Lennox GWB8-280E-2, GWB8-262E-2, GWB8-245E-2, GWB8-299E-2 User Manual

PRODUCT LITERATURE

Lennox Industries Inc. Dallas, Texas

INSTALLATION

INSTRUCTIONS

GWB8-262E-2 GWB8-245E-2 GWB8-299E-2 GWB8-280E-2

GAS FIRED BOILER

RETAIN THESE INSTRUCTIONS FOR

FUTURE REFERENCE

These instructions must be afﬁ xed on

or adjacent to the boiler .

This boiler cannot be used with all types of chimneys. Read these instructions carefully

before installing.

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 qualiﬁ ed 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 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.

C.S.A. Certiﬁ ed for

Natural gas or Propane

Tested for 50 psi. ASME

Working Pressure

P/N# 240009276, Rev. A [03/2012]

Figure 1 - Dimensions

1 - DIMENSIONS

Table 1 - Dimensions

DIMENSIONS

BOILER MODEL NUMBER

GWB8-245E-2/GWB8-262E-2

GWB8-280E-2/GWB8-299E-2

Add 5½” to height for vent Damper.

FLUE

DIAMETER

(INCH.)

“A”

WIDTH

727½

7 30¾

2 - BOILER RATINGS AND CAPACITIES

Table 2 - Ratings and Capacities

† NATURAL GAS † PROPANE GAS AFUE

(2)

BOILER MODEL NUMBER

(1)

Input

(3)

Mbh

Heating

Capacity

(3)

Mbh

NET AHRI

RATING

Water,

(3)

Mbh

GWB8-262E-2 262.5 220 191

GWB8-299E-2

299 251 218

GWB8-245E-2

GWB8-280E-2

†

Input rating for sea level to 2,000 ft. (610m) above sea level.

HIGH

ALTITUDE

INPUT

(3)

Mbh

236

269

INPUT

(3)

Mbh

HEATING

CAPACITY

(3)

Mbh

245 206 179

280 235 204

• United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m)

above sea level.

• *Canada, 2000 ft (610m) to 4500 (1350m) above sea level, reduce input per table. Over 4500 ft

(1350m) above sea level. Contact Provincial authority having jurisdiction.

+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.

NET

AHRI

RATING

Water,

(3)

Mbh

HIGH

ALTITUDE

INPUT

(3)

Mbh

220

252

INTERMITTENT

IGNITION

WITH VENT

DAMPER

83.9

83.7

83.9

83.7

(2)

Net AHRI Water rating shown based on piping and pickup allowance of 1.15. Consult manufacturer before

selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

(3)

Mbh = 1,000 Btuh = British Thermal Unit Per Hour

- Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or terminal units. Net AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on AHRI Standard as published by The Hydronics Institute.

- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of the building.

- Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.

BOILERS FOR USE AT HIGH ALTITUDE

Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner oriﬁ ce size.

For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54, or manufacturer for correct oriﬁ ce sizing information. In Canada, a high altitude conversion kit is available to convert to altitudes of 2,000 to 4,500 feet above sea level. Please consult your dealer.

3 - TABLE OF CONTENTS

1 - Dimensions .................................................... 2

2 - Ratings And Capacities .................................... 3

3 - Table of Contents ............................................4

4 - Installation Procedure .....................................5

5 - Ventilation & Combustion Air ............................6

6 - Connecting Supply And Return Piping ................7

7 - Chimney And Vent Pipe Connection ................. 11

8 - Vent Damper Operation ................................. 14

9 - Gas Supply Piping ......................................... 15

10 - Electrical Wiring .......................................... 15

11 - Wiring Diagrams ......................................... 16

12 - General Instructions .................................... 19

13 - Lighting Instructions ................................... 20

14 - Operating Your Boiler .................................. 21

15 - Maintaining Your Boiler ................................ 23

16 - Service Hints .............................................. 24

17 - Equipment And Optional Accessories ............ 25

Appendix A - Control Module ............................... 27

SAFETY SYMBOLS & WARNINGS

The following deﬁ ned symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

DANGER

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

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions COMPLETELY before installing!!

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.

WARNING

Keep boiler area clear and free from combustible materials, gasoline and other ﬂ ammable vapors and liquids.

DO NOT obstruct air openings to the boiler room. Modiﬁ cation, substitution or elimination of factory

equipped, supplied or speciﬁ ed components may result in personal injury or loss of life.

TO THE OWNER - Installation and service of this boiler must be performed by a qualiﬁ ed installer.

TO THE INSTALLER - Leave all instructions with boiler for future reference.

When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter.

WARNING

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

CAUTION

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

NOTICE

Used to address practices not related to personal injury.

4 - INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury

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/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically ﬁ red Boilers, ANSI/ASME CSD-1.

Boiler series is classiﬁ ed as a Category I. Vent installation shall be in accordance with "Venting of Equipment ," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances," of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

Boiler has met safe lighting and other performance criteria with the gas manifold and control assembly on the boiler per the latest revision of ANSI Z21.13/CGA

4.9.

Install boiler such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service, (circulator replacement, condensate trap, control replacement, etc.).

Locate boiler on level, solid base as near chimney as possible and centrally located with respect to heat distribution system as practical.

Allow 24 inches (610mm ) at front and right side for servicing and cleaning.

When installed in utility room, door should be wide enough to allow largest boiler part to enter, or to permit replacement of another appliance such as water heater.

WARNING

Fire hazard. Do not install boiler on combustible ﬂ ooring or carpeting. Failure to follow these instructions could result in death or serious injury.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY - For installation on combustible

ﬂ ooring special base must be used. (See Replacement

Parts Section.) Boiler can not be installed on

carpeting.

Table 3 -

Top 6” (152mm)

Rear 6” (152mm)

Control Side 7” (178mm)

Opposite Side 6” (152mm)

Front

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1/2” (13mm)

NOTE: Greater clearances for access should supersede fire

* Deﬁ nition of Alcove is three sided space with no wall in front of boiler. ANSI standard for alcove is 18 inches from front of appliance to leading edge of side walls as shown below.

MINIMUM CLEARANCE DIMENSIONS

Inches (mm)

18” (457mm)

protection clearances.

Minimum Clearances to Combustible

Construction (as seen from above)

BOILER

Control

Side

Front

18"

5 - VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local

building codes.

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 allowable room volume for all appliances in space. Use a different method if minimum volume not available.

A. Standard Method. Cannot be used if known air

inﬁ ltration rate is less than 0.40 air changes per hour. See Table 4 for space with boiler only. Use equation for multiple appliances.

Volume ≥ 50 ft

B. Known Air Inﬁ ltration Rate. See Table 4 for

space with boiler only. Use equation for multiple appliances. Do not use an air inﬁ ltration rate (ACH) greater than 0.60.

Volume ≥ 21 ft3⁄ACH x Total Input [Mbh]

C. Refer to National Fuel Gas Code for opening

requirements between connected indoor spaces.

x Total Input [Mbh]

• All Outdoor Air. Provide permanent opening(s)

• Refer to National Fuel Gas Code for additional

• Combination Indoor and Outdoor Air. Refer to National

Canada

National Gas and Propane Installation Code Requires providing air supply in accordance with:

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).

requirements for louvers, grilles, screens and air ducts.

Fuel Gas Code for application information.

• Section 8.2 and 8.3 when combination of appliances has a total input of up to and including 400 Mbh (120 kW).

• Section 8.4 when combination of appliances has total input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code for speciﬁ c air supply requirements for enclosure or structure where boiler is installed, including air supply openings and ducts.

Table 4 - Minimum Room Volume, Indoor Air Only*

Room Cubic Feet Volume

Input Mbh

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

Known Air Inﬁ ltration Rate Method (Air Changes Per Hour)

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.

6 - CONNECTING SUPPLY AND RETURN 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 oor or allowable safe point of discharge;

• be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line;

• have no intervening shutoff valve between safety relief 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 the valve and the discharge line;

• be independently supported and securely anchored to avoid applied stress on the relief valve;

• be as short and straight as possible;

• terminate with plain end (not threaded);

• be 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 2 - Safety Relief Valve

DISCHARGE

LINE

Check local

codes for

maximum

distance

from ﬂ oor or allowable safe point of

discharge.

RELIEF VALVE

6 - CONNECTING SUPPLY AND RETURN PIPING

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

Boiler is shipped assembled. Install discharge piping from safety relief valve. See Warning, Page 7.

Install temperature pressure gauge.

• Apply pipe sealant to threads on shaft of gauge.

• Thread gauge into supply water tee. See Figure 3.

NOTICE

DO NOT TIGHTEN GAUGE BY HAND!! Gauge should be tightened using crescent wrench or 9/16” open end wrench. See Figure 3.

Connect supply and return lines to boiler. Connections may require additional ﬁ ttings and parts, as shown on diagrams.

Figure 3 - Temperature Pressure Gauge

Verify clean water supply is available to water inlet valve. Install sand strainer when water supply is from a well or pump.

Install hot water boiler above radiation level or as required by Authority having jurisdiction install low water cutoff device at time of installation. Periodic inspection is necessary, as is ﬂ ushing of ﬂ oat type devices, per manufacturers speciﬁ c instruction.

FOR USE WITH COOLING UNITS

A. Boiler used in connection with refrigeration

system, must be installed so that chilled medium is piped in parallel with heating boiler. Appropriate valves must be used to prevent chilled medium from entering heating boiler. See Figure 5 page 9.

B. Boiler connected to heating coils located in air

handling units where they may be exposed to refrigerated air circulation, piping system shall be equipped with ﬂ ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

LOW WATER TEMPERATURE AND LARGE WATER CONTENT SYSTEM (See Figures 6 and 7, Page 10.)

Signiﬁ cant condensation may form in boiler and/or venting system if boiler is operated for long period of time with return temperatures of less than 120° F.

Condensate is corrosive and can cause severe damage to boiler and venting system. Minimum design return water temperature to prevent condensation in boiler and venting is 120°F. Minimum high limit setting is 140°F.

Boiler used in heating system where design water temperatures below 140°F are desired (e.g. radiant ﬂ oor heating), 4-way mixing valve or suitable alternative is required to prevent low temperature return water from entering boiler. Follow mixing valve manufacturer’s instructions.

Boiler connected to system having large water content (such as former gravity system), install system bypass. See Figures 6 and 7, page 10.

If boiler water reset control is used to operate boiler, minimum reset supply water temperature setpoint must be at least 140°F, unless mixing valve is used as in (1) above.

6 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Typical Hot Water Piping

Figure 5 - Chilled Water Piping

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

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