Table of Contents
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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. Certifi ed
For Natural Gas Or Propane
These instructions must be affi xed on
Improper installation, adjustment, alteration,
service, or maintenance could result in death
or serious injury. Refer to this manual for
assistance. For additional information consult
a qualifi ed installer, service agency, or the gas
supplier.
These Gas-Fired Water boilers are low pressure,
sectional cast iron boilers Design Certifi ed 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.
Tested For 50 psi.
ASME
Working Pressure
INSTALLATION
INSTRUCTIONS
GWB8-042IE-2, GWB8-075IE-2
GWB8-112IE-2, GWB8-150IE-2
GWB8-187IE-2, GWB8-225IE-2
GAS FIRED BOILER
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
or adjacent to the boiler.
WARNING
!
GAS-FIRED HOT WATER BOILERS
P/N# 240009135, Rev. C [06/2012]
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Summary of Contents for Lennox GWB8-042IE-2
- Page 1 INSTALLATION INSTRUCTIONS PRODUCT LITERATURE Lennox Industries Inc. GWB8-042IE-2, GWB8-075IE-2 Dallas, Texas GWB8-112IE-2, GWB8-150IE-2 GWB8-187IE-2, GWB8-225IE-2 GAS FIRED BOILER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions must be affi xed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance could result in death or serious injury.
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Page 2: Table Of Contents
TABLE OF CONTENTS Boiler Ratings & Capacities...... 3 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Dimensions ..........4 Safety Symbols & Warnings Installation Procedure ......5 The following defi ned symbols are used throughout this Ventilation & Combustion Air ....6 manual to notify the reader of potential hazards of varying Installation System Piping ...... -
Page 3: Boiler Ratings & Capacities
**Net Vent Diameter (Inches) Heating AHRI Input Model Capacity Rating AFUE *Mbh To Chimney Horizontal Vent *Mbh Water (Category I) (Category III) *Mbh GWB8-042IE-2 42.5 84.4 GWB8-075IE-2 75.0 83.4 GWB8-112IE-2 112.5 83.0 GWB8-150IE-2 150.0 82.7 GWB8-187IE-2 187.5 82.3 GWB8-225IE-2 225.0 82.0... -
Page 4: Dimensions
DIMENSIONS Model Width (A) GWB8-042IE-2 GWB8-075IE-2 14-1/4 GWB8-112IE-2 17-1/2 GWB8-150IE-2 20-3/4 GWB8-187IE-2 GWB8-225IE-2 27-1/4... -
Page 5: Installation Procedure
INSTALLATION PROCEDURE WARNING NOTICE Follow local regulations with respect to installation Improper installation, adjustment, alteration, service of CO detectors. or maintenance could result in death or serious injury FOR INSTALLATION ON NON-COMBUSTIBLE The installation must conform to the requirements of FLOORS ONLY - For installation on combustible the authority having jurisdiction or, in the absence fl... -
Page 6: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR • All Outdoor Air. Provide permanent opening(s) Provide combustion air and ventilation air in accordance communicating directly or by ducts with outdoors. with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections о... -
Page 7: Installation System Piping
INSTALLATION SYSTEM PIPING WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: • connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum distance from fl... - Page 8 INSTALLATION SYSTEM PIPING Figure 3 - Forced Hot Water Typical Piping Figure 4 - Forced Hot Water Typical Piping With Zone Control Valve...
- Page 9 INSTALLATION SYSTEM PIPING • Install radiation units (panels, radiators or cabinets) and Low Design Water Temperature Systems (Below supply and return mains fi rst then make connections at 140°F) And Large Water Content Systems boiler. • Verify clean water supply is available when connecting Condensation is corrosive and can eventually cause severe cold water supply to water valve.
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Page 10: Vent Installation
VENT INSTALLATION Fasten sections of vent pipe with sheet metal screws to Check Your Chimney make piping rigid. Use stovepipe wires to support pipe Chimney must be clean, right size, properly constructed from above. and in GOOD CONDITION. Do not connect to fi replace fl ue. Installation must conform to requirements of the authority having jurisdiction or, in absence of such Do not install damper on this boiler. - Page 11 VENT INSTALLATION Figure 7 - Type B Gas Vent CHECK YOUR CHIMNEY For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
- Page 12 VENT INSTALLATION Removing Existing Boiler From Common Venting Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use fl ame of a match System or candle, or smoke from a cigarette, cigar, or pipe. When an existing boiler is removed from a common After it has been determined that each appliance venting system, the common venting system is likely to be...
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Page 13: Optional Horizontal Venting Instruction
OPTIONAL HORIZONTAL VENTING INSTRUCTION Horizontal venting with a power venter is an alternate Confi rm that installing a power venter is an option allowed method of sidewall venting. This boiler is CSA listed for by local codes. Follow the specifi c power venter installation sidewall venting with standard single wall galvanized or instructions issued with the power venter kits. -
Page 14: Gas Supply Piping
GAS SUPPLY PIPING Connecting Gas Piping CAUTION Gas line enters boiler from right side. Flexible gas WHAT TO DO IF YOU SMELL GAS connectors must never breach any boiler openings. • Do not try to light any appliance. • Use piping materials and joining methods acceptable to authority having jurisdiction. - Page 15 GAS SUPPLY PIPING Table 6 - NATURAL GAS Table 7- PROPANE GAS Pipe Capacity - BTU Per Hour Input Pipe Capacity - BTU Per Hour Input Length of Length Includes Fittings Includes Fittings Pipe - Ft. Copper Tubing* Iron Pipe ½"...
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Page 16: Electrical Wiring
ELECTRICAL WIRING Electric Power Supply WARNING Run a separate 115 volt circuit from separate over current Electrical shock hazard. Turn OFF electrical power protective device 15 ampere circuit in electrical service supply at service panel before making electrical entrance panel. connections. -
Page 17: Sequence Of Operation
SEQUENCE OF OPERATION Sequence of Operation - Figure 10, Page 18. Thermostat calls for heat, control relay contacts. Circulator pump is powered through terminals C1 and C2. Control holds off burner and attempts to satisfy thermostat with residual boiler heat. Induced draft blower and transformer primary are powered. -
Page 18: Wiring Diagrams
WIRING DIAGRAMS Figure 10 - Control Module Damper is not an option. -
Page 19: Starting Your Boiler
STARTING YOUR BOILER NOTICE Do not add water into hot empty boiler. 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. •... - Page 20 STARTING YOUR BOILER Operating Instructions. WARNING STOP! Read Safety Information on previous page. If you do not follow these instructions Set the thermostat to lowest setting. exactly, a fi re or explosion may result Turn off all electric power to the appliance. causing property damage, personal injury This appliance is equipped with an ignition device which or loss of life.
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Page 21: Checking And Adjusting
CHECKING AND ADJUSTING Gas Valve Safety Shutdown Test Figure 12 - Automatic Gas Valve WARNING Electrical shock hazard. Follow instructions to turn off electric power. Failure to do so could result in death or serious injury. Ignition system safety shutoff device must be tested after placing boiler in operation. - Page 22 CHECKING AND ADJUSTING Figure 14 - Main Burner Flame Adjust Thermostat Heat Anticipator Instruction for fi nal adjustment of thermostat are packaged with thermostat. Set Heat anticipator at .2. Check thermostat operation. When set above temperature indicated on thermometer, boiler burners should ignite.
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Page 23: Maintaining Your Boiler
MAINTAINING YOUR BOILER Burners Cleaning Your Boiler And Burners Beginning of heating season visually check pilot and main Flue passages between sections should be examined yearly burner fl ames. See Figures 13, and 14. and cleaned if necessary. To clean: Safety Relief Valve •... -
Page 24: Service Hints
SERVICE HINTS 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. • Do not touch any electrical switch; do not use any phone in your building. -
Page 25: Equipment & Optional Accessories
EQUIPMENT & OPTIONAL ACCESSORIES AIR ELIMINATING FITTING (AIR PURGER) WARNING Air purger is used to remove excess air from system. It Burn and scald hazard. Safety relief valve could is installed in supply line. It will eliminate air from water discharge steam or hot water during operation. - Page 26 EQUIPMENT & OPTIONAL ACCESSORIES PRESSURE SWITCH Air pressure switch works on negative pressure. When blower comes on air pressure switch operates intermittent pilot and gas valve. Air pressure switch is factory set and will only work when blower operates properly. It will not allow boiler to come on if blower does not generate enough pressure or if venting system is blocked.
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Page 27: Appendix A - Control Module
APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations A.3 Adjusting Settings To discourage unauthorized changing of settings, procedure WARNING to enter adjustment mode is required. If you do not follow these instructions To enter adjustment mode, press UP, DOWN, and I buttons exactly, a fi... -
Page 28: Operation
APPENDIX A - CONTROL MODULE A.5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes list) Module continuously monitors boiler water temperature and and heats water in boiler until setpoint temperature is fi res or shuts off burner based on this temperature data. achieved or thermostat is satisfi... -
Page 29: Boiler High Limit Temperature Controller
APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller A.7 Troubleshooting • When water temperature reaches setpoint, controller • Following service procedures are provided as general ends heating cycle. guide. • When water temperature drops below setpoint minus •... - Page 30 APPENDIX A - CONTROL MODULE Table 2 - Troubleshooting Error Codes Error Code Defi nition Consequence Number Pressure switch failed to open (stuck closed). Wait for recovery Flame current too low. Check for fl ame. Non critical alarm Flame sensed out of normal sequence (before opening or after closing gas valve). Soft lockout Gas valve relays welded.
- Page 31 APPENDIX A - CONTROL MODULE STEP 3: Check spark ignition circuit. • Recheck ignition sequence as follows. Disconnect ignition cable at SPARK terminal on module. — Reconnect main valve wire. WARNING — Adjust thermostat above room temperature. — Verify ignition sequence at burner. Electrical shock hazard.
- Page 32 PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
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