HydroTherm GX SERIES Installation, Operating And Maintenance Manual

Gx series modulating, direct vent, gas-fired condensing boilers natural or propane 150,000 to 399,000 btuh input

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User's information manual (4 pages)

Installation, operation and maintenance manual (44 pages)

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Page 1 GX2-707 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 ENERGY STAR ENERGY STAR see note WARNING: If the information in this manual is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.
Page 2: Table Of Contents
Before undertaking the installation of the GX check the boiler rating plate to ensure that the boiler is the proper These instructions cover the GX Series gas ﬁ red, direct size for the job. vent, low pressure, hot water boiler. GX boilers have been design certiﬁ...
Page 3: Boiler Location
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 3 Figure 1- Input vs Elevation Graph 0-2000 3000 4000 5000 6000 7000 8000 9000 10000 Elevation (ft) WARNING: At elevations greater than 2000 ft, 2. An optimum site will be level, central to the hot water 660 m, the combustion of the GX must be checked piping system and close to an outside wall.
Page 4: Combustion Air
Page 4 GX INSTALLATION AND OPERATION INSTRUCTIONS Table 1 - Clearances One of the following materials is to be used for the air intake pipe: Combustible Service • GX-150 & 200: 3 in, 76 mm, PVC Sch.40 pipe or Clearance Clearance Galvanized Steel pipe.
Page 5: Horizontal Direct Vent Systems
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 5 Table 2 - Vent & Air Intake System Sizing 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 Model Equivalent Vent &...
Page 6 Page 6 GX INSTALLATION AND OPERATION INSTRUCTIONS The vent terminal shall not terminate: Consult your weather office for the maximum typical • Directly above a paved sidewalk or a paved drive-way snowfall for your region. For example, in Boston MA the that is located between two buildings, and that serves maximum typical snowfall is 12 in, 305 mm.
Page 7 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 7 When penetrating an outside wall the air intake and vent For installations that have to exit the foundation below pipes must be constrained as shown in Figure 6. The grade excavate the site as shown in Figure 8 to a point openings through which the air intake and vent pipes below where the pipes exit the building.
Page 8 Figure 12 - Vertical Concentric Terminal Location Concentric Air Intake and Vent Terminal GX-150 & 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.
Page 9: Vertical Direct Vent Systems
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 9 Figure 13 - Wall Penetration Detail 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.
Page 10: Condensate Drain
Figure 9. Concentric Air Intake and Vent Terminal GX-150 & 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.
Page 11: General Plumbing Guidelines
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 11 CAUTION: All systems must be ﬂ ushed to remove The following are important rules that must be followed when constructing the condensate system: sediment, flux, filings and other foreign matter. 1. Connect the condensate trap to the drain using Use products such as Fernox “Superﬂ...
Page 12 Page 12 GX INSTALLATION AND OPERATION INSTRUCTIONS Pressure Relief Valve Understand and follow the plumbing requirements provided in this section. Keep serviceability in mind Each boiler is equipped with a 30 psi pressure relief when installing plumbing around the boiler cabinetry. valve that must be piped in accordance with the ANSI/ Install ﬁ...
Page 13: Primary Loop Plumbing
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 13 Low Water Cut Off, LWCO Figure 22 - Boiler Head Loss If a LWCO is used ensure that the water line of the “Low GX-150 GX-200 GX-400 Water Cutoff” is at least 6 in, 152 mm, above the top of the boiler, Figure 21.
Page 14 Page 14 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 23 - Single Boiler with Indirect Hot Water Heater 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 ﬂ...
Page 15 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 15 Figure 24 - Multiple Boiler Installation 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 ﬂ exible Vibration Isolation Kit. 2.
Page 16 Page 16 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 25 - Multiple Zones Using Circulators 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 ﬂ...
Page 17 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 17 Figure 26 - Multiple Zones Valves with Bypass Valve Note: Velocity noise may be a problem when the entire output of the system pump is ﬂ owing through the zone with the highest pressure drop. Adjust the differential bypass valve to eliminate noise.
Page 18: Gas Supply Piping
WARNING: Never use an open ﬂ ame to test for installation site, call the nearest Hydrotherm distributor gas leaks. Always use an approved leak detection to resolve the problem.
Page 19: Electrical Wiring
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 19 ELECTRICAL WIRING 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 CAUTION: Label all wires prior to disconnection Sentry 2100 board.
Page 20 Page 20 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 29 - Basic Heating System and Indirect Tank Wiring Multiple Zones w/ Taco Valve Controller Multiple 4 Wire Zone Valves Figure 30 shows the basic multiple zoned system uses Models ZVC403 to ZVC 406 normally closed four (4) wire zone valves.
Page 21 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Figure 30 - Multiple 4 Wire Zone Valves...
Page 22 Page 22 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 31 - Multiple Zones w/ Taco Valve Controller, Models ZVC403 to ZVC 406...
Page 23 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 23 Multiple Zone Pump Controller Once the room thermostat is satisﬁ ed, it breaks power Models Taco SR504, Argo ARM 861 Series to the TT terminal of the pump controller de-energizing Figure 32 shows the basic multiple zoned system using the XX contacts.
Page 24 Page 24 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 33 - Boiler Ladder Diagram...
Page 25 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Figure 34 - Boiler Connection Diagram...
Page 26: Sentry 2100 Controller
Page 26 GX INSTALLATION AND OPERATION INSTRUCTIONS Figure 37 - 2100T Display Screen SENTRY 2100T CONTROLLER CAUTION: The T4.0 controller can only be used on the GX-400 and the T2.0 on the GX-150 & 200. Misapplication of the controller will result in improper boiler operation.
Page 27 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 27 Figure 38 - Input Conversion Chart Display Data - Input conversion chart LED Display Setting Sentry 2100T control Recommended Settings Programming is accomplished by a series of three push When programming the Sentry 2100T determine buttons located on the bottom side of the control.
Page 28 Page 28 GX INSTALLATION AND OPERATION INSTRUCTIONS NOTE: The design temperature is 0°F, -18°C outside Determining Reset Temperature HI Calc Once the Sentry 2100T control identiﬁ es the presence air, so at 0°F, -18°C or less, the hi setting is used, of a good outdoor sensor, the control will automatically and not surpassed.
Page 29: Boiler Set Up
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 29 BOILER SET UP 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 NOTE: Before starting the boiler, turn off the control system and any gas control that has been under electrical supply going to it.
Page 30 Page 30 GX INSTALLATION AND OPERATION INSTRUCTIONS Ignition System 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 installations; 9 to 12 in, 229 A.
Page 31 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 31 Figure 43 - Operational Flow Chart 120v Power Displays version Boiler in Applied t2.0 or t4.0 standby Mode Indirect thermostat or flow Thermostat End switch switch closes A-C or relay closes T-C (Call for Domestic) (Call for Heat) Combi model Combi or...
Page 32 Page 32 GX INSTALLATION AND OPERATION INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped •...
Page 33: Boiler Checking & Adjusting
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 33 BOILER CHECKING Gas Pressure Adjustment Optimum results are obtained when the boiler is operated & ADJUSTMENT at its full input rating. If adjustment is necessary the Input Rate following steps must be followed: Gas appliances are rated based on sea level operation 1.
Page 34: Boiler Maintenance
Page 34 GX INSTALLATION AND OPERATION INSTRUCTIONS BOILER MAINTENANCE 1. Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler. The boiler should be cleaned and inspected once a year, 2. Remove the front and left jacket panels. before each heating season.
Page 35: Wall Hung Conversion
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 35 Aquastat High Limit Figure 46 - Gas Valve Rotation The aquastat high limit controls the maximum water NEW LOCATIONS temperature in the boiler. If the water temperature FOR SCREWS reaches the set temperature before the demand for heat has been met, the aquastat high limit should shut the burners off.
Page 36: Trouble Shooting
32°F, 0°C.) Note: If problem is corrected by resetting power, Sentry control had locked-up; contact Hydrotherm. ER5 On Display The control has determined an Indirect 1. Not enough ﬂ ow to keep boiler from DHW Problem water heater problem;...
Page 37 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 37 Problem Detected Problem Solution This is displayed when the boiler is 1. Are the vinyl tubes connected between Indicates that the expecting the air switch to be closed by a the air switch and the ports on the inlet Air Switch is Open differential pressure generated when the pipe.
Page 38 Page 38 GX INSTALLATION AND OPERATION INSTRUCTIONS Problem Detected Problem Solution Ignition Sequence Stack Safety Limit Trips (Automatic Reset) This device protects the integrity of the not activated when Located on the front of the ﬂ ue box. plastic venting material. burner light is on If the temperature of the ﬂ...
Page 39 Check the Amp draw of output C1 and Ap (max 3 Amp). Check the Amp draw of control on start-up (max 6 Amps) Contact Hydrotherm. No power to control or control failure. Check for 120V between terminals L1 and Display Goes Blank L2 at Sentry.
Page 40 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, ﬁ nd the resistance and move vertically for the water probe or horizontally for the air probe until the line is intersected.
Page 41: Replacement Parts
GX INSTALLATION AND OPERATION INSTRUCTIONS Page 41 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 19 19B 4 10 SIOM-151 Item Part Number...
Page 42: Replacement Parts List
Page 42 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 49 - Replacement Parts Exploded View - Model GX400 Reverse Angle SIOM-152...
Page 43 GX INSTALLATION AND OPERATION INSTRUCTIONS Page 43 Item Part Number Description Item Part Number Description GX-83173 Premix Burner (For 400) GX-83037 TEE NYLON 3/4"HB to 3/4" GX-82761 Premix Burner Gasket GX-83038 ADAPTER NYLON, 3/4" x 1/4" GX-82457 Transformer, 24V GX-82913 SIPHON CONDENSATE TRAP GX-83171 Sentry 2100 Assembly...
Page 44 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 L5S 1L4 • (905) 672-2991 FAX (905) 672-2883...

This manual is also suitable for:

Gx-150 Gx-200 Gx-400 Pgx-150 Pgx-200 Pgx-400