Lennox International Inc. GSB8-E, GSB8-S User Manual

PRODUCT LITERATURE

WARNING

Lennox Industries Inc. Dallas, Texas

INSTALLATION

INSTRUCTIONS

GSB8-E

GAS-FIRED STEAM BOILER

GSB8-S

GAS-FIRED STEAM BOILER

RETAIN THESE INSTRUCTIONS

FOR

FUTURE REFERENCE

These instructions must be

afﬁ xed on or adjacent to the

boiler.

GAS-FIRED HOT WATER BOILERS

These Gas-Fired Water Boilers are low pressure, sectional cast iron boilers Design Certified by CSA (Canadian Standards Association) for use with Natural and Propane Gases. They are constructed and hydrostatically tested for a maximum working pressure of 50 psi (pounds per square inch) in accordance with A.S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV: Rules for Construction of Heating Boilers.

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.

P/N# 14683453, Rev. A [07/2011]

TABLE OF CONTENTS

Safety Symbols .............................................................................................................. 3

Boiler Ratings And Capacities ........................................................................................... 4

Before You Start ............................................................................................................. 5

Locating The Boiler ......................................................................................................... 5

Fresh Air For Combustion................................................................................................. 6

Installation - System Piping ............................................................................................. 7

Chimney And Vent Pipe Connection ................................................................................. 10

Vent Damper Operation ................................................................................................. 11

Gas Supply Piping ......................................................................................................... 12

Electrical Wiring ........................................................................................................... 14

Controls And Accessories ............................................................................................... 20

Operating Instructions ................................................................................................... 22

Intermittent Ignition Boiler - VR8204A/VR8304M Gas Valve Operating Instructions ................ 22

Continuous Pilot Boiler - VR8200A/VR8300A Gas Valve Operating Instructions ...................... 23

Operating Instructions ................................................................................................... 24

Checking and Adjusting ................................................................................................. 25

Cleaning Your Boiler ...................................................................................................... 27

Maintaining Your Boiler .................................................................................................. 28

Service Hints ............................................................................................................... 30

Repair Parts ................................................................................................................. 31

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

GSB8-E

GAS-FIRED STEAM BOILER

GSB8-S

GAS-FIRED STEAM BOILER

SAFETY SYMBOLS

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.

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, may result in minor or moderate injury.

READ ALL INSTRUCTIONS BEFORE INSTALLING.

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 property damage, personal injury or the loss of life.

To owner: Installation and service of this boiler must be performed by qualiﬁ ed installer.

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

NOTICE

Indicates information which should be followed to ensure proper installation and operation.

To installer: Leave all instructions with boiler for future reference.

WARNING

All installations of boilers and venting should be done only by a qualiﬁ ed expert and in accordance with the appropriate Installation, Operation and Maintenance manual.

Installing or venting a boiler or any 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 which is odorless and invisible.

Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

United States

•

National Fuel Gas Code, ANSI Z223.1/NFPA 54•

National Electrical Code, NFPA 70.•

Canada •

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

Canadian Electrical Code, Part I, Safety Standard • for Electrical Installations, CSA C22.1

Figure 1 - Dimensions

BOILER RATINGS AND CAPACITIES

BOILER SPECIFICATIONS

Natural gas Propane

Model No.

Type of Ignition

Input *MBH (KW)

GSB8-075E Electronic

GSB8-075S Standing Pilot 81.1

GSB8-112E Electronic

GSB8-112S Standing Pilot 78.8

GSB8-150E Electronic

GSB8-150S Standing Pilot 79.2

GSB8187E Electronic

GSB8187S Standing Pilot 79.6

GSB8-225E Electronic

GSB8-225S Standing Pilot 80.1

GSB8-262E Electronic

GSB8-262S Standing Pilot 80.5

GSB8-299E Electronic

GSB8-299S Standing Pilot 80.9

75,000

(22.0)

112,500

(33.0)

105,000

(44.0)

187,000

(54.8)

225,000

(65.9)

262,000

(76.9)

299,000

(87.6)

*MBH (KW)

Heating Capacity

62,000

(18.5)

91,000

(26.7)

122,000

(35.7)

153,000

(44.8)

183,000

(53.6)

214,000

(62.7)

245,000

(71.8)

(KW)

Net I=B=R *MBH

47,000

(14.7)

68,000

(19.9)

92,000

(27.0)

115,000

(33.7)

137,000

(40.1)

161,000

(47.2)

184,000

(53.9)

sq.ft. Radiation

Net I=B=R Rating

196

(18.2)

283

(26.3)

383

(35.6)

479

(44.5)

571

(53.0)

671

(62.3)

767

(71.3)

Input *MBH (KW)

70,000

(20.0)

105,000

(30.8)

140,000

(41.0)

175,000

(51.3)

210,000

(61.5)

245,000

(71.8)

280,000

(82.0)

Heating Capacity

58,000

(16.1)

85,000

(24.9)

114,000

(33.4)

143,000

(41.9)

171,000

(50.1)

200,000

(58.6)

229,000

(67.1)

Net I=B=R

*MBH (KW)

*MBH(KW)

44,000

(13.0)

64,000

(18.6)

86,000

(25.2)

107,000

(31.4)

128,000

(37.5)

150,000

(44.0)

172,000

(50.4)

(17.0)

(24.8)

(33.3)

(41.4)

(51.4)

(58.1)

(66.7)

sq.ft. Radiation

Net I=B=R Rating

82.7

183

80.4

267

80.6

358

80.9

446

81.1

553

81.3

625

81.5

717

AFUE %

Number of Sections

round

Diameter in. (mm)

Flue Size Connection

(12.7)

(15.2)

(17.8)

325

(147)

404

(183)

483

(219)

564

(256)

649

(294)

719

(326)

800

(363)

(kg) Package

Sipping Weight Lbs.

tion NPT in. (mm)

Supply & Return Connec-

2-1/2

(64.0)

in. (mm)

Drain Connection NPT

3/4

(19.0)

* MBH = 1,000 Btuh. Btuh = British Thermal Unit Per Hour. ** Add 5½" to height for Vent Damper † 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 sufﬁ x 'P' for Propane Gas.

BEFORE YOU START

Net I=B=R steam Ratings shown are based on piping and pickup allowance of 1.333.

Base selection of boiler size on "Net I=B=R Rating" being equal to or greater than installed radiation in square feet. Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements,such as intermittent system operation, exhaust piping systems, etc. Speciﬁ cations and dimensions are subject to change without notice.

For elevations above 2000 ft. (600m):

USA - Reduce input rate 4% for each 1,000 ft (300m) • above sea level.

Canada - Boiler certiﬁ ed for altitudes of 0-2000 ft • (610m) above sea level. Reduce input rate 10% for altitudes 2000-4500 ft (610-1350) above sea level. Contact Provincial authority having jurisdiction for

installations above 4500 feet (1350 m) above sea level. Verify you have right size boiler before starting installation. See rating and capacity table on previous page. Verify boiler is for type of gas you are using. Check rating plate on right side of boiler.

Verify boiler is supplied with correct type of gas, fresh air for combustion, and suitable electrical supply. Also, boiler must be connected to suitable venting system and adequate piping system. Finally, thermostat, properly located, is needed for control of heating system. If you have any doubts as to various requirements, check with local authorities and obtain professional help where needed. Take time to complete all steps for SAFE and PROPER operation of heating system.

If this boiler is installed in building under construction, special care must be taken to insure clean combustion air supply during construction process. Airborne particulates such as from drywall dust and from ﬁ berglass insulation can clog burner ports and cause incomplete combustion and sooting.

Boilers are designed for use in closed heating systems where all steam is returned to boiler as condensate and amount of make-up water required is minimal. Boilers are not designed for or intended for use in open systems of process applications using 100% make-up water. Damage to boiler resulting from such use shall not be covered under warranty.

Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

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

Following steps are all necessary for proper installation and safe operation of your boiler.

1. LOCATING THE BOILER 5. GAS SUPPLY PIPING

2. FRESH AIR FOR COMBUSTION 6. ELECTRICAL WIRING

3. INSTALLATION - SYSTEM PIPING 7. CHECKING & ADJUSTING

4. CHIMNEY & VENT PIPE CONNECTION

LOCATING THE BOILER

Select level location as centralized with piping system,

and as near chimney as possible.

Place crated boiler at selected location, remove crate

by pulling crate sides from top and bottom boards.

Combustible ﬂ oors: When boiler is to be installed on

combustible ﬂ oor, Special Base Plate must be used -

146-14-031 (2-6 Section) or 146-14-032 (7-9 Section).

This boiler must not be installed on carpeting.

Boiler is to be level. Metal shims may be used under

base legs for ﬁ nal leveling.

Equipment shall be installed in location in which

facilities for ventilation permit satisfactory combustion

of gas, proper venting, and maintenance of ambient

temperature at safe limits under normal conditions of

use. Equipment shall be located so as not to interfere

with proper circulation of air. When normal inﬁ ltration

does not provide necessary air, outside air shall be

introduced (See Page 6 - “Fresh Air for Combustion”).

Advise owner to keep air passages free of obstructions.

Ventilating and combustion air must enter boiler room

without restrictions.

United States •

National Fuel Gas Code, ANSI Z223.1/NFPA 54. • National Electrical Code, NFPA 70.•

Canada •

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

Canadian Electrical Code, Part I, Safety Standard for • Electrical Installations, CSA C22.1

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

Table - 1 Minimum Clearance

Dimensions

Top 6" (16 cm)

Rear 6" (16 cm)

Control Side 7" (18 cm)

Opposite Side 6" (16 cm)

Front Alcove

Flue/Vent Connector 6" (16 cm)

Near Boiler Piping 1" (2.5 cm)

Unit must be set on concrete or other non-combustible material base or ﬂ oor.

FRESH AIR FOR COMBUSTION

WARNING

Air openings to combustion area must not be obstructed. Following instructions below, adequate combustion air can be maintained.

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 volume for all •

appliances in space. Use a different method if

minimum volume not available.

Standard Method. Cannot be used if known air A. inﬁ ltration rate is 0.40 air changes per hour. See Table 1 for space with natural gas boiler only. Use equation for multiple appliances and/or propane.

Volume ≥ 50 ft

Known Air Inﬁ ltration Rate. See Table 1 for B. space with boiler only. Use equation for multiple appliances. Do not use an air inﬁ ltration rate (ACH) greater than 0.60.

Volume ≥

Refer to National Fuel Gas Code for opening C. requirements between connected indoor spaces.

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

Two Permanent Opening Method. Provide opening A. 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.

One Permanent Opening Method. Provide opening B. 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).

Refer to National Fuel Gas Code for additional C. requirements for louvers, grilles, screens and air ducts.

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

x Total Input [Mbh]

21 ft3⁄ACH x Total Input [Mbh]

Table 3 - Minimum Room Volume, Indoor Air Only*

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)

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 255 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.

INSTALLATION - SYSTEM PIPING

WARNING

Burn and scald hazard. Safety valve could

discharge steam or hot water during operation. Install discharge piping per these instructions

Near boiler piping, that is the piping around boiler, must be considered as part of boiler for proper water level control, and to produce dry steam. Correct near boiler piping is crucial to the proper operation of the boiler and the heating system. Follow these recommendations carefully.

Place boiler in selected location, as near chimney as

possible. Install safety valve, using furnished 3/4” coupling, into

3/4” pipe nipple on top of boiler.

Install safety valve with spindle in vertical position.•

Do no install shutoff valve between boiler and safety • valve.

Install discharge piping from safety valve. See Figure •

Use 3/4" or larger pipe.•

Use pipe suitable for temperatures of 375°F (191°C) • or greater.

Individual boiler discharge piping shall be • independent of other discharge piping.

Size and arrange discharge piping to avoid reducing • safety valve relieving capacity below minimum relief valve capacity stated on rating plate.

Run pipe as short and straight as possible to location • protecting user from scalding and properly drain piping.

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

Install elbow(s), if used, close to safety valve outlet • and downstream of union (if used).

Terminate pipe with plain end (not threaded).•

This boiler is equipped with two 2-1/2” supply connections and two 2-1/2” return connections, one each on both the left and right sides of the boiler. Unused connections must be plugged with the 2-1/2” plugs (furnished).

Figure 2 - Recommended Near Boiler Piping Using One Supply Tapping

INSTALLATION - SYSTEM PIPING

Recommended near boiler piping for gravity return

systems is shown in Figure 5. This conﬁ guration uses one supply and one return tapping. This setup can be used on any size boiler in this series. The supply and return connections may be piped both into the same side (either left or right) or one into each side of the boiler.

For installers choosing to use both supply tappings,

Figure 6A shows the correct way to pipe this system. Figure 6B shows the wrong way to pipe a header with

two risers.

Headers must be ﬁ tted with header offsets or swing • joints, or be equipped with expansion joints, so that thermal expansion and contraction of the header will not damage the boiler. Headers shall not be welded.

System takeoffs from the header must be between • the equalizer and the riser to the header nearest the equalizer. System takeoffs must never be between two risers.

Figure 3A - Recommended Near Boiler Piping Using One Supply Tapping

System takeoffs from the header must never be bull-

headed. If the steam main goes in two directions, there must be two takeoffs from

main.

All boilers in gravity return systems

with a Hartford Loop as shown in Figures 2 and 3A. 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 2-1/2” pipe size.

Equalizer line shall be minimum 1-1/2” pipe size.

10.

The near boiler piping shall include a 2-1/2” tee with a

11.

plug located on the supply line as shown for skimming (i.e. surface blowdown).

The near boiler piping shall include a 1-1/2 ball valve

12.

in the return piping as shown for bottom blowdown and draining.

the header, one for each

must be equipped

INSTALLATION - SYSTEM PIPING

For gravity return systems, the bottom of the lowest

13.

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.” For pumped return systems, follow the condensate

14.

pump or boiler feed pump manufacturer’s instructions for proper installation and hookup.

In connecting the cold water supply to the water inlet

15.

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

The boiler, when used in connection with a A. refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. See Figure 4.

Figure 3B - Common Near Boiler Piping Mistakes

Figure 4 - Chilled Water Piping

VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING

VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING

CHIMNEY AND VENT PIPE CONNECTION

For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with 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

This is a very important part of your heating system. It must be clean, the right size, properly constructed and in GOOD CONDITION. No boiler can function properly with a bad chimney. Inspect the chimney and verify that the construction and size of the chimney meets all applicable provisions of the National Fuel Gas Code and local building codes. Figure 4 gives you an idea how a boiler might be vented to a chimney. Note that the height (HT) is measured from the vent pipe to the top.

CONNECTING THE VENT DAMPER AND VENT CONNECTOR

Refer to Fig. 1 and Table 1 for the size and location of the vent (ﬂ ue opening). Use a 28 gauge (minimum) galvanized pipe to connect to the chimney.

IMPORTANT - The damper blade on the furnished vent

damper has a 1/2 square inch hole (approximately 3/4” diameter). On boilers equipped with standing pilot, the hole must be left open. On boilers equipped with intermittent ignition, the hole should be plugged by using the plug supplied with the vent damper.

Position furnished vent damper on top of ﬂ ue outlet collar. Fasten damper securely to ﬂ 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

The damper may be installed in any horizontal or vertical position, closer to the ﬂ ue outlet collar

preferred. Follow the diagrams - Figures 6, 7 and 8. Install the vent damper to service only the single boiler

for which it is intended. The damper position indicator shall be in a visible location following installation. Locate the damper so that it is accessible for servicing.

The damper must be in the open position when

appliance main burners are operating. The boiler is equipped with a factory wired harness

that plugs into the vent damper. The thermostat must be connected to the black wires marked 24 volt thermostat on the boiler.

Vent pipe must be same size as the ﬂ 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 ﬁ replace ﬂ ue.

10.

The sections of vent pipe should be fastened with sheet metal screws to make the piping rigid. Horizontal portions of the vent system must be supported to prevent sagging. Use stovepipe wires every 5’ to support the pipe from above. If the vent pipe must go through a crawl space, double wall vent pipe should be used. Where vent pipe passes through a combustible wall or partition, use a ventilated metal thimble. The thimble should be 4 inches larger in diameter than the vent pipe.

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.

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

Horizontal run should not be longer than 3/4 the chimney height (HT) (Fig.5).

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.

CHIMNEY AND VENT PIPE CONNECTION

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.

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

Figure 5 - Typical Masonry Chimney Requirements

Figure 6 - Horizontal Installation

VENT DAMPER OPERATION

Figure 7 - Alternate Vent Damper Installation

TYPICAL INSTALLATION FOR VENT DAMPER

NOTE CAUTION AND FOOTNOTES

Install the vent damper to service only the single

appliance for which it is intended. If improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result.

Do not install the vent damper on vent pipe curve.

Do not run wires near high temperature surfaces.

Use stand-off brackets if necessary.

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