing cast iron radiation be sure to add a strainer to the system to trap any sediment that may dislodge Failure to do this could harm the heat exchanger and void the warranty The use of non oxygen barrier radiant tubing is acceptable provided that non ferrous pipe valves and fittings are used throughout the entire hydronic system Failure to comply with these instructions will seriously damage the boiler voiding warranty CAUTION The boiler fittings cannot support any weight The plumbing system must be supported by the building structure A wrench must be used to
64. ls or other devices must conform to the temperature limitation of type T wire at 95 F 35 C above room temperature Use copper conductors with a minimum size of 14 awg Low voltage wiring must not be less than 18 awg with a neoprene thermoplastic or other equivalent insulation having a minimum insulation thickness of 0 012 in 3 mm Schematic and ladder diagrams of the boilers wiring are shown in Figures 33 amp 34 CAUTION The contact capacity of outputs C or A is 3 amps with a maximum inrush of 6 amps If the amp draw of the pumps exceeds these maximums a pump controller or isolation relay must be used to prevent damage to the boiler Damage caused by improper wiring will void the warranty Figure 28 Basic Heating System Wiring 120V WIRING 2 0 Tl BLUE PUMP BLACK PURPLE L1 L2 120 1 60 15 AMP FUSED ELECTRICAL BOX POWER SUPPLY GX INSTALLATION AND OPERATION INSTRUCTIONS Page 20 Figure 29 Basic Heating System and Indirect Tank Wiring CAUTION CONTACTS THAT ENERGIZE THESE INPUTS MUST BE DRY CONTACTS ONLY INDIRECT THERMOSTAT AQUASTAT g PROBE 5 V WIRING Multiple Zones w Taco Valve Controller Models ZVC403 to ZVC 406 Figure 31 shows the basic multiple zoned system using normally closed 2 3 or 4 wire Taco zone valves This wirin
65. matic Heating Drain Valve Differential Pressure Spirotrap Expansion Val Air Vent Bypass Valve Fine Particulate Tank TE Load yp ve Separator GX INSTALLATION AND OPERATION INSTRUCTIONS Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21 13 CSA 4 9 All gas connections MUST be leak tested before putting the boiler into operation WARNING Never use an open flame to test for gas leaks Always use an approved leak detection method Failure to comply with this WARNING could result in an explosion Table 4 Gas Pipe Capacity Nominal Pipe Length Iron Pipe _10 20 30 40 50 60 80 100 150 Size Gas Pipe Capacity ft hr 3 4 278 190 152 130 115 105 90 79 64 1 520 350 285 245 215 195 170 150 120 1 1 4 1050 730 590 500 440 400 350 305 250 11 2 1600 1100 890 760 670 610 530 460 0 Note Maximum pipe capacity in ft hr is based on a 0 60 specific gravity gas at a pressure of 0 5 psig and a 0 3 WC pressure drop Table 5 Equivalent Pipe Length Chart Nominal Type of Pipe Fitting d om pee Gas Cock Size Equivalent length of pipe fittings in feet 3 4 2 06 4 12 0 48 1 25 d 2 62 5 24 0 61 1 60 1 1 4 3 45 6 90 0 81 2 15 1 1 2 4 02 8 04 0 94 2 50 Whenever the gas supply piping is pressure tested the boiler gas controls must be
66. meet the heating demand The gas valve pressure regulator senses the air pressure and adjusts the gas flow to ensure correct combustion WARNING Before operating read and under stand the instructions contained in this manual Do not attempt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual Read and fully understand the operating instructions in the For Your Safety Read Before Operating section of this manual Failure to comply with this WARNING could result in a fire or explosion causing severe personal injury or death Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance GX INSTALLATION AND OPERATION INSTRUCTIONS Ignition System Connect a manometer to the line pressure port shown in Figure 41 or 42 Make sure that the gas supply piping has been purged of air and that all gas joints up to the gas valve have been thoroughly checked for leaks Wait at least five minutes for any gas to dissipate before turning on the electrical power Read understand and follow the operating instructions below Raise the thermostat at least 5 degrees above the room temperature The boiler should enter the pre purge mode before energizing the silicon carbide igniter Once the igniter is hot the main gas valve will open
67. n the supply manifold inside the boiler cabinet Problem ASO Indicates that the Air Switch is Open ASC Indicates that the Air Switch is Closed Ignition Sequence not activated when burner light is on Fan is on and Fenwal not flashing GX INSTALLATION AND OPERATION INSTRUCTIONS Solution This device protects the integrity of the plastic venting material If the temperature of the flue gases exceeds 225 F 107 C the limit will cut power to the control Blocked internal tubes can increase the stack temperature to an unacceptable level Flush out the boiler If the combustion sequence is normal and there is no flame prior to ignition the Fenwal control is defective and must be replaced If the condensate drain gets blocked the boiler will become flooded and terminate operation as the flame rod becomes immersed This will damage the flame probe To correct free the drain blockage and permanently prevent it from reoccurring Remove and dry off the probe Reinstall the probe and try for ignition if it fails to ignite leave the fan run for up to three hours to dry out the insulation and probe Reset Boiler so it will attempt to ignite Check for proper operation of ignition components Make sure igniter glows and gas valve opens Check for proper line pressure at gas valve when it opens If boiler lights check for flame signal between FC1 And FC2 on Fenwal control If
68. r location that will permit heavier than air gas to collect Local Codes may require appliances fueled with LP gas be provided with an approved means of removing unburned gases from the room Check your local codes for this requirement Failure to comply with this warning can result in extensive property damage severe personal injury or death flow Improper use or installation will seriously damage the boiler voiding warranty Locate the boiler in an area that provides good access to the unit Keep in mind that servicing may require the removal of jacket panels Accessibility clearances should take precedence over fire protection clearances Table 1 lists the minimum clearances for servicing however 24 in 670 mmis recommended 1 GX INSTALLATION AND OPERATION INSTRUCTIONS One of the following materials is to be used for the air intake pipe GX 150 amp 200 3 in 76 mm PVC Sch 40 pipe or Galvanized Steel pipe e GX 400 4 in 102 mm or 6 in 152 mm PVC Sch 40 pipe or Galvanized Steel pipe See Table 2 for the maximum equivalent air intake system length CAUTION Combustion air contaminated with fluoro carbons or other halogenated compounds such as cleaning solvents refrigerants chloride flouride bromine or iodine will result in the formation of acids in the combustion chamber These acids will cause premature failure of the boiler voiding the warranty GENERAL VENTING GUIDELINES WARNING The v
69. t 32m GX 200 105 ft 32m GX 400 4 30ft 9m 6 65ft 20m PGX 150 50 ft 15 PGX 200 50 ft 15 PGX 400 4 30ft 6 65ft 20m Note The lengths listed is for each direction Subtract 5 ft 1 5 m for each 90 elbow except for the vent and air intake elbows These don t need to be considered The length of the air inlet system must never exceed the length of the vent system The vent system length may exceed the air inlet system length by no more than 20 equivalent ft 6 1 equivalent m HORIZONTAL DIRECT VENT SYSTEMS Read the information in the GENERAL VENTING GUIDELINES section It is recommended that two elbows be used so that the 1 4 in ft 21mm m slope of the horizontal vent system does not affect the vertical plumb of the pipe connected to the boiler Figure 4 Figure 4 Vent System Attachment TWO ELBOWS RECOMMENDED EXHAUST 2 IN TO 3 IN ADAPTER When horizontal vent runs exceed 5 ft 1 5m they must be supported at 3 ft 0 9 m intervals with overhead hangers 4 ft 1 2 for 6 pipe The vent system must be pitched down toward the boiler 1 4 in ft 21mm m of vent Structural penetrations must be made using approved thimbles GX INSTALLATION AND OPERATION INSTRUCTIONS The GX condensing gas boiler is a high efficiency boiler utilizing induced power venting It is designed to be vented directly to the outdoors using the venting methods and materials detailed in this section The vent system must be both
70. t circuit 2 Reduce indirect Aquastat setting or Increase difference between Lo Setting and indirect Aquastat setting 3 Indirect limit or wiring failure 1 There is a problem in the ignition sequence it could be caused by a faulty igniter flame sensor gas valve or improper line pressure or combustion Check ignition sequence to determine which component is not functioning Sentry will retry ignition sequence 1 hour after ER6 code originally occurs or if control is reset 2 Check for 24V between B on terminal block and F1 on Sentry plug if not present a limit has tripped see wiring diagram 3 the Flow Switch on the GX 400 is also in the 24V circuit Check for proper water flow and flow switch operation If OD probe is being used the HI setting will be calculated using formula in Section 8 1 If the thermostat demand light is turning off the thermostat has satisfied 2 If DHW temp light is turning off the aquastat or call for domestic has been satisfied Detected Problem The Safety High Limit of 215 F 102 C has been reached Water Probe The water probe is transmitting an invalid signal closed circuit Water probe Sentry is sensing an open circuit at water probe Or the wiring to the outdoor probe is grounded The control has determined an Indirect water heater problem the boiler has cycled off 10 times during a single call for domestic The Indirect call will now be ignored unt
71. to operate with airless water in the system The GX boiler is provided with a 1 8 in 3 mm air vent located on the top of the unit This air vent is intended to vent the boiler on initial startup This device will NOT continuously vent air collecting in the primary loop and is not intended to be the primary venting device The air scoop as shown in Figure 21 is the primary venting location It is recommended that an additional air scoop be used in the secondary plumbing If air continues to be a problem an air scrubber must be used NOTE Only inhibited propylene glycol solutions should be used if freeze protection is required Avoid using mixtures greater than 30 unless the size of the boilers circulator s is increased accordingly Under no circumstances should a 50 mixture be exceeded Page 3 Figure 22 Boiler Head Loss 150 200 400 o 60 9 40 a 20 ar 2 4 6 8 10 12 14 16 18 20 22 24 26 7 GPM us Table 3 lists the recommended circulators for use as the primary and indirect loop pumps Figure 23 shows the proper way to plumb a primary loop for single boiler installations MULTIPLE BOILER PRIMARY LOOP Figure 24 shows the proper way to plumb a primary loop for multiple boiler installations SECONDARY LOOP PLUMBING Figures 25 and 26 show some typical primary secondary piping systems It is the responsibility of the installing contractor to determine which system best meets the n
72. to the equivalent intake length GX INSTALLATION AND OPERATION INSTRUCTIONS Consult your weather office for the maximum typical snowfall for your region For example in Boston MA the maximum typical snowfall is 12 in 305 mm Therefore the inlet must be 24 in 610 mm above any surface that will support snow and the exhaust must be 42 in 1067 mm above this surface The horizontal centerline distance between the inlet and exhaust terminals must be a minimum of 4 in 102 mm If the horizontal distance between the inlet and exhaust is more than 12 in 305 mm increase the vertical separation by the same amount to prevent flue gas recirculation For example if the horizontal separation is 24 in 610 mm a minimum vertical separation of 18 in 457mm 12 in 305mm 30 in 762 mm is required If the horizontal distance is greater than 6 ft 1 8 m no additional vertical spacing is required The vertical separation is never required to be greater then 36 in 914 mm Figure 5 Horizontal Terminal Locations WINDOW OUTSIDE ow wie ow ww ew vw wie vv ov www ew we ew eww we wv ot on vow we wv we t vow 9 wow 9 v o9 9 9 9 9 9 9 9 9 9 c9 9 9 Y 9 9 9 9 9 o v vNY we o ov otv 9 wy Kw ov vov ov ov vov oc ot NN vov t o
73. ump flow requirements This pump is wired to terminals C1 L2 See Table 3 for Indirect Water Heater pump flow requirements This pump is wired to terminals AP L2 Set pressure reducing valve to 12 PSI Use 30 psi relief valve max Locate where discharge will not cause injury or damage Follow local codes Add an inhibitor to protect system CHP from Fernox Boiler circuit piping must be sized large enough to handle maximum flow through unit Suggested piping When installing an indirect water heater consult manufacturer s manual for full details 11 Do not install any valves between the Vacuum Relief valve and the tank 12 Do not operate boiler with service valves closed isolating the boiler from the expansion tank 13 Failure to follow these instructions will result in heat exchanger damage All flux and contaminants must be flushed from piping before connecting boiler Do not connect this boiler to older systems with cast iron radiation without installing a fine particulate separator TYP Spirotrap Junior Model TDN 125 FT Do Not use non oxygen barrier radiant tubing A Notice This drawings show suggested piping configuration valving Check with local codes and ordinances for specific requirements 4 1 0 N 8 1 us NAN Gate Valve Ball Valve Pressure Check Pressure Thermometer Union Automatic Heating Drain Valve Backflow Prevention Differential Pressur
74. v vow When penetrating an outside wall the concentric terminal must be constrained as shown in Figure 13 The opening through which the concentric terminal passes must be properly sealed to prevent products of combustion from entering the building The air intake of the boiler must be connected to the terminal WARNING Failure to properly install and seal the concentric terminal can result in excessive levels of carbon monoxide which cause severe personal injury or death Page 8 Figure 9 External Air Intake and Vent Systems SUPPORTS EVERY 24 IN EXHAUST 20 FOOT MAX OUTSIDE USING ONLY 3 PIPE ON THE 150 amp 200 AND 4 PIPE ON THE 400 12 IN ABOVE MAXIMUM SNOW LINE The debris screens provided with the boiler must be installed in both the air intake and vent terminals Install the screens in the outer most opening then glue a 1 in 25 mm length of pipe into the opening to retain them Figure 10 Figure 10 Debris Screen Installation Concentric Air Intake and Vent Terminal GX 150 amp 200 Only If a concentric terminal is used it must be Hydrotherm part number GX 82666 or York part number 1CT0303 The concentric terminal must be located at least 12 in 305 mm above the normal snow line Figure 11 Position the air intake pipe on the top orto the side to prevent rain from entering the boiler Figure 13 When terminals from multiple boiler installations ex
75. w X NY v X AIR INTAKE 12 IN PLUS SNOW ALLOWANCE Page 6 The vent terminal shall not terminate e Directly above a paved sidewalk or a paved drive way that is located between two buildings and that serves both buildings e Less than 7 ft 2 1 m above grade where located adjacent to a paved driveway or public walkway Within 3 ft 0 9 m horizontally of a window or door that can be opened or non mechanical air supply inlet to any building e Within 6 ft 7 8 m of a mechanical air supply inlet to any building or roof eve containing soffit openings Above a meter regulator assembly within 3 ft 0 9 m horizontally of the vertical centerline of the regulator Within 6 ft 7 8 m of any gas service regulator vent outlet Less than 30 in 762 mm plus snow allowance above grade or any surface that will support snow ice or debris The exhaust must be a minimum of 18 in 457 mm above the air inlet and the air inlet must always be a minimum of 12 in 305 mm plus snow allowance above any surface that will support snow A 24 in 610 mm plus snow allowance is highly recommended Consult your weather office for the maximum typical snowfall for your region Underneath a verandah porch or deck So situated that the flue gases are directed towards brickwork siding or other construction in such a manner that may cause damage from heat or condensate from the flue gases Less than 3 ft 0 9 m from an inside corner of an L
76. with your municipality or local gas company to determine if disposal of untreated combustion condensate is permitted If not the condensate will have to be neutralized with lime crystals marble chips or phosphate chips Page 10 Install and seal a rain cap over the dormant chimney opening to prevent water from entering the building Use only ABS PVC 9 CPVC or AL294C pipe for the air inlet and vent systems as stated previously Ensure that the air inlet and vent system lengths are within the maximums specified in Table 2 The debris screens provided with the boiler must be installed in both the air intake and vent terminals Install the screens in the outer most opening then glue a 1 in 25 mm length of pipe into the opening to retain them Figure 9 Concentric Air Intake and Vent Terminal GX 150 amp 200 Only If a concentric terminal is used it must be Hydrotherm part number GX 82666 or York part number 1CT0303 The concentric terminal must be located at least 24 in 610 mm above the normal snow line Figure 17 The building structure must support the air inlet and vent Systems All roof penetrations must be properly flashed and sealed A dormant chimney can be used as a chase through which the air intake and vent pipes can be run All previous instructions and warnings apply When terminals from multiple boiler installations exit a roof the following conditions must apply If limited to two terminals the horizontal center

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