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PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
This boiler cannot be used with all types of
chimneys. Read these instructions carefully
before installing.
C.S.A. Certified for
Natural gas or Propane
Tested for 50 psi. ASME
Working Pressure
INSTALLATION
INSTRUCTIONS
GWB8-262E-3
GWB8-299E-3
GAS FIRED BOILER
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
These instructions must be affixed on
or adjacent to the boiler.
!
WARNING
Improper installation, adjustment,
alteration, service, or maintenance
can cause injury or property damage.
Refer to this manual. For assistance
or additional information consult a
qualified installer, service agency, or
the gas supplier.
GAS-FIRED HOT WATER BOILERS
These Gas-Fired Water boilers are low pressure,
sectional cast iron boilers Design Certified by
CSA (Canadian Standards Association) for
use with Natural and Propane Gases. They
are constructed and hydrostatically tested for
maximum working pressure of 50 psi (pounds
per square inch) in accordance with A.S.M.E.
(American Society of Mechanical Engineers)
Boiler and Pressure Vessel Code Section IV
Standards for Cast Iron Heating Boilers.
P/N 240011161, Rev. E [05/17/2017]
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Summary of Contents for Lennox GWB8-262E-3
- Page 1 INSTALLATION INSTRUCTIONS PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas GWB8-262E-3 GWB8-299E-3 GAS FIRED BOILER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions must be affixed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage.
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Page 2: Dimensions
Figure 1 - Dimensions * Minimum acceptable height for low water cutoff probe. Table 1 - Dimensions DIMENSIONS (INCH.) BOILER MODEL NUMBER FLUE “A” DIAMETER WIDTH 27½ GWB8-245E-3/GWB8-262E-3 GWB8-280E-3/GWB8-299E-3 30¾ Add 5½” to height for vent Damper. P/N 240011161, Rev. E [05/17/2017]... -
Page 3: Boiler Ratings And Capacities
INPUT RATING INPUT IGNITION WITH Water, Water, VENT DAMPER GWB8-262E-3 262.5 83.9 GWB8-299E-3 83.7 Input rating for sea level to 2,000 ft. (610m) above sea level. † • United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea level. -
Page 4: Table Of Contents
3 - TABLE OF CONTENTS Dimensions ..........2 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Boiler Ratings And Capacities ......3 Table Of Contents ........4 Installation Procedure ........5 IMPORTANT: Read the following instructions COMPLETELY before installing!! Ventilation &... -
Page 5: Installation Procedure
4 - INSTALLATION PROCEDURE WARNING WARNING Improper installation, adjustment, alteration, Fire hazard. Do not install boiler on service or maintenance could result in death or combustible flooring or carpeting. Failure to serious injury follow these instructions could result in death or serious injury. -
Page 6: Ventilation & Combustion Air
5 - VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance • All Outdoor Air. Provide permanent opening(s) with the section “Air for Combustion and Ventilation,” communicating directly or by ducts with outdoors. of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or A. -
Page 7: Connecting Supply And Return Piping
6 - CONNECTING SUPPLY AND RETURN PIPING • Run pipe as short and straight as possible to WARNING location protecting user from scalding and Burn and scald hazard. Safety relief valve properly drain piping. could discharge steam or hot water during •... -
Page 8: For Use With Cooling Units
6 - CONNECTING SUPPLY AND RETURN PIPING Verify clean water supply is available to water inlet WARNING valve. Install sand strainer when water supply is from Burn and scald hazard. Safety relief valve a well or pump. could discharge steam or hot water during Install hot water boiler above radiation level or as operation. - Page 9 6 - CONNECTING SUPPLY AND RETURN PIPING Figure 4 - Typical Hot Water Piping Figure 5 - Chilled Water Piping P/N 240011161, Rev. E [05/17/2017]...
- Page 10 6 - CONNECTING SUPPLY AND RETURN PIPING Bypass Piping Required For High Mass (Large Water Content) Systems Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN P/N 240011161, Rev. E [05/17/2017]...
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Page 11: Chimney And Vent Pipe Connection
7 - CHIMNEY AND VENT PIPE CONNECTION Connecting The Vent Damper And Vent WARNING Connector Boiler and venting installations shall be Refer to Figure 1, page 2 for size and location of vent (flue opening). performed by a qualified expert and in accordance with the appropriate manual. - Page 12 7 - CHIMNEY AND VENT PIPE CONNECTION Place in operation the appliance being inspected. WARNING Follow the lighting instructions. Adjust thermostat Boiler and venting installations shall be so appliance will operate continuously. performed by a qualified expert and in Test for spillage at the draft hood relief opening accordance with the appropriate manual.
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Page 13: Vent Damper Operation
8 - VENT DAMPER OPERATION Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement Annually check vent damper and all flue product For further information, and vent damper carrying areas of appliance, with particular attention troubleshooting guide, refer to manual packaged with given to deterioration from corrosion or other vent damper and Appendix A of this manual. -
Page 14: What To Do If You Smell Gas
9 - GAS SUPPLY PIPING • Pressure test over 1/2 psig (3.5 kPa). Disconnect CAUTION boiler and its individual gas shutoff valve from gas WHAT TO DO IF YOU SMELL GAS supply system. • Do not try to light any appliance. •... -
Page 15: Electric Power Supply
10 - ELECTRICAL WIRING VENT DAMPER WIRING WARNING Boiler is equipped with factory wired harness with 4 Electrical shock hazard. Turn OFF electrical pin molex plug, that plugs into 4 pin molex receptacle power supply at service panel before making inside vent damper operator. -
Page 16: Wiring Diagrams
11 - WIRING DIAGRAMS Figure 12 - Electronic Ignition Control WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. P/N 240011161, Rev. E [05/17/2017]... -
Page 17: Filling System With Water
12 -GENERAL INSTRUCTIONS FILLING SYSTEM WITH WATER NOTICE • Close air vents on all radiation units. Open valves Never run water in a hot empty boiler. to these units. • Verify boiler and expansion tank drain valves are closed. • Air bleed screw on tank drain fitting should be closed. -
Page 18: Lighting Instructions
13 - LIGHTING INSTRUCTIONS 5. Remove lower front panel. WARNING 6. Rotate the gas control knob clockwise If you do not follow these “OFF”. instructions exactly, a fire or Figure 13 - Automatic Gas Valve explosion may result causing property damage, personal injury or loss of life. -
Page 19: Operating Your Boiler
14 - OPERATING YOUR BOILER AUTOMATIC GAS VALVE Figure 14 - Pilot Flame Automatic Gas Valve 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. - Page 20 14 - OPERATING THE BOILER - SYSTEM START-UP CHECK THERMOSTAT OPERATION HI TEMP illuminates when boiler water A. When set above temperature indicated on temperature reaches high limit setting. Remains lit thermostat, boiler should ignite. until water temperature falls 10°. Prevents burner B.
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Page 21: Operating The Boiler - System Start-Up
OPERATING THE BOILER - SYSTEM START-UP Table 1 - Troubleshooting Burner Will Not Fire If installed with indirect water heater, insure end switch in relay box controlling No or Insufficient Domestic indirect water heater is properly connected to cable 2 (see wiring diagram). Hot Water This insures domestic water calls are prioritized. -
Page 22: Service Hints
SERVICE HINTS EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO You may avoid inconvenience and service calls by checking these points before you call for service. CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. •... -
Page 23: Expansion Tank
15 - MAINTAINING YOUR BOILER BURNERS CLEANING YOUR BOILER AND BURNERS Beginning of heating season visually check pilot end Flue passages between sections should be examined main burner flames. See Figure 16. yearly and cleaned if necessary. To clean: SAFETY RELIEF VALVE •... -
Page 24: Equipment And Optional Accessories
17 - EQUIPMENT AND OPTIONAL ACCESSORIES AIR ELIMINATING FITTING (AIR PURGER) WARNING Air purger is used to remove excess air from system. Burn and scald hazard. Safety relief valve It is installed in supply line. It will eliminate air from could discharge steam or hot water during water before it reaches radiators and bleed off this air. -
Page 25: Rollout Switch
17 - EQUIPMENT AND OPTIONAL ACCESSORIES ROLLOUT SWITCH BLOCKED VENT SAFETY SWITCH (FLAME ROLLOUT SAFETY SHUTOFF) (BLOCKED VENT SAFETY SHUTOFF) Rollout switch is temperature-sensitive fuse link Blocked vent safety switch is manual reset disc device. Located on boiler base just outside fire box. thermostat with fixed setpoint (340°F (171°C)), and In event of heat exchanger flueway blockage causing normally closed contacts. -
Page 26: Intermittent Pilot Troubleshooting
INTERMITTENT PILOT TROUBLESHOOTING Intermittent Pilot • If so, ensure adequate flame current as follows: Ignition System Checks — Turn off boiler at circuit breaker or fuse box. — Clean flame rod with emery cloth. STEP 1: Check ignition cable. — Verify electrical connections are clean and tight. •... - Page 27 INTERMITTENT PILOT TROUBLESHOOTING Figure 16 Correct Pilot Flame: 3/8 to 1/2 inch in flame. See Figure 13, Page 19. P/N 240011161, Rev. E [05/17/2017]...
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Page 28: Appendix A-1 - Vent Damper Harness
APPENDIX A-1 - VENT DAMPER HARNESS A.1 Vent Damper Harness - Molex Plugs boiler should then ignite. WARNING • IF NOT, source problem is not the damper. Go to “Aquastat end of wiring Do Not negate the action of any existing safety harness’... -
Page 29: Appendix A-2 - Vent Damper Troubleshooting
APPENDIX A-2 - VENT DAMPER TROUBLESHOOTING A.2 Vent Damper Troubleshooting Guide WARNING Do Not negate the action of any existing safety orperational controls. Avoidance of these instructions could result in death or serious injury. When servicing controls, all wires must Note be labeled prior to disconnection. - Page 30 APPENDIX A-2 - VENT DAMPER TROUBLESHOOTING For troubleshooting only. Verify damper Note is in open position. Use service switch to keep damper in open position. Place jumper between 2 & 3. If appliance fires, remove jumper and plug receptacle back into damper controller plug.
- Page 31 NOTES P/N 240011161, Rev. E [05/17/2017]...
- Page 32 • This boiler is not used for any space heating • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas...
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