Lennox GSB8-E Installation Instructions Manual

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Page 1

PRODUCT LITERATURE

Lennox Industries Inc. Dallas, Texas

INSTALLATION

INSTRUCTIONS

GSB8-E

GAS-FIRED STEAM BOILER

RETAIN THESE INSTRUCTIONS

FOR

FUTURE REFERENCE

These instructions must be

af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: Rules for Construction of 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 qualied installer,

service agency, or the gas supplier.

WARNING

P/N# 14683453, Rev. C [12/2013]

Page 2

Figure 1 - Dimensions

DIMENSIONS

BOILER MODEL

NUMBER

(1)

Dimensions (Inches)

Intermittent

Ignition w/Vent

Flue Diameter "A" Width

Damper

GSB8-075E 5 11¼

GSB8-112E 6 14½

GSB8-150E 6 17¾

GSB8-187E 7 21

GSB8-225E 7 24¼

GSB8-262E 7 27½

GSB8-299E 7 30¾

Add 5½" to height for Vent Damper

(1)

Add model number sufx 'P' for Propane Gas.

Page 3

RATINGS AND CAPACITY

Table 1 - Ratings and Capacities

BOILER MODEL NUMBER

Intermittent

Ignition w/Vent

Damper

(1)

GSB8-075E

(1)

GSB8-112E

(1)

GSB8-150E

(1)

GSB8-187E

No. of

Sec.

†Natural Gas

Fuel Type

Input

*MBTUH

Natural Gas 75 62 82.7 47 196

Propane 70 58 82.7 44 183

Natural Gas 112 91 82.0 68 283

Propane 105 85 80.4 64 267

Natural Gas 150 122 82.0 92 383

Propane 140 114 80.6 86 358

Natural Gas 187 153 82.0 115 479

Propane 175 143 80.9 107 446

Heating Capacity *MBTUH

AFUE(%)

Net AHRI

Rating *Mbh

Net AHRI

Rating Sq. Ft.

Natural Gas 225 183 82.0 137 571

(1)

GSB8-225E

Propane 210 171 81.1 128 533

Natural Gas 262 214 82.0 161 671

(1)

GSB8-262E

Propane 245 200 81.3 150 625

Natural Gas 299 245 82.0 184 767

(1)

GSB8-299E

Propane 280 229 81.5 172 717

* MBH = 1,000 Btuh. Btuh = British Thermal Unit Per Hour. † For altitudes above 2,000 ft. reduce input rate 4% for each 1,000 ft. above sea level.

Heating Capacity is based on DOE (Department of Energy) test procedure.

(1)

Add model number sufx 'P' for Propane Gas.

Net AHRI steam Ratings shown are based on a piping and pickup allowance of 1.333.

Base selection of boiler size on "Net AHRI 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,such as intermittent system operation, exhaust piping systems, etc.

Page 4

TABLE OF CONTENTS

Dimensions ................................................ 2

Ratings and Capacity .................................. 3

Safety Symbols .......................................... 5

Locating the Boiler ...................................... 6

System Piping ............................................ 7

Installation - System Piping ........................10

Fresh Air for Combustion ............................11

Chimney and Vent Pipe Connection ..............12

Vent Damper Operation ..............................14

Gas Supply Piping ......................................15

Electrical Wiring ........................................16

Operating Instructions ................................17

Operating Your Boiler .................................18

Checking and Adjusting ..............................19

Start-up Cleaning ......................................21

General Maintenance .................................22

Service Hints ............................................23

Wiring Diagrams ........................................24

Wiring diagrams ........................................25

Controls and Accessories ............................26

Introduction

Boiler is designed for use in closed heating systems where all steam is returned as condensate and make-up water is minimal. Boiler is not designed for or intended for use in open systems using 100% make-up water.

Prior to Installation

• Verify correct boiler for type of gas being used natural or propane. See Rating Plate.

• Verify boiler size and dimensions. See Figure 1 page 2.

• Verify ratings and capacity data for natural gas. See

Table 1 page 3.

Installation Requirements

• Supply boiler with correct gas (natural or propane), fresh air for combustion, and suitable electrical supply.

• Connect boiler to adequate venting and piping systems.

• Provide boiler with properly located and adjusted thermostat.

Installation of boiler in building under construction, use precaution to insure clean combustion air supply during construction process. Airborne particulate from construction materials can clog burner ports and cause incomplete combustion and sooting.

Complete all steps for safe and proper heating system operation.

Repair Parts ..............................................27

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

GAS FIRED STEAM BOILERS

Information and specications outlined in this manual in effect at the

time of printing of this manual. Manufacturer reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

Page 5

SAFETY SYMBOLS

General

Boiler and venting installation shall be completed by

qualied agency.

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Installation shall conform to requirements of

authority having jurisdiction or in absence of such requirements to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Where required by authority having jurisdiction, installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. Controls can be added to make this boiler CSD-1 compliant. Check with your local codes for requirements.

Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not limited to installation by licensed plumber or gas tter.

WARNING

Installing or venting a boiler or any other gas appliance with improper methods or materials could

result in death or serious injury due to re or to

asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

CAUTION

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

WARNING

Fire, explosion, asphyxiation hazard. Keep boiler area clear and free from combustible materials,

gasoline and other ammable vapors and liquids.

Modication, substitution or elimination of factory equipped, supplied or specied components could

result in death or serious injury.

Page 6

LOCATING THE BOILER

Locating the Boiler

Select level location as centralized with piping system, and as near chimney as possible.

Place crated boiler at selected location. Remove all crate material. Please recycle responsibly.

WARNING

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

Do not install boiler on carpeting. For installation

on non-combustible oors only. For installation on

combustible ooring, special base must be used. See

Repair Parts page 27.

Use metal shims under boiler base legs for nal leveling

if needed.

Install boiler in location that permits satisfactory combustion of gas, proper venting, and maintenance of ambient temperature at safe limits under normal conditions of use. Boiler location should not interfere with proper circulation of air. Introduce outside air

if normal inltration does not provide necessary

air.“Fresh Air for Combustion” on page 11.

Notify owner to keep air passages free of obstruction. Ventilating and combustion air must enter boiler room without restrictions.

Install boiler so automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service.

Table 2 -

Minimum Clearance Dimensions

Top 6"

Rear 6"

Control Side 7"

Opposite Side 6"

Front Alcove

Flue/Vent Connector

Draft Hood Installation

WARNING

Asphyxiation, carbon monoxide hazard. Failure to follow these instructions could result in improper combustion and possible leakage of combustion products into the living space.

Follow directions given in Figure 8. Attach draft diverter, and blocked vent switch. Mount vent damper. See "Connecting Vent Damper and Vent Connector" page 12. See Wiring Diagrams page 25.

Page 7

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 safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum distance from oor or allowable safe point of discharge.

• Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.

• Have no intervening shutoff valve between safety valve and discharge to atmosphere. Do not plug or

place any obstruction in discharge line.

• Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.

• Allow complete drainage of valve and discharge line.

• Install safety valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety valve.

• Support safety valve discharge piping.

• Be short and straight as possible.

• Terminate with plain end, not threaded.

• Constructed of material suitable for exposure to temperatures of 375° F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.

Figure 3 - Safety Valve

Safety Valve

Discharge Piping

Check local codes

for maximum distance from

oor or other

allowable safe

point of discharge

6" Above Floor

Page 8

SYSTEM PIPING

Consider near boiler piping as part of the boiler for proper water level control and to produce dry steam.

Correct near boiler piping is crucial to proper operation of boiler and heating system.

Follow these recommendations carefully.

Place boiler in selected location as near chimney as possible.

Install safety valve. Figure 3 and Warning on Page 7.

• Install union, if used, close to safety valve outlet.

• Install elbows close to safety valve outlet and

downstream of union (if used).

Boiler is equipped with two 2½" supply connections and two 2½" return connections, one each on both left and right sides of boiler. Plug unused connections with furnished 2½" plug (furnished).

When using both supply tappings to pipe system as shown in Figure 5, Page 10.

• Fit headers with header offsets, swing joints, or equip with expansion joints, so thermal expansion and contraction of header does not damage boiler. Do not weld headers.

13.

For pumped return systems, follow the condensate pump or boiler feed pump manufacturer’s instructions for proper installation and hookup.

14.

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.

For Use With Cooling Units

Install boiler, when used in connection with refrigeration system, so chilled medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering the boiler. See Figure 6.

• Place system takeoffs from header between equalizer and riser to header nearest equalizer. System takeoffs must never be between two risers. If steam main goes in two directions, place two takeoffs from header, one for each main.

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.

All boilers in gravity return systems must be equipped with a Hartford Loop as shown in Figure 5.

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.

Steam riser(s) and header shall be 2½” pipe size.

Equalizer line shall be minimum 1½” pipe size.

10.

The near boiler piping shall include a 2½” tee with a plug located on the supply line as shown for skimming (i.e. surface blowdown).

11.

The near boiler piping shall include a 1-1/2 ball valve in the return piping as shown for bottom blowdown and draining.

12.

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.”

Page 9

SYSTEM PIPING

Figure 4 - Recommended Near Boiler Piping Using One Supply Tapping

Page 10

INSTALLATION - SYSTEM PIPING

Figure 5 - Recommended Near Boiler Piping Using Two Supply Tappings

Figure 6 - Chilled Water Piping

VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING

VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING

Page 11

FRESH AIR FOR COMBUSTION

WARNING

Air openings to combustion area must not be obstructed. Follow instructions below, to maintain adequate 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 applicable provisions of local building codes.

Provide make-up air where exhaust fans, clothes dryers, and kitchen ventilation equipment interfere with proper operation.

National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air. Requirements of the authority having jurisdiction may override these methods.

• Engineered Installations. Must be approved by authority having jurisdiction.

• Mechanical Air Supply. Provide minimum of 0.35 cfm per Mbh for all appliances located within space. Additional requirements where exhaust fans installed. Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all appliances in space. Use a different method if minimum volume not available.

A. Standard Method. See Table 3 for space with natural

gas boiler only. Use equation for multiple appliances and/or propane.

Room Volume is greater than 50 cubic feet multiplied by Total Input [Mbh]

B. Known Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inltration rate air

changes per hour (ACH) greater than 0.60.

Room volume is greater than 21 cubic feet divided by ACH (air changes per hour) x Total Input [Mbh]

C. Refer to National Fuel Gas Code for opening

requirements between connected indoor spaces.

• All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors.

A. Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second opening commencing within 12 inches of bottom of enclosure.

 Direct communication with outdoors or

communicating through vertical ducts. Provide minimum free area of 1 in² per 4 Mbh of total input rating of all appliances in enclosure.

 Communicating through horizontal ducts.

Provide minimum free area of 1 in² per 2 Mbh of total input rating of all appliances in enclosure.

B. One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure. Provide minimum clearance of 1 inch on sides/back and 6 inches on front of boiler (does not supersede clearance to combustible materials).

C. Refer to National Fuel Gas Code for additional

requirements for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to National Fuel Gas Code for application information.

Table 3 - Minimum Room Volume, Indoor Air Only*

Input Mbh

75 3750 15750 7875 5250 3938 3150 2625

112.5 5625 23625 11813 7875 5906 4725 3938

150 7500 31500 15750 10500 7875 6300 5250

187 9350 39270 19635 13090 9818 7854 6545

225 11250 47250 23625 15750 11813 9450 7875

262.5 13125 55125 27563 18375 13781 11025 9188

299 14950 62790 31395 20930 15698 12558 10465

* Table values based on boiler only. Add volume for any additional appliances.

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

Known Air Inltration Rate Method (Air Changes Per Hour)

Page 12

CHIMNEY AND VENT PIPE CONNECTION

WARNING

Installing or venting a boiler or any other gas appliance with improper methods or materials could

result in death or serious injury due to re or to

asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

Boiler and venting installations shall be performed in accordance with "Venting of Equipment", of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.

Chimney Inspection

Chimney must be clean, sized correctly, properly constructed and in good condition. Installation must conform to requirements of the authority having jurisdiction or, in absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54. See Figure 7, page 13.

Connecting The Vent Damper And Vent Connector

Refer to Figure 1 for the size and location of the vent (ue

opening). Use a 28 gauge (minimum) galvanized pipe to connect to the chimney.

Furnished vent damper blade has 1/2 square inch hole (approximately 3/4” diameter). Boilers equipped with intermittent ignition, plug hole using plug supplied with vent damper.

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. Do not modify draft diverter or vent damper

As An Option

Damper may be installed in any horizontal or vertical

position, closer to ue outlet collar preferred. See

Figures 7, 8 and 9.

Install vent damper to service single boiler only for which it is intended. Damper position indicator shall be in visible location following installation. Locate damper so it is accessible for servicing.

Damper must be in open position when appliance main burners are operating.

Boiler is equipped with factory wired harness that plugs into vent damper. Connect thermostat to black wires marked 24 volt thermostat on boiler.

Vent pipe must be same size as ue outlet collar.

Slope pipe up from boiler to chimney not less than 1/4” per foot.

Run pipe as directly as possible with as few elbows as possible.

Do not connect to replace ue.

End of vent pipe must be ush with inside face of chimney ue. Use sealed-in thimble for chimney

connection.

10.

Horizontal run should not be longer than 3/4 the chimney height (HT) Figure 7, page 13.

Vent Pipe

• Fasten sections of vent pipe with 3 sheet metal screws at each joint to make piping rigid.

• Support horizontal portions of vent system to prevent sagging.

• Use stovepipe wires or metal strapping every 5’ to support pipe from above.

• Vent pipe through crawl space, use double wall vent pipe.

• Vent pipe passing through combustible wall or partition, use ventilated metal thimble. Thimble should be 4" larger in diameter than vent pipe.

NOTICE

Minimum Vent Pipe Clearance - Wood and other combustible materials must not be closer than 6” from any surface of single wall metal vent pipe. Listed Type B vent pipe or other listed venting systems shall be installed in accordance with their listing.

Removing Existing Boiler From Common Venting System

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

Seal any unused openings in the common venting system.

Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion and other deciencies

which could cause an unsafe condition.

Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a

summer exhaust fan. Close replace dampers.

Page 13

CHIMNEY AND VENT PIPE CONNECTION

3 FT (914mm)

MIN.

2 FT (610mm)

MIN.

Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame of

a match or candle, or smoke from a cigarette, cigar or pipe.

After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return

doors, windows, exhaust fans, replace dampers and

any other gas-burning appliance to their previous conditions of use.

Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When re-sizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Figure 7 - Typical Masonry Chimney Requirements

Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

Page 14

VENT DAMPER OPERATION

WARNING

Asphyxiation or burn hazard. Improper installation and operation of vent damper could result in serious

injury or death due to re or to asphyxiation from

poisonous gases such as carbon monoxide which is odorless and invisible.

Vent Damper Installation - Follow all cautions and notes.

• Install vent damper to service only single appliance for which it is intended.

• Do not install vent damper with 6" (15mm) of combustible material.

• Do not install vent damper on vent pipe curve.

• Do not run wires near high temperature surfaces. Use

standoff brackets if necessary.

• Install vent damper with actuator to sides of vent only. Do not mount above or below vent.

Check vent damper and all ue product carrying

areas of boiler annually for deterioration from corrosion or other sources. If you see corrosion or other deterioration, contact your service agent for repairs. Check vent damper operation as follows:

When boiler is off, check vent damper positions indicator points to closed position. See Figure 10.

Turn thermostat or controller up to call for heat and check vent damper indicator points to open position See Figure 10.

Turn thermostat or controller down again and check damper position indicator returns to closed position.

Return thermostat to desired position.

Inspect vent damper at least once a year by trained service technician.

Figure 8 - Horizontal Installation

Horizontal Installation

YES YES

Install vent damper

with actuator to sides

of vent only. Do not

vent.

Actuator may be installer in

any position.

To Boiler

Chimney

To Boiler

Flow

Vent Damper

Flow

Chimney

mount above or below

Vent Damper

Figure 9 - Alternate Vent Damper Installation

Caution: Do not

install Vent Damper

within 6" (152mm)

of combustible

material

Install Damper Here

Do Not

Install

Here

Chimney

Manual Operation of Vent Damper

• Place vent damper in open position to permit burner operation by using “HOLD DAMPER OPEN” switch, located on damper controller.

• Thermostat controls burner ring as before, while

damper remains open.

• DO NOT turn damper open manually, motor damage will result.

• Set switch to “AUTOMATIC OPERATION” to close vent damper during burner off cycle.

• For further information, and for vent damper troubleshooting guide, refer to manual packaged with vent damper.

Boiler

Figure 10 - Vent Damper Position Indicator

Flue Gas

Flow

Damper Closed

CLOSED

OPEN

ROTATION

Flue Gas Flow

Damper Open

OPEN

CLOSED

Showing Open and Closed Positions

ROTATION

Page 15

GAS SUPPLY PIPING

3” Minimum

Sediment

Trap

Manifold

Floor Line

Automatic

Gas Valve

Ground

Joint

Union

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 re

department.

General

• Use piping materials and joining methods acceptable

to authority having jurisdiction. In absence of such requirements National Fuel gas Code, ANSI Z223.1/ NFPA 54.

• Size and install gas piping system to provide sufcient

gas supply to meet maximum input at not less than minimum supply pressure.

See Tables 4a and 4b.

Table - 4a Gas Pipe Sizes - Natural Gas

Length of Pipe

- Ft.

Pipe Capacity - BTU Per Hour Input

Includes Fittings

1/2" 3/4" 1" 1 -1/4"

20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000 60 50,000 105,000 195,000 365,000

Table - 4b Gas Pipe Sizes - Propane Gas

Length of Pipe

- Ft.

Pipe Capacity - BTU Per Hour Input

Includes Fittings

5/8" 3/4" 1/2" 3/4"

20 131,000 216,000 189,000 393,000 40 90,000 145,000 129,000 267,000 60 72,000 121,000 103,000 217,000

Propane Installation

WARNING

Fire, explosion, asphyxiation hazard. Verify boiler

is equipped with propane gas orices and gas valve is congured for propane. Failure to follow these

instructions may result in serious injury or death.

•

Connections by licensed propane dealer only.

•

Use two stage regulator provided by propane supplier.

•

Have propane supplier check piping.

DANGER

Fire Hazard. Do not use matches, candles, open

ames, or other methods providing ignition source.

Failure to comply will result in death or serious injury.

Leak Check Gas Piping

Pressure test boiler and gas connection before placing boiler in operation. Avoid excessive pressure that could damage pressure regulators, valves, or meters.

•

Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manual gas shutoff valve.

•

Locate leakage using gas detector, noncorrosive

detection uid, or other leak detection method

acceptable to authority having jurisdiction. Do not

use matches, candles, open ames, or other methods

providing ignition source.

•

Correct leaks immediately and retest.

Figure 11 - Gas Piping At Boiler

* Outside diameter

Length of pipe or tubing should be measured from the gas meter or propane second stage regulator.

• Support piping with hooks straps, bands, brackets,

hangers, or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection. Gas valve will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for

natural and liqueed petroleum gas.

• Install eld sourced manual main shutoff valve, ground

joint union, and sediment trap upstream of gas valve. See Figure 11.

Page 16

ELECTRICAL WIRING

WARNING

Electronic Thermostats

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

NOTICE

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Electric Power Supply

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to

National Electrical Code, ANSI/NFPA 70.

Line Voltage Connections

A. Provide individual 120V, 15 amp circuit

(recommended) with fused disconnect or service

switch as required by authority having jurisdiction. B. Locate a shut-off switch at the boiler. C. Connect 115V electrical supply to primary leads on

24 volt transformer. Securely fasten with wire nuts. D. Set heat anticipator at 0.6 amps for boilers

equipped with intermittent ignition. Connect 24

volt thermostat leads to two wires tagged “24 volt

thermostat” on boiler. E. Boilers with 67D-1 oat type low water cut-off, two

wires are black. One wire is located on secondary

of 24 volt transformer, second wire is located on

pressure limit control. F. Boilers with PS-802 probe type low water cut-

off, one wire is green and is located on terminal

B of PS-802, second wire is black and located on

pressure limit control.

VENT DAMPER

Boiler is equipped with factory wired 4 pin molex harness, that plugs into 4 pin molex receptacle inside vent damper control.

Vent damper must be connected for boiler to operate.

Figure 12a - Isolation Relay Wiring For Steam Boilers With Float Type Low Water Cut Off And Use of Electronic Thermostat

Figure 12b - Isolation Relay Wiring For Steam Boilers With Probe Type Low Water Cut Off And Use of Electronic Thermostat

A. Some electronic thermostats may lose their

memory or shut down. With probe type low water cutoff, this may occur each time low water cutoff detects low water condition. If this is the case, an isolation relay is required for thermostat circuit. A 24 volt single pole single throw (SPST) normally open (N.O.) relay is required, such as Honeywell R8222A or equivalent. Wire as shown in Figure 12a or Figure 12b.

B. Some electronic thermostats are not acceptable

for use with steam systems, check manufacturer suggested use.

Thermostat Installation

Install thermostat on inside wall per manufacturer's

instructions.

NEVER install thermostat on outside wall.

Do not install thermostat where it will be affected by

drafts, hot or cold pipes, sunlight, lighting xtures, televisions, replace, or chimney.

Check thermostat operation by raising and lowering thermostat setting as required to start and stop burners.

Instructions for nal adjustment of thermostat see manufacturer's instructions.

Page 17

OPERATING INSTRUCTIONS

For Your Safety Read Before Operating

WARNING

If you do not follow these instructions

exactly, a re or explosion may result

causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area for gas. Be sure to smell next to oor because

some gas is heavier than air and will settle to the

oor.

• Use only your hand to turn the gas shutoff valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualied

service technician. Force or attempted repair may

result in re or explosion.

• Do not use this appliance if any part has been under water. Immediately call a qualied

service technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

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 re

department.

STOP! Read the safety information on this page.

Set the thermostat to lowest setting.

Turn off all electric power to the appliance.

This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

Figure 13 - Gas Valve

Remove lower front panel.

Rotate the gas control knob clockwise to“OFF”.

Wait ve (5) minutes to clear out any gas. Then smell for gas, including near the oor. If you smell gas,

STOP! Follow “B” in the safety information on this page If you don’t smell gas, go to next step.

Rotate the gas control knob counterclockwise to “ON.”

Replace lower front panel.

10.

Turn on all electric power to the appliance.

11.

Set thermostat to desired setting.

12.

If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

Set the thermostat to lowest setting.

Turn off all electric power to the appliance if service is to be performed.

Push in gas control knob slightly and turn clockwise

to “OFF” Do not force.

Page 18

OPERATING YOUR BOILER

WARNING

Burn Hazard. Never run water into a hot empty boiler. Failure to follow these instructions could result in death or serious injury.

Filling System With Water

Steam heating systems boiler is partially lled with water.

Fill boiler to correct level for proper system operation. Correct water level is about halfway up glass water level

gauge as marked on boiler jacket.

Close boiler drain valve.

Open valves at top and bottom of glass water level gauge.

Open ll valve. Allow water to run into boiler.

Allow boiler to ll until water runs out gauge drain

valve. Then close gauge drain valve.

Continue to ll boiler until water reaches indicated

water line about halfway up glass gauge.

Water Level

• Normal water level is 24" above the oor as shown on

left side of boiler.

Thermostat

A. Set thermostat to desired room temperature. B. Set thermostat to lower setting if heat is not

required

C. System is self-checking. If failure of any component

system will not operate or will go into safety lockout.

D. On call for heat, each component must function

properly to permit operation.

E. Turn thermostat to lowest setting for one minute

and back to normal setting to reset on safety lockout.

• Determine water level when boiler is off and cold, when all water in the system is inside the boiler and return piping below water line, and everything above water line is air, no steam.

• When boiler is making steam, water level drops two to three inches below normal water line.

Page 19

CHECKING AND ADJUSTING

Adjust Pilot Burner

Pilot ame should surround 3/8” to 1/2” of pilot sensor. See

Figure 15. To adjust Flame.

Remove screw cover over pilot adjusting screw. See Figure 13.

Insert small screwdriver and adjust ame as needed. Turn screw counterclockwise to increase ame, clock-

wise to decrease.

Replace screw cover over pilot adjusting screw.

Figure 14 - Igniter

Main Burners

• Main burners do not require primary air adjustment and are not equipped with primary air shutters.

• Main burner ames form sharp blue inner cones in

softer blue outer mantel, with no yellow. Remain still

when observing main burner ames.

• Check main burner orices, burner throat and ame ports for dust and lint obstruction if ame appearance

is not correct.

• Remove rollout shield if necessary to observe main burner ames.

• Replace rollout shield after observation.

Figure 15 - Main Burner

Gas Valve Safety Shutdown Test

Test ignition system safety shutoff device after placing boiler in operation.

Boilers equipped with intermittent ignition, with

main burners ring, disconnect ignition cable from

intermittent pilot control box. Gas valve will shut off main burners.

TURN OFF ELECTRIC POWER to boiler before reconnecting ignition cable, to prevent electric shock.

Page 20

CHECKING AND ADJUSTING

Adjust Steam Pressure Control

• Steam pressure limit control (pressuretrol) shuts off gas to main burners when steam pressure in boiler reaches cut-off setpoint (i.e. sum of cut-in and differential setpoints).

• Burners rere when steam pressure drops to cut-in

setpoint.

• System pressure requirements are based on size and condition of pipes, and load.

• Cut-in setting of pressuretrol should never be less than twice system pressure drop for good system operation.

A. In typical single family residence with clean one-

pipe heating system and cast iron radiation, cut-in is usually set at minimum setting, i.e. 1/2 psi.

• Steam radiation is sized based on square feet of equivalent direct radiation (EDR). This is based on steam pressure in the radiator of just less than 2 psi.

• Set differential adjustment at 1 psi, i.e. steam pressure required in radiators. Results in cut-off setpoint of 1½ psi.

• Larger systems or other types of systems such as two pipe systems, or systems with convectors or fan coil units, pressuretrol settings need to be determined on system-by-system basis.

• Cut-in setpoint is determined by system pressure drop to furthest radiator or terminal unit. Double system pressure drop as safety factor, resulting in the rule cut-in setting should never be less than twice system pressure drop.

• Differential setpoint is steam pressure required at terminal heating units.

Boiler Equipped With Optional WF-2U-24 Water Feeder

E. Continue thermostat call for heat after low water

cut off recognizes low water condition.

F. One minute time delay, water feeder starts feeding

water to boiler.

G. Feeder feeds for one minute, and then goes into

another one minute waiting period.

H. Cycle of alternately waiting and feeding will repeat

until :

• For Model 67D-1 oat type low water cutoffs - as the water level raises the oat above the burner

cut off switch level, the burners should ignite. The water feeder remains powered until the water

level raises the oat to the water feeder switch

level, satisfying the water feeder.

• For probe type low water cutoffs - the water level will rise until water in the boiler makes contact with the probe, satisfying the water feeder, and igniting the burners.

I. In either case, one and two inches of water should

be visible in glass gauge when both water feeder is

satised, and burners are allowed to ignite.

• Time delays in feed cycles are designed to prevent boiler from ooding due to slow return lines.

• To check pressure limit, run boiler until pressure

reaches system demand. Turn pressure screw and drop pressure setting until boiler shuts down. This shows the pressure limit is operating properly.

• Refer to control manufacturer’s instructions for more information.

Boiler will now operate in correct pressure range. It maintains enough steam pressure to send steam out to furthest radiator, and not go over optimum steam pressure required at the radiators.

Checking Controls

Low Water Cut-Off

A. Turn off power to boiler or turn thermostat down to

lowest setting.

B. Drain water to below visible bottom of water gauge

glass. Turn power on and turn thermostat to call for heat.

C. Gas valve opens for approximately 10 seconds

(time delay on probe type LWCO), gas valve will close and red indicator illuminates on LWCO.

D. When water is restored, it waits 30 seconds before

reactivating burner circuit.

Check Thermostat Operation

Thermostat set above temperature indicated on thermometer, boiler should ignite.

Verify thermostat turns boiler off when room temperature reaches selected setting and starts boiler operating when room temperature falls few degrees.

Set thermostat for desired temperature. Conditions in your home and location of thermostat will govern this setting.

Page 21

START-UP CLEANING

WARNING

Following service procedures must be performed

by qualied service agent. Boiler owner shall not

attempt these steps. Failure to do so could result in

death or serious injury.

It is very important to clean a new steam boiler after it has been installed and put into continuous operation.

This must be done to remove any accumulation of oil, grease, sludge, etc., that may have be present in system. These substances may cause boiler water to foam and surge, producing an unsteady water line, throwing water into steam header, and possibly preventing steam generation.

Follow skimming and blow-down steps in order to remove contaminants.

Skimming and Blow-down

WARNING

Burn Scald Hazard. Water temperatures in excess of 125°F. Failure to follow these instructions could result in death or serious injury.

New boilers must be skimmed at time of installation to

remove threading oil and other impurities that oat on

surface of water.

Remove cap from skimmer female adapter tee and pipe

to oor drain or bucket. See Figures 4 and 5 page 9.

Raise water level to skimmer tapping.

Fire burners to maintain water temperature of 180200°F.

Feed water to boiler to maintain water level. Adjust

water feed rate to maintain continuous ow of 1 gallon

per minute. Do not allow boiler to steam.

Continue skimming until water runs clear. This may take several hours.

Drain boiler completely to remove any foreign material.

Fill boiler to water line.

• Fire burners, allow normal steam pressure to build up.

Clean water with no additives is essential to proper operation of your boiler and heating system. Boiler cleaners and chemical cleaning, if used and not rinsed properly, may be harmful to the system

If cleaning is necessary, repeat skimming and blow-down procedure above. A long skim will be all you need to clean the boiler.

In more troublesome cases it may be desirable to ush the

system while, in very extreme cases, it may be necessary

to chemically clean and ush heating system.

Consult boiler manufacturer before introducing any chemicals into boiler.

Check water level frequently. Be sure top and bottom valves on gauge are always open so actual water level is shown at all times.

• Maintain at least 180°F for 15 minutes to remove

dissolved gasses from fresh water.

• Shut off burners.

Allow system to operate for one week to give majority of system dirt a chance to work its way back to boiler.

• Check water in gauge glass. Gauge glass should be

dry above water line.

• Water line should not bounce more than one inch

when boiler is steaming.

• If you see water droplets carrying over from top of

gauge glass, or excessive bouncing of water line, boiler needs further cleaning.

• Take water sample and boil it on stove to see if it

foams. If it does, this indicates boiler needs to be cleaned.

NOTICE

• Run connection from boiler drain valve to safe discharge point outside.

• Shut off gas burners, open drain valve, allow all of water in boiler to drain out.

• Close drain valve.

• Allow boiler to cool, slowly rell boiler to water line.

• Repeat this step as many times as necessary until

blow-down water is clear.

Following nal blow-down, allow boiler to cool.

• Add fresh water slowly up to normal water line.

• Start burners.

Page 22

GENERAL MAINTENANCE

Low Water Cut-Off

Low Water Cut-Off interrupts electrical current to burner when water line in boiler drops to low level.

Check Low Water Cut-Off monthly to verify it is providing proper protection. See “Checking and Adjusting” on page

21. Remove Low Water Cut-Off probes beginning of each

heating season for inspection and cleaning. More cleaning may be required on boilers requiring frequent additions of make up water.

Boiler Flue Passages and Burners

Beginning of heating season visually check pilot and main

burner ames. See page 19. Recommend you have ue passages, burner adjustment,

and operation of controls checked once each year by trained Service Technician.

Before start of each season or whenever system has been shut down for some time, check system, boiler and vent pipe for leaks.

Boiler Water Treatment Other Than Cleaners

In steam systems where system is tight, free from leaks, and all steam is returned to boiler as condensate, amount of make up water is small. Water treatment is generally not required.

In steam systems with less than 90% of steam being returned as condensate, or with very hard or corrosive make up water, treatment may be desirable. Follow recommendations of your local boiler water treatment specialist.

Foaming, Priming, or Surging

These terms are used to describe a uctuating water line

when water leaves boiler with steam. It is caused by any combination of following:

1. Threading oil and organic matter in boiler water. Follow

Vent Pipe

Check vent piping at lease once a season. Verify vent pipe connections to chimney are secure and no obstructions are present. If vent piping shows sign of leaking, replace it immediately.

Safety Valve

See Manufacturer's Instructions.

instructions under “Start-up Cleaning.” Faulty quick vents that do not release air until sizeable

pressure is built up - if old style, replace - if dirty, clean until you can easily blow through valve.

Adjustment of steam limit control to wide differential

increases difculty if quick vents are old style, slow-

releasing type or dirty. Always set steam limit control differential as low as possible.

Soap and chemicals in boiler water cause extreme surging. Boiler cleaners and chemical cleaning additives are not recommended. If used and not rinsed properly, may be harmful to the system.

Cleaning Boiler Flue Passages and Burners

1. Remove burners, pilot, vent pipe, top and front jacket

panels. Remove hold-down nuts and bolts from ue

collector.

2. Use putty knife to cut through silicone. Lift ue collector off boiler sections. Remove old silicone material.

3. Clean passageways between sections with ue brush. Remove dirt from bottom of boiler and from between sections by vacuuming.

4. Verify all ame ports in burners are open and clear. Shake or blow out loose dirt in burners.

5. Apply generous bead of 400°F RTV silicone to four

mounting surface anges of ue collector. Mount ue

collector on heat exchanger. Tighten nuts and bolts.

6. Seal front edge and four corners of ue collector to heat exchanger with silicone sealant.

7. Use ashlight to verify there are no gaps in silicone seal.

8. Install draft diverter, vent damper, vent pipe, and jacket top and front cover.

9. Reassemble all parts.

10. Check tightness of pilot connections and condition of

burner ames after reassembly. See Figures 14 and 15.

Page 23

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.

• Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re

department.

IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

Possible Cause What to do

Thermostat is not set correctly

Burner is not operating properly

No electric power to boiler

Controls out of adjustment

Radiators not heating

Poor electrical contact

Reset thermostat above room temperature.

Inspect ame. If yellow, burner is not getting enough air. If blue and noisy and

seems to lift off burner, burner is getting too much air. Contact service technician.

Verify electric power supply circuit is “ON”. Contact your service technician to verify over current protection.

Reset according to instructions.

Inspect steam air vents for proper operation. Contact service technician to inspect for faulty steam traps.

Contact your service technician to inspect all control terminals and wire joints.

Rollout switch blown

Chimney ue is blocked

Vent damper not operating

Have your service technician check heat exchanger for blockage.

Spill switch contacts open, requiring manual reset of spill switch. Have your service technician check and correct chimney problem.

Consult troubleshooting guide, packaged with vent damper.

IF BURNER IS NOISY . . .

Gas input amount is incorrect Contact your service technician.

IF WALLS OR WINDOWS SWEAT . . .

Not enough ventilation Contact your service technician

Chimney ue is blocked Contact service technician to inspect and correct, if necessary.

IF RADIATORS ARE NOISY . . .

Air in system refer to "Radiators Not Heating" above

SAFETY VALVE LEAKING . . .

Dirt on seat

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

Contact service technician.

Page 24

WIRING DIAGRAMS

Figure 13 - Wiring Diagrams For Boilers With PS-802 Probe Type Low Water Cut-Off

Shown PS802

Terminals PS802 To CG400 Cross Reference

PS802 CG400

N 2

H 1

C P1

E P2

W A

If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.

Page 25

WIRING DIAGRAMS

Figure 17 - Wiring Diagrams For Boilers With 67D-1 Float Type Low Water Cut-Off

If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.

Page 26

CONTROLS AND ACCESSORIES

SAFETY VALVE

Safety valve is designed to open automatically if boiler steam pressure exceeds pressure rating of valve (15 psig). Should it fail to open under this condition, shut down your boiler. If valve discharge occurs, or valve fails to open as described

above, contact a qualied service technician to replace safety

valve and inspect heating system to determine cause, as this may indicate equipment malfunction.

STEAM PRESSURE GAUGE

Boiler is equipped with pressure gauge installed. Gauge enables monitoring of the pressure in the system. If safety devices fail to shut off your boiler at proper settings, notify your serviceman immediately.

WATER LEVEL GAUGE

Boiler water level can be seen through glass tube in water level gauge at side of boiler. Correct cold boiler water level is stamped on side jacket panel. Check water level regularly for proper level.

Located on right side of boiler jacket panel, there are three holes for glass water level gauge. Top hole is common for both types of low water cut off, and is used for upper gauge

glass tting. Middle hole, 9” down from top hole, is used for bottom gauge glass tting for the Model 67D-1 and 47-2 oat type low water cut off. Lowest hole, 121/4” down from top hole, is used for bottom gauge glass tting for Model

PS-802 probe type low water cut off. Cover unused with sheet metal knockout.

STEAM PRESSURE CONTROL

Steam pressure limit control (pressuretrol) shuts off gas to main burners when steam pressure in boiler reaches cutoff setpoint (i.e. sum of cut-in and differential setpoints).

Burners rere when steam pressure drops to cut-in

setpoint. System pressure requirements are based on size and condition of pipes, and load.

WATER FEEDER (Optional)

Model WF-2U-24 water feeder maybe used with either of the low water cutoffs listed. Water feeder maintains safe minimum water level. Keeps boiler running by compensating for minor evaporative steam leaks, and prevents freeze-ups if homeowners are away and return line leaks. McDonnell and Miller Model 101 water feeders may be

used, however water feed rates are too high and need to be regulated or throttled and wiring will have to be revised. Consult boiler manufacturer before using these or any other non-standard types of controls.

Automatic water feeder is safety device, not convenience item. It is not designed to maintain “normal” water line. Water feeder does not take place of responsible person monitoring and maintaining normal water line. Steam boilers require attention.

VENT DAMPER

Automatic, motorized stack damper developed to increase

efciency of heating systems by reducing standby losses

from boiler and conditioned air space. Damper closes chimney vent when burner is off and fully opens it when combustion is required.

ROLLOUT SWITCH (FLAME ROLLOUT SAFETY SHUTOFF)

Rollout switch is temperature-sensitive fuse link device.

Located on boiler base just outside re box. In event of heat exchanger ueway blockage causing ame to roll out of re box, fuse will blow, shutting down ow of gas to main

burners. Fuse does not change in appearance when blown.

If rollout switch blows, replace with exact replacement.

Check heat exchanger ueways for blockage when

restoring system to operating condition. Do not operate system without rollout switch.

LOW WATER CUT-OFF Model 67D-1

Float operated switch which shuts down gas burner if water falls below visible bottom of gauge glass.

Probe Type Models

Electronic probe type LWCO. Probe is located inside boiler. LWCO will shut down burners if water loses contact with probe for 10 seconds.

Refer to manufacturer’s instructions (enclosed) for more information.

SPILL SWITCH (BLOCKED VENT SAFETY SHUTOFF)

Spill switch is manual reset disc thermostat with xed

setpoint (280° F), and normally closed contacts. It is located at relief opening of draft diverter. In event of chimney or venting system blockage causing products of combustion to spill out of relief opening, spill switch disc heats up and

spill switch contacts open, shutting down ow of gas to main

burners by removing power to gas valve. In event spill switch contacts open, reset button on back of

switch will pop up. Manually reset spill switch after switch has cooled off, push reset button down. Check venting system and chimney for blockage when restoring system to operating condition. DO NOT operate boiler without spill switch.

Page 27