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

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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

7 - CHIMNEY AND VENT PIPE CONNECTION

WARNING

Boiler and venting installations shall be performed by a qualiﬁ ed expert and in accordance with the appropriate manual. Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due to ﬁ re or to asphyxiation from poisonous gases such as carbon monoxide with is odorless and invisible.

Boilers connecting to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or “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.

Check Your Chimney

It must be clean, right size, properly constructed and in good condition.

Chimney Sizing

Chimney sizing, and vent installation must be in accordance with The National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, or applicable provisions of local building codes.

This is a high efﬁ ciency boiler with low stack temperature. Following recommendations are in addition to requirements of the National Fuel Gas Code.

1. Type B double wall vent pipe is recommended for vent connector. Single wall vent connectors should not be used unless following conditions are true:

a) Except for basement, boiler is not installed in

unheated space.

b) Total horizontal portion of vent connector, not

including elbows is less than 5 feet in length.

2. Outside chimneys (i.e. chimneys exposed to outdoors below roof line) should not be used unless they are:

a) enclosed in a chase, or b) lined with type B vent pipe, or listed ﬂ exible

vent liner, or other certiﬁ ed chimney lining system.

3. Where possible it is recommended to common vent boiler and water heater.

4. For multiple boiler installations, consult boiler manufacturer for venting recommendations.

Connecting The Vent Damper And Vent Connector

Refer to Figure 1, page 2 for size and location of vent (ﬂ ue opening).

NOTICE

Damper blade on furnished vent damper has 1/2 square inch hole (approximately 3/4” diameter). Boilers equipped with intermittent ignition, hole should be plugged by using plug supplied with vent damper.

Position furnished vent damper on top of ﬂ ue outlet collar. Fasten damper securely to ﬂ ue outlet collar with sheet metal screws. Verify damper blade has clearance to operate inside of diverter. Do not modify either draft diverter or vent damper during installation.

As An Option

Damper may be installed in horizontal or vertical position, closer to ﬂ ue outlet collar preferred. See Figures 8, 9 and 10 and enclosed vent damper instructions.

Install vent damper to service only single boiler for which it is intended. Damper position indicator shall be in visible location following installation. Locate damper so it is accessible for servicing. See Figure 9.

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

Boiler is equipped with factory wired harness that plugs into vent damper.

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 ﬁ replace ﬂ ue.

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

Fasten sections of vent pipe with sheet metal screws to make piping rigid. Support horizontal potions of vent system to prevent sagging. Use stovepipe wires every 5’ to support pipe from above. Use double wall vent pipe if vent pipe must go through crawl space. Where vent pipe passes through combustible wall or partition, use ventilated metal thimble. Thimble should be 4 inches larger in diameter than vent pipe.

7 - CHIMNEY AND VENT PIPE CONNECTION

WARNING

Do not connect boiler to any portion of mechanical draft system operating under positive pressure.

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 F rom C ommon Venting System

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

At time of removal of existing boiler, following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to 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 deﬁ 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 ﬁ replace dampers.

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 ﬂ 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, ﬁ 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, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

8 - VENT DAMPER OPERATION

Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement

Annually check vent damper and all ﬂ ue product carrying areas of appliance, with particular attention given to deterioration from corrosion or other sources. If you see corrosion or other deterioration, contact your heating contractor for repairs. Check vent damper operation as follows:

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

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

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

Vent Damper Manual Operation

Vent damper may be placed in open position to permit burner operation by using “HOLD DAMPER OPEN” switch, located on damper controller. Thermostat will control burner ﬁ ring as before, while

damper will remain open. DO NOT turn damper

open manually or motor damage will result. Set switch to “AUTOMATIC OPERATION” to close vent damper during burner off cycle.

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

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

Figure 10 - Vent Damper Position Indicator

9 - GAS SUPPLY PIPING

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 ﬁ re department.

CHECK GAS SUPPLY

Gas pipe to your boiler must be correct size for length of run and for total BTU per hour input of all gas utilization equipment connected to it. See Table 5 for proper size. Be sure your gas line complies with local codes and gas company requirements.

CONNECTING THE GAS PIPING See Figure 11.

Gas line enters boiler from right side.

• Use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements:

• USA - National Fuel gas Code, ANSI Z223.1/NFPA 54

• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1

• Use pipe joint compound suitable for LP gas on male threads only.

• Use ground joint unions.

• Install sediment trap upstream of gas controls.

• Use two pipe wrenches when making connection to gas valve to keep it from turning.

• Install manual shut-off valve in vertical pipe about 5 feet above ﬂ oor.

• Tighten all joints securely.

•

Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

•

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 ﬂ uid, or other leak detection method acceptable to authority having jurisdiction. Do not use matches, candles, open ﬂ ames, or other methods providing ignition source.

•

Correct leaks immediately and retest.

Table 5 - Gas Pipe Sizes

NATURAL GAS

Pipe Capacity - BTU Per Hour Input

Includes Fittings

Length of Pipe - FT

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

Length of

Pipe - FT

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

* Outside diameter Measure length of pipe or tubing from gas meter or

propane second stage regulator.

½” ¾” 1” 1¼”

PROPANE GAS

Pipe Capacity - BTU Per Hour Input

Includes Fittings

Copper Tubing * Iron Pipe

⅝”¾”½”¾”

Figure 11 - Gas Piping

• Propane gas connections should only be made by licensed propane installer.

• Two-stage regulation should be used by propane installer.

• Propane gas piping should be checked out by propane installer.

CHECKING GAS PIPING

DANGER

Fire Hazard. Do not use matches, candles, open ﬂ ames, or other methods providing ignition source. Failure to comply will result in death or serious injury.

Pressure test boiler and gas connection before placing boiler in operation.

10 - ELECTRICAL WIRING

WARNING

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.

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

• USA- National Electrical Code, ANSI/NFPA 70.

• Canada - Canadian Electrical Code, Part I, CSA C22.1:

Safety Standard for Electrical Installations.

ELECTRIC POWER SUPPLY

Run separate 120 volt circuit from separate over current protective device in electrical service entrance panel. This should be a 15 ampere circuit. Locate shut-off switch at boiler. It must be turned off during any maintenance. Connect 120 volt power supply to control leads L1 (HOT) and L2.

Run a 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

VENT DAMPER WIRING

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

Vent damper must be connected for boiler to operate.

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.

THERMOSTAT INSTALLATION

Thermostat should be installed on an inside wall about four feet above the ﬂ oor.

NEVER install thermostat on outside wall.

Do not install a thermostat where it will be affected by drafts, hot or cold pipes, sunlight, lighting ﬁ xtures, televisions, a ﬁ replace, or a chimney.

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

Instructions for the ﬁ nal adjustment of the thermostat are packaged with the thermostat (adjusting heating anticipator, calibration, etc.)

Set heat anticipator at .2 amps. 24 volt thermostat connects to aquastat terminals T and TV.

11 - WIRING DIAGRAMS

Figure 12 - Integrated High Limit Electronic Ignition Control (240008781)

WARNING

Modiﬁ cation, substitution or elimination of factory equipped, supplied or speciﬁ ed components may result in personal injury or loss of life.

Inducer is not an option.

11 - WIRING DIAGRAMS

Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)

11 - WIRING DIAGRAMS

Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)

12 -GENERAL INSTRUCTIONS

FILLING SYSTEM WITH WATER

• Close air vents on all radiation units. Open valves to

these units.

• Verify boiler and expansion tank drain valves are closed.

• Air bleed screw on tank drain ﬁ tting should be closed.

• Open valve in line from boiler to expansion tank. Open

water inlet to your boiler and leave it open. Start with lowest radiation unit. Open air vent on this unit. When all air has escaped and water starts to ﬂ ow from vent, close it.

• Go to next radiation unit, and repeat this process.

Repeat until you have covered every radiation units in the system (ending up at highest unit in system).

• If your units have automatic vents, manual venting is

unnecessary but it will speed up the proper ﬁ lling of your system.

• If your system is closed expansion tank system, you

may leave it open to reﬁ ll system automatically as needed.

• Check temperature pressure gauge. Not position of hand

indicating pressure. This should be between 10 and 15 psi. Any lowering of this movable hand below 10 psi. Will indicate loss of water due to leakage. Automatic ﬁ ll valve should compensate for this. Instructions are packaged with the valve.

NOTICE

Never run water in a hot empty boiler.

13 - LIGHTING INSTRUCTIONS

WARNING

If you do not follow these instructions exactly, a ﬁ 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 ﬂ oor because some gas is heavier than air and will settle to the ﬂ 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 qualiﬁ ed service technician. Force or attempted repair may result in ﬁ re or explosion.

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

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

LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM

For Your Safety, Read Before Operating!!

A. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to light appliance by hand.

CAUTION

WHAT TO DO IF YOU SMELL GAS

5. Remove lower front panel.

6. Rotate the gas control knob clockwise to “OFF”.

Figure 15 - Automatic Gas Valve

PRESSURE REGULATOR (UNDER CAP SCREW)

INLET

PRESSURE

TAP

INLET

GAS CONTROL

KNOB

ADJUSTMENT

OFF

PILOT ADJUSTMENT

(UNDER CAP SCREW)

7. Wait ﬁ ve (5) minutes to clear out any gas. Then

smell for gas, including near the ﬂ oor. If you smell gas, STOP! Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you don’t smell gas, go to next step.

8. Rotate gas control knob counterclockwise to

“ON”.

9. 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

WIRING TERMINALS (2)

OUTLET PRESSURE TAP

GROUND TERMINALS

(2)

OUTLET

PILOT OUTLET

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use any phone in your building.

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

• If you cannot reach your gas supplier, call the ﬁ re department.

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to

light the pilot by hand.

1. Set the thermostat to lowest setting.

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

3. Push in gas control knob slightly and turn clockwise to “OFF” Do not force.

14 - OPERATING YOUR BOILER

AUTOMATIC GAS VALVE

Automatic Gas Valve opens or closes according to heat requirements of thermostat and temperature limit control. It closes if pilot goes out. Each individual control must be operating correctly before any gas can pass to burners. Any one control can hold gas supply from burner regardless of demand of any other control.

SAFETY PILOT

Safety Pilot prevents ﬂ ow of gas to burner if pilot goes out, or will not ignite.

GAS VALVE SAFETY SHUTDOWN TEST

Ignition system safety shutoff device must be tested after placing boiler in operation.

RELIGHT

Electric and gas shall be off for 5 minutes before relighting.

THERMOSTAT

Keep it set at desired room temperature. If windows are to be opened or heat is not needed, move thermostat pointer to lower setting.

Figure 16 - Pilot Flame

MAIN BURNER(S)

NOTICE

In event of failure of any component, system will not operate or will go into safety lockout. System is completely self-checking. On every call for heat, each component must be functioning properly to permit operation. Safety lockout system has to be reset by turning thermostat to lowest setting for one minute, then back to normal setting.

Figure 17 - Burner

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

• Main burner ﬂ ames form sharp blue inner cones in softer blue outer mantel, with no yellow.

• Puffs of air from blowing on ﬂ ame or stamping on ﬂ oor will cause ﬂ ames to turn orange momentarily. This is not unusual. Remain still when observing main burner ﬂ ames.

• If ﬂ ame appearance is not correct, check main burner oriﬁ ces, burner throat and ﬂ ame ports for dust and lint obstruction. It may be necessary to remove rollout shield to observe main burner ﬂ ames. Replace rollout shield after observation. Refer to Figure 17.

ADJUST PILOT BURNER

Pilot ﬂ ame should surround 3/8” to 1/2” of the pilot sensor. See Figure 16. If ﬂ ame needs adjusting, do it as follows:

Remove screw cover over pilot adjusting screw.

Insert small screwdriver and adjust ﬂ ame as needed. Turn screw counterclockwise to increase ﬂ ame, clockwise to decrease.

Replace screw cover over pilot adjusting screw.

ADJUST LIMIT CONTROLS

Instructions for each control are included with controls. Settings can be changed. Refer to Appendix A page 27 for information.

14 - OPERATING YOUR BOILER

CHECK THERMOSTAT OPERATION

A. When set above temperature indicated on

thermostat, boiler should ignite.

B. Verify thermostat turns boiler off when room

temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees.

C. After setting limit control to limit setting, check to

see if it shuts off gas supply to burners. Turn your thermostat up to call for heat and let boiler run until temperature of water reaches limit setting. Gas valve should shut off and circulator running until thermostat is satisﬁ ed, or water cools enough to restart burners through limit control.

D. Set thermostat for desired temperature. Conditions

in your home and location of thermostat will govern this setting.

15 - MAINTAINING YOUR BOILER

BURNERS

Beginning of heating season visually check pilot and main burner ﬂ ames. See Figure 16.

SAFETY RELIEF VALVE

Refer to page 7 for important information. To test safety relief valve refer to valve manufacturer’s instructions packaged with relief valve. Call Technical Support if

manufacturer’s instruction are not located.

EXPANSION TANK

Tank may become waterlogged, or may receive excess of air. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature (and “knocking”) indicates excess air in tank.

To correct:

Close valve between boiler and tank. Drain tank until empty.

Check all tank plugs and ﬁ ttings. Tighten as necessary.

Open valve between boiler and tank. Water will rise to normal height in tank if you have automatic ﬁ ll valve (otherwise, manually reﬁ ll system).

CLEANING YOUR BOILER AND BURNERS

Flue passages between sections should be examined yearly and cleaned if necessary.

To clean:

• Remove burners, pilot, and vent pipe.

• Remove top and front jacket panels.

• Remove two screws attaching intermediate front panel to left and right side jacket panels.

• Remove draft diverter and intermediate front panel together.

• Carefully remove cerafelt gasket strips.

• Clean passageways between sections with ﬂ exible handle wire brush. Remove dirt from bottom of boiler and from between sections by vacuuming.

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

• Reseal seams between adjacent sections as necessary with 400

• Reassemble all parts.

• Verify tightness of pilot connections and condition of burner ﬂ ames after reassembly. See Figures 16 and 17, pages 21.

F RTV silicone sealant.

BOILER FLUE PASSAGES

Recommend following checked annually by qualiﬁ ed service agent.

• ﬂ ue passages

• burner adjustment

• operation of controls

Before start of each season (or whenever system has been shut down for some time) recheck whole system for leaks and recheck boiler and vent pipe for leaks. Replace or patch any boiler seals that are faulty.

VENT PIPE

Venting and piping should be checked at least once a season. If vent piping shows any sign of leaking, replace immediately.

WATER SYSTEM

If system is to remain out of service during freezing weath-

er, always drain it completely (water left in to freeze will

crack pipes and/or boiler).

• Verify vent pipe connections to chimney are secure and

HOUSEKEEPING

no obstructions are present.

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

• Keep boiler area clear of debris and other materials obstructing ﬂ ow of combustion and ventilation air.

16 - SERVICE HINTS

EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO

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 the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

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

You may avoid inconvenience and service calls by checking these points before you call for service.

Possible Cause What to do

Thermostat is not set correctly Reset thermostat above room temperature Burner is not operating properly Check ﬂ ame. If it is yellow, burner is not getting enough air.

Or, if ﬂ ame is blue and noisy and seems to lift off burner, burner is getting too much air. Contact your service technician.

No electric power to boiler Check over current protection. Verify electric power supply circuit is “ON”.

Controls out of adjustment Reset according to instructions. Radiators not heating Open radiator vents to expel air. Check ﬂ ow control valve (if

used). It may be in closed position. Circulating pump not running Check over current protection. Check relay operation. Poor electrical contact Check all control terminals and wire joints. Rollout switch blown Have your service agent check heat exchanged for blockage.

Replace rollout switch with exact replacement. Blocked vent blown Have your service agent check venting system and chimney

for blockage, or down draft condition. Reset blocked vent. Vent damper not operating Consult troubleshooting guide in Efﬁ kal manual, packaged with

vent damper.

IF BURNER IS NOISY . . .

Possible Cause What to do

Gas input amount is incorrect Contact your service agent.

RELIEF VALVE LEAKING . . .

Possible Cause What to do

Dirt on seat Open valve manually. Allow water to run and clear valve seat. Water logged expansion tank Drain tank, see instructions.

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

17 - EQUIPMENT AND OPTIONAL ACCESSORIES

EXPANSION TANK

Expanding water ﬂ ows into expansion tank. Tank should be correct size. Tank is ﬁ lled with air. As water expands it compresses air in the tank to form air pressure cushion. This “spring-like” cushion serves to maintain correct operating water pressure regardless of water temperature. This assures “full measure” of water, even in highest radiation unit of system. It also prevents blowing off of safety relief valve. Air in tank in beginning (with system ﬁ lled with cold water) is sufﬁ cient for proper operation. Tank also serves as trap for excess air in system. Air would cause gurgling in pipes and in efﬁ cient circulation in radiators if left in system.

It is possible for tank to become “waterlogged” (ﬁ lled with water). It can also become overﬁ lled with air. This can hap- pen after ﬁ lling system with new water. Fittings provided on tank and in line to tank are for bleeding off excess water or air.

When installing this tank, it is important:

Tank be higher than boiler top.

Pipe to tank continuously rises up to tank (so air can “bubble” up to it).

AUTOMATIC FILL VALVE

For a safe, efﬁ cient operation, hot water system must be

completely ﬁ lled with water. Adding new water, when

needed can be done manually (by use of hand valve in water supply line). Requires regular attention to system’s needs. Automatic ﬁ ll valve accomplishes this without atten- tion. Install in supply line on hot water boilers only. Valve operates through water pressure differentials. It does not require electrical connection.

DRAIN VALVE

Manual valve provides means of draining all water from boiler and system. It is often installed in 3/4” tapping at bottom of end boiler section. Or it can be installed in tee where return line enters boiler.

WATER TEMPERATURE CONTROL

Water temperature limit control in relay is adjustable and may be set as necessary. It may be set as low as

104°F (40°C), or as high as 220°F (104°C). This depends on type and amount of radiation involved and weather conditions.

DIAPHRAGM TYPE EXPANSION TANK

Diaphragm type expansion tank takes place of conventional expansion tank. Carefully read instructions packed with your tank assembly.

Tank comes with 10-12 pounds per square inch air charge. This is the same as pressure produced in system by automatic ﬁ ll valve. When system is ﬁ rst ﬁ lled, tank will contain little or no water.

As water is heated its pressure increases. It expands into tank, compressing air in tank. Compressed air cushion permits water in system to expand as temperature changes. Diaphragm type tank can be mounted on air purger ﬁ tting or at any convenient place in supply or return line.

AIR ELIMINATING FITTING (AIR PURGER)

Air purger is used to remove excess air from system. It is installed in supply line. It will eliminate air from water before it reaches radiators and bleed off this air.

MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM TYPE EXPANSION TANK

Before system is ﬁ lled with water, there is air in pipes and radiation units. Some of it will be trapped as system is ﬁ lled . It is possible to eliminate most of this air through air vent on radiation units. Main air vent will speed and simplify this. Install on highest point in supply main when all radiation is below top of boiler.

CIRCULATING PUMP

Every forced hot-water system requires circulating pump. Separate pump or zone valve is required for each zone, if you have a two or more zone system. Pump must have capacity to provide circulation required by your system. Pump is connected into main just ahead of boiler. It is also wired to electrical system.

VENT DAMPER

This product is automatic, motorized stack damper developed to increase efﬁ ciency of heating system by reducing standby losses from heating apparatus and conditioned air space. Damper closes chimney vent when burner is off and fully opens it when combustion is required.

17 - EQUIPMENT AND OPTIONAL ACCESSORIES

ROLLOUT SWITCH (FLAME ROLLOUT SAFETY SHUTOFF)

Rollout switch is temperature-sensitive fuse link device. Located on boiler base just outside ﬁ re box. In event of heat exchanger ﬂ ueway blockage causing ﬂ ame to roll out of ﬁ re box, fuse does not change in appearance when blown.

If rollout switch blows, it must be replaced with exact replacement. Check heat exchanger ﬂ ueways for blockage when restoring system to operating condition. DO NOT operate system without rollout switch.

BLOCKED VENT SAFETY SWITCH (BLOCKED VENT SAFETY SHUTOFF)

Blocked vent safety switch is manual reset disc thermostat with ﬁ xed setpoint (340°F (171°C)), and normally closed contacts. It is located at relief opening of integral draft diverter. In event of chimney or venting system blockage causing products of combustion to spill out of relief opening, blocked vent disc heats up and blocked vent contacts open, shutting down ﬂ ow of gas to main burners by removing power to gas valve.

In event blocked vent contacts open, reset button on back of switch will pop up. Blocked vent safety switch must be reset manually, after switch has cooled off, by pushing reset button down. Check venting system and chimney for blockage when restoring system to operating condition. DO NOT operate boiler without Blocked vent safety switch.

APPENDIX A - CONTROL MODULE

A.1 Installation Environment Considerations

WARNING

If you do not follow these instructions exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

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

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

• Do not allow water to drip on controls. Prevent condensation by allowing air circulation around module and gas control.

• Do not use corrosive chemicals around or on module or gas control.

• Controls can be damaged by excessively high

temperatures. Verify adequate air circulation around control is maintained when installing boiler.

A.2 Electrical Connections Connect Module Connectors Figure 14, Page 18

• L1& L2 leads inside J-box using wire nuts. Secure J-

box cover.

• Circulator harness to circulator. Harness comes

plugged into module with Molex® plug.

A.3 Adjusting Settings

To discourage unauthorized changing of settings, procedure to enter adjustment mode is required.

To enter adjustment mode, press UP, DOWN, and I buttons simultaneously for three seconds. Press and release I button until parameter requiring adjustment is displayed.

See Figure 12, page 16.

о “SP_” Setpoint (180 °F default setting; adjustable

between 130 and 220 °F)

о “Df_” Setpoint Differential (15 °F default setting;

adjustable between 10 and 30 °F)

о “°F_” Degrees Fahrenheit

Press UP or DOWN button until parameter has reached desired value. After 60 seconds without any button inputs,

control automatically returns to READ mode.

A.4 Display

In RUN mode, status items and parameters are viewable.

Example, to display setpoint, control ﬂ ashs “sp” (setpoint)

followed by temperature (i.e., 135), followed by °F or °C. To read settings, press and release I key to ﬁ nd parameter

of interest.

Example, press and release I until setpoint (sp) is

displayed, followed by three-digit number, i.e., 190, followed by °F or °C. Press I button again will display (S1T) Sensor 1 Temperature followed by three-digit number and corresponding degree designator.

See Display Readout.

• Thermostat connection to yellow wires marked TT

using wire nuts.

• Ensure remaining Molex® plug connectors have not

worked loose during transit.

• Check sensing bulb is fully inserted in well and is not

loose.

• Refer to enclosed addendum for wiring instructions

when using indirect hot water heater.

Figure 18

- Display Readout

APPENDIX A - CONTROL MODULE

A.5 Operation

Module continuously monitors boiler water temperature and ﬁ res or shuts off burner based on this temperature data.

When “Call for Heat” occurs, control enables circulator and monitors boiler water temperature to determine whether thermostat can be satisﬁ ed without ﬁ ring burners.

Control determines burner operation is required,

module proceeds to start burner (see state codes list) and heats water in boiler until setpoint temperature is achieved or thermostat is satisﬁ ed. .

Burner is de-activated, ignition module completes heating cycle, returns to idle and waits for temperature to drop again.

Circulator is turned on throughout “Call for Heat.”

Table 6 - Operation State Codes

State Code

Number

4 Pre-purge System is purging before ignition trial; includes Pilot Valve circuit diagnostics.

6 Spark System sparking. Flame is not present up to 13 seconds

7 Flame stabilization

8 Running System is running. Flame signal must be present.

9 Post-Purge System is purging at end of call for heat

13 Soft lock-out Soft lockout duration is one hour, may override with manual reset.

14 Hard lock-out Manual reset is required for hard lockout

15 Wait for limit to close Possible thermostat call for heat; limit switch is open.

16 Flame out of sequence

18 Wait for damper to open

19 Wait for damper to close

Current leakage detection

Wait for damper to open

Wait for damper to close

Deﬁ nition Explanation

Idle Standby - no call for heat

Circulator

Retry Recycle Delay

Pilot valve diagnostics Pilot valve circuitry diagnostics during pre-purge.

Wait for recovery

(Failed close)

(Failed open)

Heat request present. Boiler temperature sufﬁ ciently high to run circulator pump only.

Flame signal is being established. Variation in signal is allowed during this state, ﬂ ame must be stable at end of period

Successful ignition was not detected, and delay is called before retry.

Flame signal was lost during state 7 or 8, and delay is called before retry (32 second delay)

Flame signal sensed before trial for ignition. Appropriate alarm is sent.

Flame signal sensed out of sequence during post purge. Appropriate alarm is s ent. OR

Flame signal present when not expected. Appropriate alarm is sent.

Self check performed at start up, again at beginning of heat cycle, and during “Wait for Recovery “ State.

Self check performed at start up, again at beginning of heat cycle, and during “Wait for Recovery “ State

Control has signaled damper/pressure switch to close, and is waiting for completion. If damper/pressure switch does not close within 60 seconds, control goes to State 20.

Damper is closed and control waits for damper to open. Checked at beginning of heat cycle before opening damper. If damper does not open in 60 seconds, control goes to State 21.

Damper has not opened (end swich not closed) at beginning of heat cycle. Alarm message is sent, control is NOT in lockout.

Damper has not closed despite actuator de-energized. Alarm message is sent, control is NOT in lockout.

APPENDIX A - CONTROL MODULE

A.6 Boiler High Limit Temperature Controller

• When water temperature reaches setpoint, controller ends heating cycle.

• When water temperature drops below setpoint minus differential, controller restarts heat cycle to re-heat boiler water.

• If water temperature exceeds maximum allowed temperature (220°F or 104°C), controller enters manual reset lockout state.

• For models having reset capability, press any onboard button or cycle power to reset.

Figure 20 - Basic Control Algorithm Example

A.7 Troubleshooting

• Following service procedures are provided as general guide.

• On lockout and retry models, meter readings between gas control and ignition module must be taken within trial for ignition period. Once ignition module shuts off, lockout models must be reset through key buttons and display. On retry models, wait for retry or reset at thermostat.

• Check for correct installation and wiring before replacing any component.

• Control module cannot be repaired. If it malfunctions, it must be replaced.

• Use only qualiﬁ ed service agent to service ignition systems.

Perform checkout as ﬁ rst step in troubleshooting.

Check troubleshooting guide to pinpoint cause of problem. See Table 7 , page 30.

If troubleshooting indicates ignition problem, see Ignition System Checks to isolate and correct the problem.

Perform checkout procedure following troubleshooting guide again to verify system is operating normally.

A.8 Troubleshooting Error Codes

Integrated boiler control uses advanced diagnostic capability to assist in troubleshooting error conditions.

Table 6 page 28 shows codes that could arise on integrated display during fault.

Suggestions are provided in Table 6 for servicing these potential errors.

APPENDIX A - CONTROL MODULE

Table 7 - Troubleshooting Error Codes

Error Code

Number

4 Flame current too low. Check for ﬂ ame. Non critical alarm

18 Gas valve relays welded. Five consecutive soft lockouts. Hard lockout

55 Atmospheric damper end switch failed to close (end switch contacts stuck open). Wait for recovery

56 Atmospheric damper end switch failed to open (end switch contacts stuck close). Wait for recovery

58 Igniter ﬂ ame rod shorted to burner ground. Repair or replace igniter. Wait for recovery

59 Line Voltage error - voltage out of speciﬁ cation high or low (15-37V (44-66Hz)) Wait for recovery

Flame sensed out of normal sequence (before opening or after closing gas valve).

Flame sensed during prepurge ( before gas valve signaled opened).

Sensor 1 error. Temperature sensor in well is not reading correctly. Verify it is connected to board. Replace if necessary.

Igniter ﬂ ame rod shorted to burner ground

Applies only to thermostats having on-board transformer. Polarity is wrong in this case.

Thermostat input higher than threshold.

Line voltage unstable - possibly too may heavy loads switching on and off causing erratic supply voltage.

Deﬁ nition Consequence

Soft lockout

Wait for recovery

63 Soft lockout: maximum number of recycles exceeded. Soft lockout

64 Soft Lockout - electronics failure. On-board self diagnostics detected error. Soft lockout

Note: Soft lockout time is 1 hour or manual reset. Hard lockout requires manual reset.

A.9 Intermittent Pilot

Ignition System Checks

STEP 1: Check ignition cable.

• Verify ignition cable does not touch metal surfaces.

• Verify only factory supplied Ignition cable (or approved replacement) is used.

• Verify connections to ignition module and igniter or igniter-sensor are clean and tight.

• Verify ignition cable provides good electrical continuity.

Soft lockout: maximum number of retries exceeded.

Soft lockout is reset after one hour if alarm reason disappears.

Over temperature error. Sensor measured temperature in excess of maximum allowable limit.

STEP 2:

Verify ignition system grounding. Nuisance shutdowns are often caused poor or erratic grounding.

Common ground is required for module and pilot burner/ igniter sensor.

— Check for good metal-to-metal contact between pilot burner bracket and the main burner. — Check ground lead from GND (BURNER) terminal

on module to pilot burner. Verify connections are clean and tight. If wire is damaged or deteriorated, replace with No. 14-18 gauge, moisture-resistant, thermoplastic insulated wire with 105°C [221°F] minimum rating.

— Check ceramic ﬂ ame rod insulator for cracks or

evidence of exposure to extreme heat, which can permit leakage to ground. Replace pilot burner/igniter sensor and provide shield if necessary.

Soft lockout

APPENDIX A - CONTROL MODULE

— If ﬂ ame rod or bracket is bent out of position, restore

to correct position.

STEP 3: Check spark ignition circuit.

Disconnect ignition cable at SPARK terminal on module.

WARNING

Electrical shock hazard. Ignition circuit generates over 10,000 volts. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

Energize module and listen for audible sparking noise. When operating normally, there should be buzzing noise turns on and off twice per second for duration of 1–7 seconds, depending on model.

STEP 4: Verify pilot and main burner light-off.

• Initiate call for heat. Turn thermostat above room temperature. Ignition sequence may be delayed by thermal purge until boiler water temperature is below 140°F (60°C)

• Watch pilot burner during ignition sequence.

• Recheck ignition sequence as follows.

— Reconnect main valve wire. — Adjust thermostat above room temperature. — Verify ignition sequence at burner. — If spark does not stop after pilot lights, replace

module.

— If main burner does not light or if main burner lights

and system locks out, check module, ground wire and gas control as described in troubleshooting table. See Table 7, Page 30.

Figure 19 - Troubleshooting Pilot Flame

— Verify ignition spark continues after pilot is lit. — Verify pilot lights and spark stops, verify main

burner does not light.

• If so, ensure adequate ﬂ ame current as follows.

— Turn off boiler at circuit breaker or fuse box. — Clean ﬂ ame rod with emery cloth. — Verify electrical connections are clean and tight.

Replace damaged wire..

— Check for cracked ceramic insulator, which can

cause short to ground, and replace igniter-sensor if necessary.

— At gas valve, disconnect main valve wire from MV

terminal.

— Turn on power and set thermostat to call for heat. Pilot

should light, main burner will remain off because main valve actuator is disconnected.

— Check pilot ﬂ ame. Verify it is blue, steady and

envelops 3/8 to 1/2 in. [10 to 13 mm] of ﬂ ame rod. See Figure 19 for possible ﬂ ame problems and causes.

— If necessary, adjust pilot ﬂ ame by turning pilot

adjustment screw on gas control clockwise to decrease or counterclockwise to increase pilot ﬂ ame. Following adjustment, always replace pilot adjustment cover screw and tighten ﬁ rmly to assure proper gas control operation. Figure 16, page 20.

— Set temperature below room set-point to end call for

heat.

Correct Pilot Flame: 3/8 to 1/2 inch in ﬂ ame. See Figure 16, Page 21.

PRODUCT LITERATURE

Lennox Industries Inc.

Dallas, Texas

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

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

Specifications and Main Features

Frequently Asked Questions

User Manual