Lennox International Inc. Gas-Fired Hot Water Boiler manual

P/N# 240009276, Rev . A [03/2012] RET AIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions must be af fi xed on or adjacent to the boiler . GAS FIRED BOILER INST ALLA TION INSTRUCTIONS PRODUCT LITERA TURE Lennox Industries Inc. Dallas, T exas This boiler cannot be used with all types of chimneys. R ead these instructions carefully before[...]

2 1 - DIMENSIONS Table 1 - Dimensions BOILER MODEL NUMBER DIMENSIONS (INCH.) FLUE DIAMETER “A” WIDTH GWB8-245E-2/GWB8-262E-2 72 7 ½ GWB8-280E-2/GWB8-299E-2 7 30¾ Add 5½” to height for vent Damper . Figure 1 - Dimensions[...]

3 2 - BOILER RATINGS AND CAPACITIES Table 2 - Ratings and Capacities BOILER MODEL NUMBER (1) † NATURAL GAS † PROPANE GAS AFUE Input (3) Mbh Heating Capacity (3) Mbh (2) NET AHRI RATING Water, (3) Mbh HIGH ALTITUDE INPUT (3) Mbh INPUT (3) Mbh HEATING CAPACITY (3) Mbh (2) NET AHRI RATING Water, (3) Mbh HIGH ALTITUDE INPUT (3) Mbh INTERMITTENT IGN[...]

4 3 - TABLE OF CONTENTS IMPORT ANT : Read the following instructions COMPLETEL Y before installing!! KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE WARNING K eep boiler area clear and free from combustible materials, gasoline and other fl ammable vapors and liquids. DO NO T obstruct air openings to the boiler room. Modi fi cation, subst[...]

5 4 - INSTALLATION PROCEDURE Table 3 - MINIMUM CLEARANCE DIMENSIONS Inches (mm) T op 6” (152mm) Rear 6” (152mm) Control Side 7” (178mm) Opposite Side 6” (152mm) Front 18” (457mm) Flue/V ent Connector 6” (152mm) Near Boiler Piping 1/2” (13mm) WARNING Improper installation, adjustment, alteration, service or maintenance could result in [...]

6 5 - VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes. Pro[...]

7 6 - CONNECTING SUPPLY AND RETURN PIPING RELIEF VALVE DISCHARGE LINE Check local codes for maximum distance from fl oor or allowable safe point of discharge . WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valv e outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water durin[...]

8 6 - CONNECTING SUPPLY AND RETURN PIPING WARNING Burn and scald hazard. Safety relief valv e could discharge steam or hot water during oper ation. In- stall discharge piping per these instructions. ! Figure 3 - Temperature Pressure Gauge V erify clean water supply is av ailable to water inlet valv e. Install sand strainer when w ater supply is fro[...]

9 Figure 5 - Chilled Water Piping Figure 4 - Typical Hot Water Piping 6 - CONNECTING SUPPLY AND RETURN PIPING[...]

10 Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN Bypass Piping Required For High Mass (Large Water Content) Systems 6 - CONNECTING SUPPLY AND RETURN PIPING[...]

11 Boilers connecting to gas vents or chimneys, vent installations shall be in accordance with “V enting of Equipment” , of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or “Venting Systems and Air Supply for Appliances,” of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes[...]

12 Minimum Vent Pipe Clearance W ood and other combustible materials must not be closer than 6” from any surface of single wall metal vent pipe. Listed T ype B vent pipe or other listed venting systems shall be installed in accordance with their listing. Removing E xisting B oiler F rom C ommon Venting S ystem When an existing boiler is removed f[...]

13 8 - VENT DAMPER OPERATION Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement Annually check vent damper and all fl ue product carrying areas of appliance, with particular attention given to deterior ation from corrosion or other sources. If you see corrosion or other deterior ation, contact your heating contr actor for repairs[...]

14 9 - GAS SUPPLY PIPING CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions. • If you cannot reach your gas supplier, call the fi re departme[...]

15 10 - ELECTRICAL WIRING Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. R efer to: • USA- National Electrical Code, ANSI/NFPA 70. • Canada - Canadian Electrical Code, Part I, CSA C22.1: Safety Standard for Electrical Installations. ELECTRIC POWER SUPPLY Run separ ate 120 volt circuit from s[...]

16 11 - WIRING DIAGRAMS Figure 12 - Integrated High Limit Electronic Ignition Control (240008781) I Inducer is not an option. WARNING Modi fi cation, substitution or elimination of factory equipped, supplied or speci fi ed components may result in personal injury or loss of life. ![...]

17 11 - WIRING DIAGRAMS Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)[...]

18 11 - WIRING DIAGRAMS Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)[...]

19 12 -GENERAL INSTRUCTIONS FILLING SYSTEM WITH WATER • Close air vents on all radiation units. Open valves to these units. • Verify boiler and expansion tank drain valves are closed. • Air bleed screw on tank drain fi tting should be closed. • Open valve in line from boiler to expansion tank. Open water inlet to your boiler and leave it o[...]

20 13 - LIGHTING INSTRUCTIONS 1. STOP! R ead the safety information above. 2. Set the thermostat to lowest setting. 3. T urn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. OFF ON INLET GAS CONTROL KNOB PILOT ADJUSTMENT (UNDER[...]

21 14 - OPERATING YOUR BOILER AUTOMATIC GAS VALVE Automatic Gas V alve opens or closes according to heat requirements of thermostat and temperature limit control. It closes if pilot goes out. Each individual control must be operating correctly before any gas can pass to burners. Any one control can hold gas supply from burner regardless of demand o[...]

22 14 - OPERATING YOUR BOILER CHECK THERMOSTAT OPERATION A. When set above temperature indicated on thermo stat, boiler should ignite. B. Verify thermostat turns boiler off when room temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees. C. After setting limit control to limit setting, check to s[...]

23 15 - MAINTAINING YOUR BOILER BURNERS Beginning of heating season visually check pilot and main burner fl ames. See Figure 16. SAFETY RELIEF VALVE Refer to page 7 for important information. T o test safety relief valv e refer to valv e manufacturer’s instructions packaged with relief valv e. Call T echnical Support if manufacturer’s instruct[...]

24 EQUIPMENT AND OPTIONAL AC CESSORIES - WHA T THEY DO 16 - SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. Possible Cause What to do Thermostat is not set correctly Reset thermostat abov e room temperature Burner is not operating properly Check fl ame. If it is y ellow , burner is [...]

25 17 - EQUIPMENT AND OPTIONAL ACCESSORIES EXPANSION TANK Expanding water fl ows into expansion tank. T ank should be correct size. T ank is fi lled with air . As water expands it compresses air in the tank to form air pressure cushion. This “spring-like” cushion serves to maintain correct operating w ater pressure regardless of water temper [...]

26 BLOCKED VENT SAFETY SWITCH (BLOCKED VENT SAFETY SHUTOFF) Blocked vent safety switch is manual reset disc thermostat with fi xed setpoint (340°F (171°C)), and normally closed contacts. It is located at relief opening of integral draft diverter. In event of chimney or venting system blockage causing products of combustion to spill out of relief[...]

27 APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations WARNING If you do not follow these instructions ex actly, a fi re or explosion may result causing property damage, personal injury or loss of life. • Do not use this appliance if any part has been under water. Immediately call a quali fi ed service technician to inspect [...]

28 APPENDIX A - CONTROL MODULE A.5 Operation Module continuously monitors boiler water temper ature and fi res or shuts off burner based on this temperature data. 1. When “Call for Heat” occurs, control enables circulator and monitors boiler water temperature to determine whether thermostat can be satis fi ed without fi ring burners. 2. Cont[...]

29 APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller • When water temperature reaches setpoint, controller ends heating cycle. • When water temperature drops below setpoint minus differential, controller restarts heat cycle to re-heat boiler water. • If water temperature exceeds maximum allowed temperature (220°F or 10[...]

30 APPENDIX A - CONTROL MODULE Table 7 - Troubleshooting Error Codes Error Code Number De fi nition Consequence 4 Flame current too low . Check for fl ame. Non critical alarm 6 Flame sensed out of normal sequence (before opening or after closing gas valv e). Soft lockout 18 Gas valv e relays welded. Five consecutiv e soft lockouts. Hard lockout 2[...]

31 APPENDIX A - CONTROL MODULE — If fl ame rod or bracket is bent out of position, restore to correct position. STEP 3: Check spark ignition circuit. Disconnect ignition cable at SPARK terminal on module. WARNING Electrical shock hazard. Ignition circuit generates over 10,000 v olts. T urn OFF electrical power supply at service panel before maki[...]

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