Lennox GSB8-112E, GSB8-112S, GSB8-150E, GSB8-150S, GSB8187E Installation Instructions Manual
...
PRODUCT LITERATURE
affi xed on or adjacent to the boiler.
GAS-FIRED HOT WATER BOILERS
These Gas-Fired Water Boilers are low
Association) for use with Natural and
for cast iron heating boilers.
Lennox Industries Inc.
Dallas, Texas
INSTALLATION
INSTRUCTIONS
GSB8-E
GAS-FIRED STEAM BOILER
GSB8-S
GAS-FIRED STEAM BOILER
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
These instructions must be
affi xed on or adjacent to the boiler.
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 a 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.
WARNING
Impr oper insta l lat i on, ad just ment ,
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.
P/N# 14683453, Rev. 2.2 [11/07]
GSB8-E GAS-FIRED STEAM BOILER & GSB8-S GAS-FIRED STEAM BOILER
INSTALLATION, OPERATION & MAINTENANCE MANUAL
P/N# 14683453, Rev.2.2 [11/07]
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
These instructions must be afxed on or adjacent to the boiler
GAS-FIRED HOT STEAM BOILERS
These Gas-Fired Steam Boilers are low pres-
sure, sectional cast iron boilers Design Certied
by AGA (American Gas Association) for use with
Natural and Propane Gases. They are constructed and hydrostatically tested for a maximum
working pressure of 15 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.
Improper installation, adjustment, alteration, service, or maintenance can cause
injury or property damage. Refer to this
manual. For assistance or additional
information consult a qualied installer,
service agency or the gas supplier.
TABLE OF CONTENTS
Boiler Ratings and Capacities ................3, 4
Before You Start .........................................4
Locating the Boiler ......................................5
Fresh Air for Combustion .......................6, 7
Installation – System Piping ..................7-10
Chimney and Vent Pipe Connection ....10-12
Vent Damper Operation ............................13
Gas Supply Piping ....................................14
Electrical Wiring ........................................15
Controls & Accessories – What They Do .....21, 22
For Your Safety – Read Before Operating .....22
Gas Valve Operating Instructions .......23, 24
Operating Your Boiler .........................24, 25
Checking and Adjusting .......................25-26
Cleaning Your Boiler ............................26,27
Maintaining Your Boiler ........................27-30
Service Hints ............................................30
Troubleshooting ........................................31
Repair Parts.........................................32-35
BOILER RATINGS AND CAPACITIES
Figure #1
DESIGN CERTIFIED FOR NATURAL AND PROPANE GAS
3
BOILER SPECIFICATIONS
Natural gas Propane
Capacity US
Gallons (L)
Size IPS
Gas Piping
in. (mm)
Model No.
GSB8-075E Electronic
GSB8-075S Standing Pilot 81.1
GSB8-112E Electronic
GSB8-112S Standing Pilot 78.8
GSB8-150E Electronic
GSB8-150S Standing Pilot 79.2
GSB8187E Electronic
GSB8187S Standing Pilot 79.6
GSB8-225E Electronic
GSB8-225S Standing Pilot 80.1
GSB8-262E Electronic
GSB8-262S Standing Pilot 80.5
GSB8-299E Electronic
GSB8-299S Standing Pilot 80.9
1) The Ratings marked “Net I=B=R Ratings” indicate the amount of equivalent direct cast iron radiation each boiler will take care of under normal conditions and
thermostatic control. The Net I=B=R Steam Ratings shown are based on an allowance of 1.333 in accordance with the factors shown in the I=B=R Code as
published by the Hydronics Institute. Selection of boiler size should be based upon “Net I=B=R Rating” Being equal to or greater than installed radiation in
square feet. Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements. Specications and dimensions are
subject to change without notice.
2) Annual Flue Utilization Efciency based on U.S. DOE test procedures and FTC labeling regulations.
Type of Ignition
Input Btuh (KW)
75,000
(22.0)
112,500
(33.0)
105,000
(44.0)
187,000
(54.8)
225,000
(65.9)
262,000
(76.9)
299,000
(87.6)
(KW
Heating Capacity Btuh
62,000
47,000
(18.5)
(14.7)
91,000
68,000
(26.7)
(19.9)
122,000
92,000
(35.7)
(27.0)
153,000
115,000
(44.8)
(33.7)
183,000
137,000
(53.6)
(40.1)
214,000
161,000
(62.7)
(47.2)
245,000
184,000
(71.8)
(53.9)
sq.ft. Radiation
1) Net I=B=R Rating
1) Net I=B=R Btuh (KW)
196
(18.2)
283
(26.3)
383
(35.6)
479
(44.5)
571
(53.0)
671
(62.3)
767
(71.3)
Input Btuh (KW)
70,000
(20.0)
105,000
(30.8)
140,000
(41.0)
175,000
(51.3)
210,000
(61.5)
245,000
(71.8)
280,000
(82.0)
(KW
Heating Capacity Btuh
58,000
44,000
(16.1)
(13.0)
85,000
64,000
(24.9)
(18.6)
114,000
86,000
(33.4)
(25.2)
143,000
107,000
(41.9)
(31.4)
171,000
128,000
(50.1)
(37.5)
200,000
150,000
(58.6)
(44.0)
229,000
172,000
(67.1)
(50.4)
sq.ft. Radiation
1) Net I=B=R Rating
1) Net I=B=R Btuh (KW)
183
(17.0)
267
(24.8)
358
(33.3)
446
(41.4)
553
(51.4)
625
(58.1)
717
(66.7)
82.7
80.4
80.6
80.9
81.1
81.3
81.5
2) AFUE %
Number of Sections
4.20
3
(16.1)
5.90
4
(22.3)
7.60
5
(28.8)
9.30
6
(35.2)
11.00
7
(41.6)
12.70
8
(48.1)
14.40
9
(54.5)
Full
Water Level
2.60
(9.84)5(12.7)
3.80
(14.4)6(15.2)
5.00
(18.9)6 (15.2)
6.20
(23.5)7(17.8)
7.40
(28.0)
8.60
(32.6)
9.80
(37.1)
Flue Size Connection
7
(17.8)
Package
Natural
Sipping Weight Lbs. (kg)
Diameter in. (mm) round
325
(147)
1/2
404
(12.7)
(183)
483
(219)
564
(256)
649
3/4
(294)
(19.0)
719
(326)
800
(363)
Propane
3/4
(19.0)
Supply & Return Connection
2-1/2
(64.0)
NPT in. (mm)
(19.0)
(mm)
Drain Connection NPT in.
3/4
BEFORE YOU START
Check to be sure you have the right size boiler before
starting the installation. See rating and capacity table on
previous page. Also be sure the new boiler is for the type
of gas you are using. Check the rating plate on the right
side of the boiler.
You must see that the boiler is supplied with the correct type of gas, fresh air for combustion, and a suitable
electrical supply. Also, the boiler must be connected to a
suitable venting system and an adequate piping system.
Finally, a thermostat, properly located, is needed for control
of the heating system. If you have any doubts as to the
various requirements, check with local authorities and
obtain professional help where needed. Take the time to
complete all of the steps for SAFE and PROPER operation of the heating system.
If this boiler is installed in a building under construction,
special care must be taken to insure a clean combustion air supply during the construction process. Airborne
particulates such as from drywall dust and from berglass
insulation can clog the burner ports and cause incomplete
combustion and sooting.
These boilers are designed for use in closed heating
systems where all of the steam is returned to the boiler as
condensate and the amount of make-up water required is
minimal. These boilers are not designed for or intended
for use in open systems of process applications using
100% make-up water. Damage to the boiler resulting
from such use shall not be covered under the warranty.
Where required by the authority having jurisdiction,
the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, No. 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.
The following steps are all necessary for proper
installation and safe operation of your boiler.
1. LOCATING THE BOILER
2. FRESH AIR FOR COMBUSTION
3. INSTALLATION – SYSTEM PIPING
4. CHIMNEY & VENT PIPE CONNECTION
5. GAS SUPLY PIPING
6. ELECTRICAL WIRING
7. CHECKING & ADJUSTING
KEEP BOILER AREA CLEAN AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND
OTHER FLAMMABLE VAPORS AND LIQUIDS
4
LOCATING THE BOILER
1. Select level location as centralized with piping
system, and as near chimney, as possible.
2. Place crated boiler at selected location, remove
crate by pulling crate sides from top and bottom
boards. Combustible oors: When boiler is to be
installed on a combustible oor, a Special Base
Plate must be used – 146-14-031 (3-6 Section)
or 146-14-032 (7-9 Section). This boiler must
not be installed on carpeting.
3. Boiler is to be level. Metal shims may be used
under base legs for nal leveling.
4. Additional clearances for service may exceed
clearances for re protection. Always comply
with the minimum re protection clearances
shown on the boiler. An 18 inch clearance
should be maintained on any side where passage is required to access another side for
cleaning, servicing, inspection or replacement
of any part that may need attention. An 18 inch
clearance is recommended on the control side
for servicing.
Where the actual ceiling height of a room is
greater than 8’, the volume of a room shall be
gures on the basis of a ceiling height of 8’.
Determination of room size should be based
on the total volume of all gas red equipment
installed in the room. Consult section 6.3.1 of
the National Fuel Gas Code for further information, including approved methods for reducing
clearances in large rooms.
5. Equipment shall be installed in a location in
which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and
maintenance of ambient temperature at safe
limits under normal conditions of use. Equipment shall be located so as not to interfere
with proper circulation of air. When normal
inltration does not provide the necessary air,
outside air shall be introduced (See - “Fresh
Air for Combustion” following page).
6. Advise owner to keep air passages free of
obstructions. Ventilating and combustion air
must enter boiler room without restrictions.
Figure 2 shows minimum clearances to com-
bustible construction. Rooms that are large
in comparison with the size of the boiler are
dened as rooms having a volume equal to or
greater than 16 times the volume of the boiler.
Figure #2
BOILER CLEARANCES
Alcove*, or Room
Unit
To p 6” 6”
Rear 6” 6”
Control Side 7” 6”
Opposite Side 6” 6”
Front 18” 18”
Flue/Vent Connector 6” 6”
Near Boiler Piping 1” 1”
* Alcove - boiler may be installed in an area inclosed on 3 sides (U shped) with
the front open.
Not Large in
Comparison
With Boiler
Room Large In
Comparison
With Boiler
7. The boiler shall be installed such that the automatic gas ignition system components are
protected from water (dripping, spraying, rain,
etc.) during appliance operation and service
(condensate trap, control replacement, etc.).
BOILER VOLUME SPECIFICATIONS
Boiler
Size
3 sect. 6.3 100.4
4 sect. 8.1 129.4
5 sect. 9.9 158.4
6 sect. 11.7 187.4
7 sect. 13.5 216.4
8 sect. 15.3 245.4
9 sect. 17.2 274.5
* For room with single boiler only.
Boiler
Volume
(Cu. Ft.)
Minimum Room
Volume Required
To Be Large (Cu.Ft.)*
This unit must be set on a concrete or other noncombustible material base or oor.
IT MUST NOT BE INSTALLED ON CARPETING.
5
FRESH AIR FOR COMBUSTION
Provision for combustion and ventilation air must be in accordance with Section 5.3,
Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI A223.1 – latest
revision, or applicable provisions of the local building codes.
WARNING
!
!
Be sure to provide enough fresh air for
combustion. Enough air insures proper combustion and assures that no hazard will
develop due to the lack of oxygen.
You must provide for enough fresh air to assure
proper combustion. The re in the boiler uses
oxygen. It must have a continuous supply. The
air in a house contains only enough oxygen to
supply the burner for a short time. Outside air
must enter the house to replace that used by
the burner. Study following examples 1 and 2 to
determine your fresh air requirements.
EXAMPLE 1:
Boiler Located in Unconned Space
An unconned space is dened as a space
whose volume is not less than 50 cubic feet per
1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (un-partitioned
basement) in a conventional house, the air that
leaks through the cracks around doors and windows will usually be adequate to provide air for
combustion. The doors should not t tightly. Do
not caulk the cracks around the windows.
Equipment located in buildings of unusually
tight construction shall be provided with air for
combustion, ventilation, and dilution of ue gases
using the methods described in example 2B
or shall be specially engineered. The authority
having jurisdiction must approve specially engineered installations.
EXAMPLE 2:
Boiler Located in Unconned Space
A. All Air from Inside the Building: The conned
space shall be provided with two permanent
openings communicating directly with an ad-
ditional room(s) of sufcient volume so that
the combined volume of all spaces meets the
criteria for an unconned space. The total input
of all gas utilization equipment installed in the
combined space shall be considered in making
this determination. Each opening shall have a
minimum free area of one square inch per 1,000
Btu per hour of the total input rating of all gas
utilization equipment in the conned space, but
not less than 100 square inches. One opening
shall be within 12 inches of the top and one
within 12 inches of the bottom of the enclosure.
The minimum dimension of air openings shall
not be less than 3 inches.
B. All Air from Outdoors: The conned space
shall communicate with the outdoors in accordance with methods 1 or 2. The minimum
dimension of air openings shall not be less than
3 in. Where ducts are used, they shall be of the
same cross-sectional area as the free area of
the openings to which they connect.
1. Two permanent openings, one commencing
within 12 inches of the top, and one commencing within 12 inches of the bottom, of
the enclosure shall be provided. The openings shall communicate directly, or by the
ducts, with the outdoors or spaces (crawl
or attic) that freely communicate with the
outdoors.
a) Where directly communicating with the
outdoors or where communicating to the
outdoors through vertical ducts, each
opening shall have a minimum free area
of 1 sq. in. per 4000 Btu per hour or total
input rating of all equipment in the enclosure. (See Figure 3A.)
b) Where communicating with the outdoors
through horizontal ducts, each opening
shall have a minimum free area of 1 sq.
in. per 2000 Btu per hour or total input
rating of all equipment in the enclosure.
(See Figure 3B.)
6
FRESH AIR FOR COMBUSTION
2. One permanent opening commencing with
12 inches of the top of the enclosure, shall
be permitted where the equipment has clearance of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
The opening shall directly communicate with
the outdoors or shall communicate through
a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely communicate with the outdoors, and shall have a
minimum free area of:
a) 1 sq. inch per 3000 Btu per hour of the
total input of all equipment located in the
enclosure (See Figure 4), and
b) Not less than the sum of the areas of all
vent connectors in the conned space.
Figure #3A
FRESH AIR DUCT CAPACITIES (Btuh)
1 Square Inch per 4,000 Btuh
100% Free
Area
Fresh Air
Duct Size
3” x 12” 144,000 108,000 36,000
8” x 8” 256,000 192,000 64,000
8” x 12” 384,000 288,000 96,000
8½” x 16” 512,000 384,000 128,000
¼” Wire
Mesh
75% Free
Area
Metal
Louvers
25% Free
Area
Wood
Louvers
Figure #3B
FRESH AIR DUCT CAPACITIES (Btuh)
1 Square Inch per 2,000 Btuh
100% Free
Area
Fresh Air
Duct Size
3” x 12” 72,000 54,000 18,000
8” x 8” 128,000 96,000 32,000
8” x 12” 192,000 144,000 48,000
8½” x 16” 256,000 192,000 64,000
¼” Wire
Mesh
75% Free
Area
Metal
Louvers
25% Free
Area
Wood
Louvers
Figure #4
FRESH AIR DUCT CAPACITIES (Btuh)
1 Square Inch per 3,000 Btuh
100% Free
Area
Fresh Air
Duct Size
3” x 12” 108,000 81,000 27,000
8” x 8” 192,000 144,000 48,000
8” x 12” 288,000 216,000 72,000
8½” x 16” 384,000 288,000 96,000
¼” Wire
Mesh
75% Free
Area
Metal
Louvers
25% Free
Area
Wood
Louvers
INSTALLATION — SYSTEM PIPING
The near boiler piping, that is the piping around
the boiler must be considered as part of the boiler
for proper water level control, and to produce dry
steam. Correct near boiler piping is crucial to the
proper operation of the boiler and the heating system. Follow these recommendations carefully.
1. Place boiler in selected location, as near chimney
as possible.
2. Install the pop safety valve, using the furnished
¾” coupling, into the ¾” pipe nipple on the top
of the boiler. Make a discharge pipe, using ¾”
pipe (not furnished) to carry the water or steam
to a nearby drain. Do not connect the discharge
pipe directly to a drain but leave an air gap. The
downstream end of the discharge pipe must be
unthreaded. No shutoff of any description shall
be placed between the pop safety valve and
the boiler, or on discharge pipes between such
safety valves and the atmosphere. Installation
of the pop valve shall conform to the requirements of the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV. The manufacturer is
not responsible for any water damage.
3. This boiler is equipped with two 2 ½” supply
connections and two 2 ½” return connections,
one each on both the left and right sides of the
boiler. Unused connections must be plugged
with the 2 ½” plugs (furnished).
4. Recommended near boiler piping for gravity
return systems is shown in Figure 5. This
7
INSTALLATION — SYSTEM PIPING
Figure #5
RECOMMENDED NEAR BOILER PIPING USING ONE SUPPLY TAPPING
con guration uses one supply and one return
tapping. This setup can be used on any size
boiler in this series. The supply and return
connections may be piped both into the same
side (either left or right) or one into each side
of the boiler.
5. For installers choosing to use both supply tappings, Figure 6A shows the correct way to
pipe this system. Figure 6B shows the wrong
way to pipe a header with two risers.
• Headers must be tted with header offsets or
swing joints, or be equipped with expansion
joints, so that thermal expansion and contraction of the header will not damage the boiler.
Headers shall not be welded.
• System takeoffs from the header must be
between the equalizer and the riser to the
header nearest the equalizer. System takeoffs must never be between two risers.
6. System takeoffs from the header must never
be bullheaded. If the steam main goes in two
directions, there must be two takeoffs from the
header, one for each main.
8
INSTALLATION — SYSTEM PIPING
Figure #6A
RECOMMENDED NEAR BOILER PIPING USING TWO SUPPLY TAPPINGS
7. All boilers in gravity return systems must be
equipped with a Hartford Loop as shown in
Figures 5 and 6A.
8. When piping the vertical risers from the boiler
to the header, the bottom of the header must
be a minimum of 24 inches above the water
level line on the right side of the boiler.
9. Steam riser(s) and header shall be 2 ½” pipe size.
10. Equalizer line shall be minimum 1 ½” size.
11. The near boiler piping shall include a 2 ½” tee
with a plug located on the supply line as shown
for skimming (i.e. surface blowdown).
12. The near boiler piping shall include a 1 ½” ball
valve in the return piping as shown for bottom
blowdown and draining.
13. For gravity return systems, the bottom of the
lowest steam carrying pipe, be it a dry return,
or the end of the steam main, must be at least
28” above the normal water level line on the
right side of the boiler. This is known as “Dimension A.”
14. For pumped return systems, follow the condensate pump or boiler feed pump manufacturer’s instructions for proper installation and
hookup.
15. In connecting the cold water supply to the
water inlet valve, make sure that a clean water
supply is available. When the water supply is
from a well or pump, a sand strainer should be
installed at the pump.
9
INSTALLATION — SYSTEM PIPING
Figure #6B
COMMON NEAR BOILER PIPING MISTAKES
FOR USE WITH COOLING UNITS
A. This boiler, when used in connection with
chilled water systems, must be installed so
that the chilled water is piped in parallel with
the heating boiler. Appropriate valves must be
used to prevent the chilled water from entering
the heating boiler (Figure 7).
B. When this boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air circulation, the pip-
ing system shall be equipped with ow control
valves or other automatic means to prevent
gravity circulation of the boiler water during the
cooling cycle.
Figure #7
CHILLED WATER PIPING
10
CHIMNEY AND VENT PIPE CONNECTION
For boilers for connection to gas vents or chimneys, vent installations shall be
in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI
Z223.1-latest revision and applicable provisions of the local building codes.
CHECK YOUR CHIMNEY
This is a very important pat of your heating system. It must be clean, the right size, properly
constructed and in GOOD CONDITION. No boiler
can function properly with a bad chimney. Inspect
the chimney and verify that the construction and
size of the chimney meets all applicable provisions of the National Fuel Gas Code and local
building codes. Figure 8 gives you an idea how
a boiler might be vented to a chimney. Note that
the height (HT) is measured from the vent pipe
to the top.
CHIMNEY SIZING
Chimney sizing and all other aspects of the vent
installation must be in accordance with Part 7 of
the National Fuel Gas Code, ANSI Z223.1-latest
revision, and applicable provisions of the local
building codes.
CONNECTING THE VENT DAMPER AND
VENT CONNECTOR
Refer to Figure 1 ue diagram for the size and
location of the vent (ue opening). Use a 28
gauge (minimum) galvanized pipe to connect to
the chimney.
IMPORTANT: The damper blade on the
furnished vent damper has a ½ square inch
hold (approximately ¾” diameter). On boilers equipped with standing pilot, the hole
must be left open. On boilers equipped
with intermittent ignition, the hole should be
plugged by using the plug supplied with the
vent damper.
1. Position furnished vent damper on top of ue
outlet collar. Fasten damper securely to ue
outlet collar with sheet metal screws. Make
sure damper blade has clearance to operate
inside of diverter.
AS AN OPTION:
The damper may be installed in any horizontal or ver-
tical position, closer to the ue outlet collar preferred.
Follow the diagrams – Figures 9, 10, and 11.
2. Install the vent damper to service only the single boiler for which it is intended. The damper
position indicator shall be in a visible location
following installation. Locate the damper so
that it is accessible for servicing.
3. The damper must be in the open position when
appliance main burners are operating.
4. The boiler is equipped with a factory wired harness that plugs into the vent damper. The thermostat must be connected to the black wires
marked 24 Volt
thermostat on
the boiler.
5. Vent pipe must be
CHIMNEY REQUIREMENTS
Figure #8
TYPICAL MASONRY
same size as the
ue outlet collar.
6. Slope pipe up
from boiler to
chimney not less
than ¼” per foot.
7. Run pipe as
directly as possible with as
few elbows as
possible.
8. Do not connect to
replace ue.
9. End of vent pipe
must be flush
with inside face
of chimney ue.
Use a sealed-in
thimble for the
chimney connection.
10. Horizontal run should not be longer than ¾
the chimney height (HT) (Figure 8).
11
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