INSTALLATION
INSTRUCTIONS
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
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 affixed on
or adjacent to the boiler.
!
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
qualified installer, service agency, or
the gas supplier.
This boiler cannot be used with all types of
chimneys. Read these instructions carefully
before installing.
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
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.
Tested for 50 psi. ASME
Working Pressure
C.S.A. Certified for
Natural gas or Propane
P/N# 240009276, Rev. A [03/2012]
2 - BOILER RATINGS AND CAPACITIES
Table 2 - Ratings and Capacities
† NATURAL GAS
† PROPANE GAS
AFUE
(2)
(2)
HIGH
NET
HIGH
ALTITUDE
INPUT
(3) Mbh
BOILER MODEL
NUMBER(1)
NET AHRI
HEATING
CAPACITY
(3)Mbh
INTERMITTENT
IGNITION
WITH VENT
DAMPER
Input
(3) Mbh
Heating
Capacity
(3) Mbh
ALTITUDE INPUT
AHRI
RATING
Water,
(3) Mbh
RATING
Water,
(3) Mbh
(3)Mbh
INPUT
(3) Mbh
GWB8-262E-2
GWB8-299E-2
GWB8-245E-2
GWB8-280E-2
262.5
299
220
251
191
218
83.9
83.7
83.9
83.7
236
269
245
280
206
235
179
204
220
252
†
Input rating for sea level to 2,000 ft. (610m) above sea level.
• 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.
(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.
Mbh = 1,000 Btuh = British Thermal Unit Per Hour
(3)
- 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
orifice 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
orifice 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
3 - TABLE OF CONTENTS
KEEP THIS MANUAL NEAR BOILER
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
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 flammable vapors
and liquids.
DO NOT obstruct air openings to the boiler room.
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
TO THE OWNER - Installation and service of this
boiler must be performed by a qualified installer.
SAFETY SYMBOLS & WARNINGS
The following defined symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
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.
!
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.
4
4 - INSTALLATION PROCEDURE
!
!
WARNING
WARNING
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
1. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
flooring special base must be used. (See Replacement
Parts Section.) Boiler can not be installed on
carpeting.
1. 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.
2. Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically fired Boilers,
ANSI/ASME CSD-1.
Table 3 - MINIMUM CLEARANCE DIMENSIONS
Inches
(mm)
Top
6”
6”
(152mm)
(152mm)
(178mm)
(152mm)
(457mm)
(152mm)
(13mm)
3. Boiler series is classified 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.
Rear
Control Side
Opposite Side
Front
7”
6”
18”
6”
Flue/Vent Connector
Near Boiler Piping
1/2”
4. 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.
NOTE: Greater clearances for access should supersede fire
protection clearances.
5. 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.).
* Definition 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.
6. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
Minimum Clearances to Combustible
Construction (as seen from above)
7. Allow 24 inches (610mm ) at front and right side for
servicing and cleaning.
6"
8. 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.
6"
7"
Control
Side
BOILER
Front
18"
5
5 - VENTILATION & COMBUSTION AIR
Provide combustion air and ventilation air in accordance
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
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.
A. Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
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.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
Communicating through horizontal ducts.
Provide minimum free area of 1 in² per 2
Mbh of total input rating of all appliances in
enclosure.
• Engineered Installations. Must be approved by
authority having jurisdiction.
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).
• 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.
• Refer to National Fuel Gas Code for additional
requirements for louvers, grilles, screens and air
ducts.
• All Indoor Air. Calculate minimum allowable room
volume for all appliances in space. Use a different
method if minimum volume not available.
• Combination Indoor and Outdoor Air. Refer to National
Fuel Gas Code for application information.
A. Standard Method. Cannot be used if known air
infiltration rate is less than 0.40 air changes per
hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.
Canada
National Gas and Propane Installation Code Requires
providing air supply in accordance with:
Volume ≥ 50 ft3 x Total Input [Mbh]
• Section 8.2 and 8.3 when combination of appliances
has a total input of up to and including 400 Mbh (120
kW).
B. Known Air Infiltration Rate. See Table 4 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate
(ACH) greater than 0.60.
• Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW).
• Refer to Natural Gas and Propane Installation Code
for specific air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.
Volume ≥ 21 ft3⁄ACH x Total Input [Mbh]
C. Refer to National Fuel Gas Code for opening
requirements between connected indoor spaces.
Table 4 - Minimum Room Volume, Indoor Air Only*
Room Cubic Feet Volume
Known Air Infiltration Rate Method (Air Changes Per Hour)
Standard
Method
Input Mbh
0.1
0.2
0.3
0.4
0.5
0.6
262.5
299
13125
14950
55125
62790
27563
31395
18375
20930
13781
15698
11025
12558
9188
10465
* Table values based on boiler only. Add volume for any additional appliances.
6
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 floor 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
RELIEF VALVE
DISCHARGE
LINE
Check local
codes for
maximum
distance
from floor
or allowable
safe point of
discharge.
7
6 - CONNECTING SUPPLY AND RETURN PIPING
Verify clean water supply is available to water inlet
!
WARNING
valve. Install sand strainer when water supply is from
a well or pump.
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation. In-
stall discharge piping per these instructions.
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 flushing of float type
devices, per manufacturers specific instruction.
1. Boiler is shipped assembled. Install discharge piping
from safety relief valve. See Warning, Page 7.
2. Install temperature pressure gauge.
• Apply pipe sealant to threads on shaft of gauge.
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 flow control valves or other
automatic means to prevent gravity circulation of
boiler water during cooling cycle.
• 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.
3. Connect supply and return lines to boiler. Connections
may require additional fittings and parts, as shown on
diagrams.
LOW WATER TEMPERATURE AND LARGE WATER
CONTENT SYSTEM (See Figures 6 and 7, Page 10.)
Significant 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.
Figure 3 - Temperature Pressure Gauge
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.
1. Boiler used in heating system where design water
temperatures below 140°F are desired (e.g. radiant
floor 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.
2. Boiler connected to system having large water content
(such as former gravity system), install system bypass.
See Figures 6 and 7, page 10.
3. 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.
8
6 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4 - Typical Hot Water Piping
Figure 5 - Chilled Water Piping
9
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
10
7 - CHIMNEY AND VENT PIPE CONNECTION
Connecting The Vent Damper And Vent
WARNING
!
Connector
Refer to Figure 1, page 2 for size and location of vent
(flue opening).
Boiler and venting installations shall be performed
by a qualified 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 fire or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
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.
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.
1. Position furnished vent damper on top of flue outlet
collar. Fasten damper securely to flue 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.
Check Your Chimney
It must be clean, right size, properly constructed and
in good condition.
As An Option
Damper may be installed in horizontal or vertical
position, closer to flue outlet collar preferred. See
Figures 8, 9 and 10 and enclosed vent damper
instructions.
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.
2. 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.
This is a high efficiency boiler with low stack
temperature. Following recommendations are in
addition to requirements of the National Fuel Gas
Code.
3. Damper must be in the open position when appliance
main burners are operating.
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:
4. Boiler is equipped with factory wired harness that plugs
into vent damper.
a) Except for basement, boiler is not installed in
unheated space.
5. Slope pipe up from boiler to chimney not less than 1/4”
per foot.
b) Total horizontal portion of vent connector, not
including elbows is less than 5 feet in length.
6. Run pipe as directly as possible with as few elbows as
2. Outside chimneys (i.e. chimneys exposed to
outdoors below roof line) should not be used unless
they are:
possible.
7. Do not connect to fireplace flue.
8. End of vent pipe must be flush with inside face of
chimney flue. Use a sealed-in thimble for chimney
connection.
a) enclosed in a chase, or
b) lined with type B vent pipe, or listed flexible
vent liner, or other certified chimney lining system.
3. Where possible it is recommended to common vent
boiler and water heater.
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.
4. For multiple boiler installations, consult boiler
manufacturer for venting recommendations.
11
7 - CHIMNEY AND VENT PIPE CONNECTION
5. Test for spillage at the draft hood relief opening after
WARNING
!
5 minutes of main burner operation. Use the flame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
Boiler and venting installations shall be performed
by a qualified 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 fire or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
6. 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, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.
!
WARNING
7. 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.
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 From Common
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.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. 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 fireplace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
12
8 - VENT DAMPER OPERATION
Figure 8 - Vent Damper Installation
Figure 9 - Vent Damper Placement
Annually check vent damper and all flue 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:
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
qualified service technician.
• 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.
Figure 10 - Vent Damper Position Indicator
• 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 firing 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.
13
9 - GAS SUPPLY PIPING
•
•
•
Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas
supply system.
!
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve.
• Do not touch any electrical switch; do not use
any phone in your building.
Locate leakage using gas detector, noncorrosive
detection fluid, or other leak detection method
acceptable to authority having jurisdiction. Do
not use matches, candles, open flames, or other
methods providing ignition source.
• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the fire
department.
•
Correct leaks immediately and retest.
CHECK GAS SUPPLY
Table 5 - Gas Pipe Sizes
NATURAL GAS
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.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
Length of
Pipe - FT
½”
¾”
1”
1¼”
CONNECTING THE GAS PIPING See Figure 11.
Gas line enters boiler from right side.
20
40
60
92,000
63,000
50,000
190,000
130,000
105,000
350,000
245,000
195,000
625,000
445,000
365,000
• 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
PROPANE GAS
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
Pipe Capacity - BTU Per Hour Input
Includes Fittings
• Use pipe joint compound suitable for LP gas on male
threads only.
Copper Tubing *
Iron Pipe
Length of
Pipe - FT
⅝”
¾”
½”
¾”
• Use ground joint unions.
20
40
60
131,000
90,000
72,000
216,000
145,000
121,000
189,000
129,000
103,000
393,000
267,000
217,000
• Install sediment trap upstream of gas controls.
• Use two pipe wrenches when making connection to gas
valve to keep it from turning.
* Outside diameter
Measure length of pipe or tubing from gas meter or
propane second stage regulator.
• Install manual shut-off valve in vertical pipe about 5
feet above floor.
Figure 11 - Gas Piping
• Tighten all joints securely.
• 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
flames, 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.
14
10 - ELECTRICAL WIRING
VENT DAMPER WIRING
!
WARNING
Boiler is equipped with factory wired harness with 4 pin
molex plug, that plugs into 4 pin molex receptacle inside
vent damper operator.
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.
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.
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.
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall about
four feet above the floor.
2. NEVER install thermostat on outside wall.
3. Do not install a thermostat where it will be affected
by drafts, hot or cold pipes, sunlight, lighting fixtures,
televisions, a fireplace, or a chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop the
burners.
5. Instructions for the final 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.
15
11 - WIRING DIAGRAMS
Figure 12 - Integrated High Limit Electronic Ignition Control (240008781)
!
WARNING
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
I
Inducer is not an option.
16
11 - WIRING DIAGRAMS
Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)
17
11 - WIRING DIAGRAMS
Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)
18
12 -GENERAL INSTRUCTIONS
FILLING SYSTEM WITH WATER
NOTICE
Never run water in a hot empty boiler.
• 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 fitting 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 flow 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 filling of
your system.
• If your system is closed expansion tank system, you
may leave it open to refill 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
fill valve should compensate for this. Instructions are
packaged with the valve.
19
13 - LIGHTING INSTRUCTIONS
5. Remove lower front panel.
!
WARNING
6. Rotate the gas control knob clockwise
“OFF”.
to
If you do not follow these instructions
exactly, a fire 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.
Figure 15 - Automatic Gas Valve
WIRING
PRESSURE REGULATOR ADJUSTMENT
(UNDER CAP SCREW)
TERMINALS (2)
OUTLET
PRESSURE
TAP
INLET
PRESSURE
TAP
GROUND
TERMINALS
(2)
• Before operating smell all around appliance area
for gas. Be sure to smell next to floor because
some gas is heavier than air and will settle to the
floor.
OUTLET
INLET
ON
PILOT
OFF
OUTLET
•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 qualified
service technician. Force or attempted repair may
result in fire or explosion.
PILOT ADJUSTMENT
(UNDER CAP SCREW)
GAS CONTROL KNOB
7. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. 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.
•Do not use this appliance if any part has
been under water. Immediately call a qualified
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
8. Rotate gas control knob counterclockwise
“ON”.
to
LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
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.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” and call
your service technician or gas supplier.
!
CAUTION
TO TURN OFF GAS TO APPLIANCE
WHAT TO DO IF YOU SMELL GAS
1. Set the thermostat to lowest setting.
• Do not try to light any appliance.
2. Turn off all electric power to the appliance if
service is to be performed.
• Do not touch any electrical switches; do not use
any phone in your building.
3. Push in gas control knob slightly and turn
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
clockwise
to “OFF” Do not force.
• If you cannot reach your gas supplier, call the fire
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.
20
14 - OPERATING YOUR BOILER
Figure 16 - Pilot Flame
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 flow 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.
MAIN BURNER(S)
• Main burners do not require primary air adjustment and
are not equipped with primary air shutters.
THERMOSTAT
• Main burner flames form sharp blue inner cones in softer
blue outer mantel, with no yellow.
Keep it set at desired room temperature. If windows
are to be opened or heat is not needed, move
thermostat pointer to lower setting.
• Puffs of air from blowing on flame or stamping on floor
will cause flames to turn orange momentarily. This is
not unusual. Remain still when observing main burner
flames.
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.
• If flame appearance is not correct, check main burner
orifices, burner throat and flame ports for dust and
lint obstruction. It may be necessary to remove rollout
shield to observe main burner flames. Replace rollout
shield after observation. Refer to Figure 17.
Figure 17 - Burner
ADJUST PILOT BURNER
Pilot flame should surround 3/8” to 1/2” of the pilot
sensor. See Figure 16. If flame needs adjusting, do it
as follows:
1. Remove screw cover over pilot adjusting screw.
2. Insert small screwdriver and adjust flame as needed.
Turn screw counterclockwise to increase flame, clockwise
to decrease.
ADJUST LIMIT CONTROLS
3. Replace screw cover over pilot adjusting screw.
Instructions for each control are included with
controls. Settings can be changed. Refer to
Appendix A page 27 for information.
21
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 satisfied, 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.
22
15 - MAINTAINING YOUR BOILER
BURNERS
CLEANING YOUR BOILER AND BURNERS
Beginning of heating season visually check pilot and main
burner flames. See Figure 16.
Flue passages between sections should be examined yearly
and cleaned if necessary.
To clean:
SAFETY RELIEF VALVE
• Remove burners, pilot, and vent pipe.
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
• Remove top and front jacket panels.
• Remove two screws attaching intermediate front panel
to left and right side jacket panels.
manufacturer’s instruction are not located.
• Remove draft diverter and intermediate front panel
together.
EXPANSION TANK
• Carefully remove cerafelt gasket strips.
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.
• Clean passageways between sections with flexible
handle wire brush. Remove dirt from bottom of boiler
and from between sections by vacuuming.
• Verify all flame ports in burners are open and clear.
Shake out or blow out all loose dirt in burners.
To correct:
1. Close valve between boiler and tank. Drain tank until
• Reseal seams between adjacent sections as necessary
with 400° F RTV silicone sealant.
empty.
2. Check all tank plugs and fittings. Tighten as necessary.
• Reassemble all parts.
3. Open valve between boiler and tank. Water will rise to
normal height in tank if you have automatic fill valve
(otherwise, manually refill system).
• Verify tightness of pilot connections and condition of
burner flames after reassembly. See Figures 16 and 17,
pages 21.
• Verify vent pipe connections to chimney are secure and
no obstructions are present.
BOILER FLUE PASSAGES
Recommend following checked annually by qualified service
agent.
HOUSEKEEPING
• flue passages
• Keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors and
liquids.
• burner adjustment
• operation of controls
• Keep boiler area clear of debris and other materials
obstructing flow of combustion and ventilation air.
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).
23
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 fire
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 properlyCheck flame. If it is yellow, burner is not getting enough air.
Or, if flame 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
Radiators not heating
Reset according to instructions.
Open radiator vents to expel air. Check flow control valve (if
used). It may be in closed position.
Circulating pump not running Check over current protection. Check relay operation.
Poor electrical contact
Rollout switch blown
Check all control terminals and wire joints.
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 Effikal 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
Dirt on seat
What to do
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.
24
17 - EQUIPMENT AND OPTIONAL ACCESSORIES
AUTOMATIC FILL VALVE
EXPANSION TANK
Expanding water flows into expansion tank. Tank should
be correct size. Tank is filled 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
filled with cold water) is sufficient for proper operation.
Tank also serves as trap for excess air in system. Air
would cause gurgling in pipes and in efficient circulation in
radiators if left in system.
For a safe, efficient operation, hot water system must be
completely filled 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 fill 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.
It is possible for tank to become “waterlogged” (filled with
water). It can also become overfilled with air. This can hap-
pen after filling system with new water. Fittings provided on
tank and in line to tank are for bleeding off excess water or
air.
WATER TEMPERATURE CONTROL
Water temperature limit control in relay is adjustable
When installing this tank, it is important:
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.
1. Tank be higher than boiler top.
2. Pipe to tank continuously rises up to tank (so air
can “bubble” up to it).
DIAPHRAGM TYPE EXPANSION TANK
CIRCULATING PUMP
Diaphragm type expansion tank takes place of conventional
expansion tank. Carefully read instructions packed with
your tank assembly.
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.
Tank comes with 10-12 pounds per square inch air charge.
This is the same as pressure produced in system by
automatic fill valve. When system is first filled, 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 fitting or at any convenient place in supply or return
line.
VENT DAMPER
This product is automatic, motorized stack damper
developed to increase efficiency 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.
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 filled with water, there is air in pipes and
radiation units. Some of it will be trapped as system is
filled . 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.
25
17 - EQUIPMENT AND OPTIONAL ACCESSORIES
BLOCKED VENT SAFETY SWITCH
ROLLOUT SWITCH
(FLAME ROLLOUT SAFETY SHUTOFF)
(BLOCKED VENT SAFETY SHUTOFF)
Rollout switch is temperature-sensitive fuse link device.
Located on boiler base just outside fire box. In event of
heat exchanger flueway blockage causing flame to roll
out of fire box, fuse does not change in appearance when
blown.
Blocked vent safety switch is manual reset disc thermostat
with fixed 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 flow of gas to main burners by removing power to gas
valve.
If rollout switch blows, it must be replaced with exact
replacement. Check heat exchanger flueways for blockage
when restoring system to operating condition. DO NOT
operate system without rollout switch.
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.
26
APPENDIX A - CONTROL MODULE
A.1 Installation Environment Considerations A.3 Adjusting Settings
To discourage unauthorized changing of settings, procedure
to enter adjustment mode is required.
!
WARNING
If you do not follow these instructions
exactly, a fire or explosion may result
causing property damage, personal injury
or loss of life.
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
•Do not use this appliance if any part has
been under water. Immediately call a qualified
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
between 130 and 220 °F)
о “Df_” Setpoint Differential (15 °F default setting;
adjustable between 10 and 30 °F)
о “°F_” Degrees Fahrenheit
• Do not allow water to drip on controls. Prevent
condensation by allowing air circulation around
module and gas control.
Press UP or DOWN button until parameter has reached
desired value. After 60 seconds without any button inputs,
control automatically returns to READ mode.
• Do not use corrosive chemicals around or on
module or gas control.
A.4 Display
In RUN mode, status items and parameters are viewable.
• Controls can be damaged by excessively high
temperatures. Verify adequate air circulation around
control is maintained when installing boiler.
Example, to display setpoint, control flashs “sp” (setpoint)
followed by temperature (i.e., 135), followed by °F or °C.
To read settings, press and release I key to find parameter
of interest.
A.2 Electrical Connections
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.
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.
See Display Readout.
• Thermostat connection to yellow wires marked TT
using wire nuts.
Figure 18 - Display Readout
• 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.
27
APPENDIX A - CONTROL MODULE
module proceeds to start burner (see state codes list)
A.5 Operation
and heats water in boiler until setpoint temperature is
achieved or thermostat is satisfied. .
Module continuously monitors boiler water temperature and
fires or shuts off burner based on this temperature data.
3. Burner is de-activated, ignition module completes heat-
ing cycle, returns to idle and waits for temperature to
drop again.
1. When “Call for Heat” occurs, control enables circulator
and monitors boiler water temperature to determine
whether thermostat can be satisfied without firing
burners.
4. Circulator is turned on throughout “Call for Heat.”
2. Control determines burner operation is required,
Table 6 - Operation State Codes
State
Code
Definition
Explanation
Number
Idle
Standby - no call for heat
1
Heat request present. Boiler temperature sufficiently high to run circulator
pump only.
Circulator
4
6
Pre-purge
Spark
System is purging before ignition trial; includes Pilot Valve circuit diagnostics.
System sparking. Flame is not present up to 13 seconds
Flame signal is being established. Variation in signal is allowed during this
state, flame must be stable at end of period
7
Flame stabilization
8
9
Running
System is running. Flame signal must be present.
System is purging at end of call for heat
Post-Purge
Successful ignition was not detected, and delay is called before retry.
Retry Recycle Delay
10
Flame signal was lost during state 7 or 8, and delay is called before retry (32
second delay)
13
14
15
Soft lock-out
Hard lock-out
Soft lockout duration is one hour, may override with manual reset.
Manual reset is required for hard lockout
Wait for limit to close
Possible thermostat call for heat; limit switch is open.
Flame signal sensed before trial for ignition. Appropriate alarm is sent.
OR
16
17
Flame out of sequence
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.
Pilot valve circuitry diagnostics during pre-purge.
Pilot valve diagnostics
Self check performed at start up, again at beginning of heat cycle, and during
“Wait for Recovery “ State.
Current leakage detection
Self check performed at start up, again at beginning of heat cycle, and during
“Wait for Recovery “ State
Wait for recovery
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.
18
19
Wait for damper to open
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.
Wait for damper to close
Wait for damper to open
(Failed close)
Damper has not opened (end swich not closed) at beginning of heat cycle.
Alarm message is sent, control is NOT in lockout.
20
21
Wait for damper to close
(Failed open)
Damper has not closed despite actuator de-energized.
Alarm message is sent, control is NOT in lockout.
28
APPENDIX A - CONTROL MODULE
A.6 Boiler High Limit Temperature Controller
A.7 Troubleshooting
• When water temperature reaches setpoint, controller
ends heating cycle.
• Following service procedures are provided as general
guide.
• When water temperature drops below setpoint minus
differential, controller restarts heat cycle to re-heat
boiler water.
• 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.
• If water temperature exceeds maximum allowed
temperature (220°F or 104°C), controller enters manual
reset lockout state.
• Check for correct installation and wiring before replacing
any component.
• For models having reset capability, press any onboard
button or cycle power to reset.
• Control module cannot be repaired. If it malfunctions, it
must be replaced.
Figure 20 - Basic Control Algorithm Example
• Use only qualified service agent to service ignition
systems.
1. Perform checkout as first step in troubleshooting.
Check troubleshooting guide to pinpoint cause of problem.
See Table 7 , page 30.
2. If troubleshooting indicates ignition problem, see
Ignition System Checks to isolate and correct the
problem.
3. 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.
29
APPENDIX A - CONTROL MODULE
Table 7 - Troubleshooting Error Codes
Error
Code
Definition
Consequence
Number
4
6
Flame current too low. Check for flame.
Non critical alarm
Soft lockout
Flame sensed out of normal sequence (before opening or after closing gas valve).
Gas valve relays welded. Five consecutive soft lockouts.
18
23
Hard lockout
Soft lockout
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.
32
Wait for recovery
55
56
57
58
59
Atmospheric damper end switch failed to close (end switch contacts stuck open).
Atmospheric damper end switch failed to open (end switch contacts stuck close).
Igniter flame rod shorted to burner ground
Wait for recovery
Wait for recovery
Wait for recovery
Wait for recovery
Wait for recovery
Igniter flame rod shorted to burner ground. Repair or replace igniter.
Line Voltage error - voltage out of specification high or low (15-37V (44-66Hz))
Applies only to thermostats having on-board transformer.
Polarity is wrong in this case.
60
Wait for recovery
Thermostat input higher than threshold.
Line voltage unstable - possibly too may heavy loads switching on and off causing
erratic supply voltage.
61
62
Wait for recovery
Soft lockout
Soft lockout: maximum number of retries exceeded.
Soft lockout is reset after one hour if alarm reason disappears.
Soft lockout: maximum number of recycles exceeded.
63
64
Soft lockout
Soft lockout
Soft Lockout - electronics failure. On-board self diagnostics detected error.
Over temperature error. Sensor measured temperature in excess of maximum
allowable limit.
65
Soft lockout
Note: Soft lockout time is 1 hour or manual reset. Hard lockout requires manual reset.
STEP 2:
A.9 Intermittent Pilot
Verify ignition system grounding. Nuisance shutdowns are
often caused poor or erratic grounding.
Ignition System Checks
Common ground is required for module and pilot burner/
igniter sensor.
STEP 1: Check ignition cable.
• Verify ignition cable does not touch metal surfaces.
— Check for good metal-to-metal contact between
pilot burner bracket and the main burner.
• Verify only factory supplied Ignition cable (or approved
replacement) is used.
— 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.
• Verify connections to ignition module and igniter or
igniter-sensor are clean and tight.
• Verify ignition cable provides good electrical continuity.
— Check ceramic flame 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.
30
APPENDIX A - CONTROL MODULE
— If flame rod or bracket is bent out of position, restore
• Recheck ignition sequence as follows.
to correct position.
— Reconnect main valve wire.
STEP 3: Check spark ignition circuit.
Disconnect ignition cable at SPARK terminal on module.
— Adjust thermostat above room temperature.
— Verify ignition sequence at burner.
!
WARNING
— If spark does not stop after pilot lights, replace
module.
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.
— 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
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.
— Verify ignition spark continues after pilot is lit.
— Verify pilot lights and spark stops, verify main
burner does not light.
• If so, ensure adequate flame current as follows.
— Turn off boiler at circuit breaker or fuse box.
— Clean flame 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 flame. Verify it is blue, steady and
envelops 3/8 to 1/2 in. [10 to 13 mm] of flame rod.
See Figure 19 for possible flame problems and causes.
— If necessary, adjust pilot flame by turning pilot
adjustment screw on gas control clockwise to decrease
or counterclockwise to increase pilot flame. Following
adjustment, always replace pilot adjustment cover
screw and tighten firmly 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 flame.
See Figure 16, Page 21.
31
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
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