Lennox International Inc. GWB8-075IE-2, GWB8-042IE-2, GWB8-187IE-2, GWB8-150IE-2, GWB8-112IE-2 User Manual

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PRODUCT LITERATURE

Lennox Industries Inc. Dallas, Texas

INSTALLATION

INSTRUCTIONS

GWB8-042IE-2, GWB8-075IE-2

GWB8-112IE-2, GWB8-150IE-2

GWB8-187IE-2, GWB8-225IE-2

GAS FIRED BOILER

RETAIN THESE INSTRUCTIONS FOR

FUTURE REFERENCE

These instructions must be afﬁ xed on

or adjacent to the boiler .

WARNING

Improper installation, adjustment, alteration, service, or maintenance could result in death or serious injury. Refer to this manual for assistance. For additional information consult a qualiﬁ ed installer, service agency, or the gas supplier.

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

before installing.

C.S.A. Certiﬁ ed

For Natural Gas Or Propane

Tested For 50 psi.

ASME

Working Pressure

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.

P/N# 240009135, Rev. C [06/2012]

TABLE OF CONTENTS

Boiler Ratings & Capacities...................... 3

Dimensions ............................................. 4

Installation Procedure ............................. 5

Ventilation & Combustion Air .................. 6

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

Vent Installation ................................... 10

Optional Horizontal Venting Instruction 13

Gas supply Piping .................................. 14

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

Sequence of Operation .......................... 15

Wiring Diagrams ................................... 18

Starting Your Boiler ............................... 19

Checking and Adjusting ......................... 21

Maintaining Your Boiler ......................... 23

Service Hints ......................................... 24

Equipment & Optional Accessories ........ 25

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

A.1 Installation Environment Considerations .27

A.2 Electrical Connections .......................... 27

A.3 Adjusting Settings ............................... 27

A.4 Display .............................................. 27

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

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

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.

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

A.5 Operation .......................................... 28

A.6 Boiler High Limit Temperature Controller 29

A.7 Troubleshooting .................................. 29

A.8 Troubleshooting Error Codes ................. 29

A.9 Intermittent Pilot ................................ 30

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 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 Commonwealth of Massachusetts installation must be performed by Licensed Plumber or Licensed Gas Fitter.

BOILER RATINGS & CAPACITIES

Table 1 RATINGS NATURAL AND PROPANE GASES

**Net

Model

GWB8-042IE-2 42.5 36 31 84.4 4 3

GWB8-075IE-2 75.0 63 55 83.4 4 3

GWB8-112IE-2 112.5 94 82 83.0 4 3

GWB8-150IE-2 150.0 125 109 82.7 4 3

GWB8-187IE-2 187.5 155 135 82.3 4 4

GWB8-225IE-2 225.0 186 162 82.0 4 4

* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only.

Input *Mbh

Heating

Capacity

*Mbh

AHRI

Rating

Water

*Mbh

AFUE

Vent Diameter (Inches)

To Chimney

(Category I)

Horizontal Vent

(Category III)

• U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level.

• Canada Only - Boilers may be used at high altitude (2,000-4500 feet/640-1350m) by using a certiﬁ ed ﬁ eld conversion kit, resulting in a 10% de-rate. Contact Provincial authority having jurisdiction for

installations above 4500 ft (1350m)above sea level.+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.

** Net AHRI Water Ratings i

ndicate amount of remaining heat input that can be used to heat the radiation or terminal units. Net AHRI Ratings shown are based on an allowance of 1.15 Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of building.

Manufacturer should be consulted before selecting a boiler for installations having unusual piping

and pickup requirements.

New York City MEA Number 484-84-E Vol. IV.

This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing. These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron boilers Design Certiﬁ ed by C.S.A. (Canadian Standards

Association) for use with Natural and Propane Gases. Constructed and hydrostatically tested for maximum working pressure of 50 psi in accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.

Boilers must stand on noncombustible ﬂ oor. If installed on combustible ﬂ oor, please refer to Repair Parts manual for appropriate Combustible Floor Base part number.

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.

U.S.A. Only - 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, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1, or manufacturer for correct oriﬁ ce sizing information.

Canada Only - For altitudes in the range of 2,000-4,500 feet (610 - 1350m) above sea level, boilers may be ﬁ eld equipped for use at high altitude by using a certiﬁ ed ﬁ eld conversion kit. The change in main burner oriﬁ ce size results in the boiler’s input rating being reduced by 10%.The conversion shall be carried out by a manufacturer’s authorized representative, in accordance with the requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in accordance with the requirements of CSA-B149 Natural Gas and Propane Installation Code. The certiﬁ ed ﬁ eld conversion kit includes a conversion data plate, which must be attached to the boiler adjacent to the rating plate, indicating that the boiler has been converted for high altitude use. The conversion data plate must be ﬁ lled in with the correct conversion information.

For altitudes over 4500 feet (1350m), contact Provincial authority having jurisdiction.

DIMENSIONS

Model Width (A)

GWB8-042IE-2 11 GWB8-075IE-2 14-1/4 GWB8-112IE-2 17-1/2 GWB8-150IE-2 20-3/4 GWB8-187IE-2 24 GWB8-225IE-2 27-1/4

INSTALLATION PROCEDURE

WARNING

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

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1

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

This 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 gas manifold and control assembly on boiler per latest revision of ANSI Z21.13/CGA 4.9.

Install 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.

Verify you have the right size boiler before starting installation. See rating and capacity table.

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.

Boiler installed in building under construction, take care 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.

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.

NOTICE

Follow local regulations with respect to installation of CO detectors.

10.

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

ﬂ ooring special base must be used. (See Replacement Parts Section.) Do Not Install Boiler on carpeting.

11.

Verify boiler is supplied with correct type of gas, fresh air for combustion, and suitable electrical supply.

Figure 1 - Minimum Clearances To Combustible

Construction

6”

8”

Rear

Opposite Side

6”

Boiler

Front

18”

Table 2 - BOILER MINIMUM CLEARANCE TO

COMBUSTIBLES

Unit

Top 6” (152mm)

Rear 6” (152mm)

Control Side 8” (203mm)

Opposite Side 6” (152mm)

Front (Alcove) 18” (457mm)

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1/2” (13mm)

Control Side

8”

Minimum

Clearances

Set unit on concrete or other noncombustible material base or ﬂ oor. DO NOT INSTALL ON CARPETING.

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 jurisdictions.

• 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.

о Standard Method. Cannot be used if known air

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

inﬁ ltration rate is less than 0.40 air changes per hour. See Table 3 for space with boiler only. Use equation for multiple appliances.

Volume ≥ 50 ft

x Total Input [Mbh]

о Known Air Inﬁ ltration Rate. See Table 3 for

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

Volume ≥ 15 ft3/ACH x Total Input [Mbh]

о Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

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

о Two Permanent Opening Method. Provide opening

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

 Direct communication with outdoors or

communicating through vertical ducts. Provide minimum free area of 1 in

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.

о One Permanent Opening Method. Provide opening

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

о Combination Indoor and Outdoor Air. Refer to

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

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

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

о Does not have draft control device.

• 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 3- Air Inﬁ ltration Rate

Input Mbh

Standard

Method

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

0.1 0.2 0.3 0.4 0.5 0.6

42.5 2125 6375 3188 2125 1594 1275 1063

75 3750 11250 5625 3750 2813 2250 1875

112.5 5625 16875 8438 5625 4219 3375 2813

150 7500 22500 11250 7500 5625 4500 3750

187.5 9375 28125 14063 9375 7031 5625 4688

225 11250 33750 16875 11250 8438 6750 5625

INSTALLATION SYSTEM PIPING

WARNING

Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

• connect to 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; or greater.

Refer to local codes and appropriate ANSI/ASME Boiler and Pressure Vessel Code, Section IV, or Boiler, Pressure Vessel and Pressure Piping Code, CSA B51 for additional installation requirements.

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

Install relief valve on 3/4” pipe nipple in tapped boiler opening.

A. Pipe discharge line following guidelines in preceding

Warning. See Figure 2.

B. Discharge line pipe size shall be equal or greater

than that of relief valve outlet over entire length of discharge line with no intervening shutoff valve between safety relief valve and discharge to atmosphere.

C. Discharge line shall terminate with plain end to

atmosphere where any discharge will be clearly visible and is at no risk of freezing.

D. Discharge line shall be independently supported to

avoid applied stress on relief valve.

E. Installation shall allow complete drainage of relief

valve and discharge line.

Install Drain Valve on lower left side of boiler as marked.

Install Temperature and Pressure Gauge into ¼” bushing threaded in tee furnished with supply piping. See

Figures 3 and 4

Connect Supply and Return Lines to boiler. Figure 3 &

4. Connections may require certain additional ﬁ ttings and parts.

Figure 2 - Safety Relief Valve Discharge Piping

RELIEF VALVE

DISCHARGE

PIPING

Check local codes

for maximum

distance from

ﬂ oor or other

allowable safe

point of discharge

INSTALLATION SYSTEM PIPING

Figure 3 -

Forced Hot Water Typical Piping

Figure 4 - Forced Hot Water Typical Piping

With Zone Control Valve

INSTALLATION SYSTEM PIPING

• Install radiation units (panels, radiators or cabinets) and supply and return mains ﬁ rst then make connections at boiler.

• Verify clean water supply is available when connecting cold water supply to water valve. Install sand strainer at pump when water supply is from well or pump.

• Provide low water cutoff device when boiler is installed above radiation level or as required by the Authority having jurisdiction, either provide as part of boiler or at time of boiler installation. Periodic inspection is necessary, as is ﬂ ushing of ﬂ oat type devices, per manufacturers speciﬁ c instructions.

• Boiler used in connection with refrigeration systems shall be installed so chilled medium is piped in parallel with heating boiler with appropriate valves to prevent chilled medium from entering heating boiler. See

• Boiler connected to heating coils located in air handling units 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.

Figure 5

Low Design Water Temperature Systems (Below 140°F) And Large Water Content Systems

Condensation is corrosive and can eventually cause severe damage to boiler and venting system.

• Minimum design return water temperature to prevent

• Boiler used in heating systems where design water

• Boiler connected to system having large water content

condensation in boiler and venting is 120°F. Minimum high limit setting is 140°F.

temperatures below 140°F are desired (e.g. radiant ﬂ oor heating), a 3-way or 4-way mixing valve or suitable alternative is required to prevent low temperature return water from entering boiler. When using mixing valve, follow manufacturer’s installation instructions.

(such as former gravity system), suggest use of bypass piping. See

Figure 6

Figure 5

- Piping Arrangements For Boiler When Used In Connection With Refrigeration System

Figure 6

- Bypass Piping

VENT INSTALLATION

Check Your Chimney

Chimney must be clean, right size, properly constructed and in GOOD CONDITION.

Installation must conform to requirements of the authority having jurisdiction or, in absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes..

Boiler’s induced draft blower has 3” outlet. 3” X 4” increaser ﬁ tting is included in parts bag. Locate increaser ﬁ tting on outlet of induced draft blower, and secure gas-tight with bead of furnished silicone sealant. Increaser ﬁ tting is required on this boiler for Category I venting, and 4” is minimum permissible vent diameter. This does not imply vent connector is intended to be 4” diameter pipe. Vent connector shall be sized according to appropriate venting tables in the National Fuel Gas Code and may be required to be larger than 4” diameter.

NOTICE

Boiler installation for chimney venting is not complete unless increaser ﬁ tting is located and secured.

These are high efﬁ ciency boilers with low stack or exhaust temperature.

Venting into masonry chimney without liner, line chimney from top to bottom with either:

A. Listed Type B vent pipe B. Listed ﬂ exible vent liner C. Poured ceramic liner.

11.

Fasten sections of vent pipe with sheet metal screws to make piping rigid. Use stovepipe wires to support pipe from above.

12.

Do not connect to ﬁ replace ﬂ ue.

13.

Do not install damper on this boiler.

Minimum Vent Pipe Clearance

• Use Type B vent pipe 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.

• Boiler installed with single wall vent, must have 6” clearance between its surface and any combustible material. New Type B gas vent or ﬂ exible liner must be installed in accordance with instructions furnished with vent. Maintain clearances as speciﬁ ed for vent pipe.

• Verify vent pipe is ﬁ re-stopped where it goes through ﬂ oor or ceiling. It should have approved vent cap with clearances from roof. If clearances are less than shown in have vent checked by local authorities. See Figure 7, Page 11.

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

Outside chimneys should not be used unless they are (choose one of the following):

A. Enclosed in a chase B. Lined with Type B vent pipe C. Use listed ﬂ exible vent liner D. Use certiﬁ ed chimney lining system

Vent connector from boiler to chimney should run as directly as possible with as few elbows as possible.

Where possible, it is recommended to common vent water heater and boiler. Consult appropriate Vent Sizing Tables in National Fuel Gas Code for speciﬁ c requirements of multiple appliance venting.

Boiler is only appliance connected to vent, Type B vent pipe is recommended for vent connector.

Slope pipe up from boiler to chimney not less than 1/4” per foot (21mm/m).

10.

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

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