Lennox GSB8-E User manual

P/N# 14683453, Rev. 2.2 [11/07]
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 Standards
for cast iron heating boilers.
GSB8-E
GAS-FIRED STEAM BOILER
GSB8-S
GAS-FIRED STEAM BOILER
INSTALLATION
INSTRUCTIONS
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
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.
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 Standards
for cast iron heating boilers.
Improper installation, adjustment,
Improper installation, adjustment,
alteration, service, or maintenance can

3
INSTALLATION, OPERATION & MAINTENANCE MANUAL
P/N# 14683453, Rev.2.2 [11/07]
GSB8-E GAS-FIRED STEAM BOILER & GSB8-S GAS-FIRED STEAM BOILER
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
These instructions must be afxed on or adjacent to the boiler
GAS-FIRED HOT STEAM BOILERS
These Gas-Fired Steam Boilers are low pres-
sure, sectional cast iron boilers Design Certied
by AGA (American Gas Association) for use with
Natural and Propane Gases. They are construct-
ed and hydrostatically tested for a maximum
working pressure of 15 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.
Improper installation, adjustment, altera-
tion, service, or maintenance can cause
injury or property damage. Refer to this
manual. For assistance or additional
information consult a qualied installer,
service agency or the gas supplier.
TABLE OF CONTENTS
Boiler Ratings and Capacities ................3, 4
Before You Start .........................................4
Locating the Boiler......................................5
Fresh Air for Combustion .......................6, 7
Installation – System Piping ..................7-10
Chimney and Vent Pipe Connection....10-12
Vent Damper Operation............................13
Gas Supply Piping....................................14
Electrical Wiring........................................15
Controls & Accessories – What They Do.....21, 22
For Your Safety – Read Before Operating .....22
Gas Valve Operating Instructions .......23, 24
Operating Your Boiler .........................24, 25
Checking and Adjusting.......................25-26
Cleaning Your Boiler ............................26,27
Maintaining Your Boiler........................27-30
Service Hints ............................................30
Troubleshooting........................................31
Repair Parts.........................................32-35
BOILER RATINGS AND CAPACITIES
DESIGN CERTIFIED FOR NATURAL AND PROPANE GAS
Figure #1

4
BOILER SPECIFICATIONS
Model No.
Type of Ignition
Natural gas Propane
2) AFUE %
Number of Sections
Capacity US
Gallons (L)
Flue Size Connection
Diameter in. (mm) round
Sipping Weight Lbs. (kg)
Package
Gas Piping
Size IPS
in. (mm)
Supply & Return Connection
NPT in. (mm)
Drain Connection NPT in.
(mm)
Input Btuh (KW)
Heating Capacity Btuh
(KW
1) Net I=B=R Btuh (KW)
1) Net I=B=R Rating
sq.ft. Radiation
Input Btuh (KW)
Heating Capacity Btuh
(KW
1) Net I=B=R Btuh (KW)
1) Net I=B=R Rating
sq.ft. Radiation
Full
Water Level
Natural
Propane
GSB8-075E Electronic 75,000
(22.0)
62,000
(18.5)
47,000
(14.7)
196
(18.2)
70,000
(20.0)
58,000
(16.1)
44,000
(13.0)
183
(17.0)
82.7 34.20
(16.1)
2.60
(9.84)
5
(12.7)
325
(147)
1/2
(12.7)
3/4
(19.0)
2-1/2
(64.0)
3/4
(19.0)
GSB8-075S Standing Pilot 81.1
GSB8-112E Electronic 112,500
(33.0)
91,000
(26.7)
68,000
(19.9)
283
(26.3)
105,000
(30.8)
85,000
(24.9)
64,000
(18.6)
267
(24.8)
80.4 45.90
(22.3)
3.80
(14.4)
6
(15.2)
404
(183)
GSB8-112S Standing Pilot 78.8
GSB8-150E Electronic 105,000
(44.0)
122,000
(35.7)
92,000
(27.0)
383
(35.6)
140,000
(41.0)
114,000
(33.4)
86,000
(25.2)
358
(33.3)
80.6 57.60
(28.8)
5.00
(18.9)
6
(15.2)
483
(219)
GSB8-150S Standing Pilot 79.2
GSB8187E Electronic 187,000
(54.8)
153,000
(44.8)
115,000
(33.7)
479
(44.5)
175,000
(51.3)
143,000
(41.9)
107,000
(31.4)
446
(41.4)
80.9 69.30
(35.2)
6.20
(23.5)
7
(17.8)
564
(256)
3/4
(19.0)
GSB8187S Standing Pilot 79.6
GSB8-225E Electronic 225,000
(65.9)
183,000
(53.6)
137,000
(40.1)
571
(53.0)
210,000
(61.5)
171,000
(50.1)
128,000
(37.5)
553
(51.4)
81.1 711.00
(41.6)
7.40
(28.0)
7
(17.8)
649
(294)
GSB8-225S Standing Pilot 80.1
GSB8-262E Electronic 262,000
(76.9)
214,000
(62.7)
161,000
(47.2)
671
(62.3)
245,000
(71.8)
200,000
(58.6)
150,000
(44.0)
625
(58.1)
81.3 812.70
(48.1)
8.60
(32.6)
719
(326)
GSB8-262S Standing Pilot 80.5
GSB8-299E Electronic 299,000
(87.6)
245,000
(71.8)
184,000
(53.9)
767
(71.3)
280,000
(82.0)
229,000
(67.1)
172,000
(50.4)
717
(66.7)
81.5 914.40
(54.5)
9.80
(37.1)
800
(363)
GSB8-299S Standing Pilot 80.9
1) The Ratings marked “Net I=B=R Ratings” indicate the amount of equivalent direct cast iron radiation each boiler will take care of under normal conditions and
thermostatic control. The Net I=B=R Steam Ratings shown are based on an allowance of 1.333 in accordance with the factors shown in the I=B=R Code as
published by the Hydronics Institute. Selection of boiler size should be based upon “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. Specications and dimensions are
subject to change without notice.
2) Annual Flue Utilization Efciency based on U.S. DOE test procedures and FTC labeling regulations.
BEFORE YOU START
KEEP BOILER AREA CLEAN AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND
OTHER FLAMMABLE VAPORS AND LIQUIDS
Check to be sure you have the right size boiler before
starting the installation. See rating and capacity table on
previous page. Also be sure the new boiler is for the type
of gas you are using. Check the rating plate on the right
side of the boiler.
You must see that the boiler is supplied with the cor-
rect type of gas, fresh air for combustion, and a suitable
electrical supply. Also, the boiler must be connected to a
suitable venting system and an adequate piping system.
Finally, a thermostat, properly located, is needed for control
of the heating system. If you have any doubts as to the
various requirements, check with local authorities and
obtain professional help where needed. Take the time to
complete all of the steps for SAFE and PROPER opera-
tion of the heating system.
If this boiler is installed in a building under construction,
special care must be taken to insure a clean combus-
tion air supply during the construction process. Airborne
particulates such as from drywall dust and from berglass
insulation can clog the burner ports and cause incomplete
combustion and sooting.
These boilers are designed for use in closed heating
systems where all of the steam is returned to the boiler as
condensate and the amount of make-up water required is
minimal. These boilers are not designed for or intended
for use in open systems of process applications using
100% make-up water. Damage to the boiler resulting
from such use shall not be covered under the warranty.
Where required by the authority having jurisdiction,
the installation must conform to American Society of Me-
chanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, No. CSD-1.
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-latest revision.
The following steps are all necessary for proper
installation and safe operation of your boiler.
1. LOCATING THE BOILER
2. FRESH AIR FOR COMBUSTION
3. INSTALLATION – SYSTEM PIPING
4. CHIMNEY & VENT PIPE CONNECTION
5. GAS SUPLY PIPING
6. ELECTRICAL WIRING
7. CHECKING & ADJUSTING

5
LOCATING THE BOILER
1.Select level location as centralized with piping
system, and as near chimney, as possible.
2.Place crated boiler at selected location, remove
crate by pulling crate sides from top and bottom
boards. Combustible oors: When boiler is to be
installed on a combustible oor, a Special Base
Plate must be used – 146-14-031 (3-6 Section)
or 146-14-032 (7-9 Section). This boiler must
not be installed on carpeting.
3.Boiler is to be level. Metal shims may be used
under base legs for nal leveling.
4.Additional clearances for service may exceed
clearances for re protection. Always comply
with the minimum re protection clearances
shown on the boiler. An 18 inch clearance
should be maintained on any side where pas-
sage is required to access another side for
cleaning, servicing, inspection or replacement
of any part that may need attention. An 18 inch
clearance is recommended on the control side
for servicing.
Figure 2 shows minimum clearances to com-
bustible construction. Rooms that are large
in comparison with the size of the boiler are
dened as rooms having a volume equal to or
greater than 16 times the volume of the boiler.
Where the actual ceiling height of a room is
greater than 8’, the volume of a room shall be
gures on the basis of a ceiling height of 8’.
Determination of room size should be based
on the total volume of all gas red equipment
installed in the room. Consult section 6.3.1 of
the National Fuel Gas Code for further informa-
tion, including approved methods for reducing
clearances in large rooms.
5.Equipment shall be installed in a location in
which the facilities for ventilation permit satis-
factory combustion of gas, proper venting, and
maintenance of ambient temperature at safe
limits under normal conditions of use. Equip-
ment shall be located so as not to interfere
with proper circulation of air. When normal
inltration does not provide the necessary air,
outside air shall be introduced (See - “Fresh
Air for Combustion” following page).
6.Advise owner to keep air passages free of
obstructions. Ventilating and combustion air
must enter boiler room without restrictions.
7.The boiler shall be installed such that the au-
tomatic gas ignition system components are
protected from water (dripping, spraying, rain,
etc.) during appliance operation and service
(condensate trap, control replacement, etc.).
This unit must be set on a concrete or other noncombustible material base or oor.
IT MUST NOT BE INSTALLED ON CARPETING.
Figure #2
BOILER CLEARANCES
Alcove*, or Room
Not Large in
Comparison
With Boiler
Room Large In
Comparison
With Boiler
Unit
Top 6” 6”
Rear 6” 6”
Control Side 7” 6”
Opposite Side 6” 6”
Front 18” 18”
Flue/Vent Connector 6” 6”
Near Boiler Piping 1” 1”
BOILER VOLUME SPECIFICATIONS
Boiler
Size
Boiler
Volume
(Cu. Ft.)
Minimum Room
Volume Required
To Be Large (Cu.Ft.)*
3 sect. 6.3 100.4
4 sect. 8.1 129.4
5 sect. 9.9 158.4
6 sect. 11.7 187.4
7 sect. 13.5 216.4
8 sect. 15.3 245.4
9 sect. 17.2 274.5
* Alcove - boiler may be installed in an area inclosed on 3 sides (U shped) with
the front open. * For room with single boiler only.

6
FRESH AIR FOR COMBUSTION
Be sure to provide enough fresh air for
combustion. Enough air insures proper com-
bustion and assures that no hazard will
develop due to the lack of oxygen.
Provision for combustion and ventilation air must be in accordance with Section 5.3,
Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI A223.1 – latest
revision, or applicable provisions of the local building codes.
You must provide for enough fresh air to assure
proper combustion. The re in the boiler uses
oxygen. It must have a continuous supply. The
air in a house contains only enough oxygen to
supply the burner for a short time. Outside air
must enter the house to replace that used by
the burner. Study following examples 1 and 2 to
determine your fresh air requirements.
EXAMPLE 1:
Boiler Located in Unconned Space
An unconned space is dened as a space
whose volume is not less than 50 cubic feet per
1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (un-partitioned
basement) in a conventional house, the air that
leaks through the cracks around doors and win-
dows will usually be adequate to provide air for
combustion. The doors should not t tightly. Do
not caulk the cracks around the windows.
Equipment located in buildings of unusually
tight construction shall be provided with air for
combustion, ventilation, and dilution of ue gases
using the methods described in example 2B
or shall be specially engineered. The authority
having jurisdiction must approve specially engi-
neered installations.
EXAMPLE 2:
Boiler Located in Unconned Space
A.All Air from Inside the Building: The conned
space shall be provided with two permanent
openings communicating directly with an ad-
ditional room(s) of sufcient volume so that
the combined volume of all spaces meets the
criteria for an unconned space. The total input
of all gas utilization equipment installed in the
combined space shall be considered in making
this determination. Each opening shall have a
minimum free area of one square inch per 1,000
Btu per hour of the total input rating of all gas
utilization equipment in the conned space, but
not less than 100 square inches. One opening
shall be within 12 inches of the top and one
within 12 inches of the bottom of the enclosure.
The minimum dimension of air openings shall
not be less than 3 inches.
B.All Air from Outdoors: The conned space
shall communicate with the outdoors in ac-
cordance with methods 1 or 2. The minimum
dimension of air openings shall not be less than
3 in. Where ducts are used, they shall be of the
same cross-sectional area as the free area of
the openings to which they connect.
1. Two permanent openings, one commencing
within 12 inches of the top, and one com-
mencing within 12 inches of the bottom, of
the enclosure shall be provided. The open-
ings shall communicate directly, or by the
ducts, with the outdoors or spaces (crawl
or attic) that freely communicate with the
outdoors.
a) Where directly communicating with the
outdoors or where communicating to the
outdoors through vertical ducts, each
opening shall have a minimum free area
of 1 sq. in. per 4000 Btu per hour or total
input rating of all equipment in the enclo-
sure. (See Figure 3A.)
b) Where communicating with the outdoors
through horizontal ducts, each opening
shall have a minimum free area of 1 sq.
in. per 2000 Btu per hour or total input
rating of all equipment in the enclosure.
(See Figure 3B.)
WARNING
!
!

7
INSTALLATION — SYSTEM PIPING
The near boiler piping, that is the piping around
the boiler must be considered as part of the 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 sys-
tem. Follow these recommendations carefully.
1. Place boiler in selected location, as near chimney
as possible.
2. Install the pop safety valve, using the furnished
¾” coupling, into the ¾” pipe nipple on the top
of the boiler. Make a discharge pipe, using ¾”
pipe (not furnished) to carry the water or steam
to a nearby drain. Do not connect the discharge
pipe directly to a drain but leave an air gap. The
downstream end of the discharge pipe must be
unthreaded. No shutoff of any description shall
be placed between the pop safety valve and
the boiler, or on discharge pipes between such
safety valves and the atmosphere. Installation
of the pop valve shall conform to the require-
ments of the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV. The manufacturer is
not responsible for any water damage.
3. This boiler is equipped with two 2 ½” supply
connections and two 2 ½” return connections,
one each on both the left and right sides of the
boiler. Unused connections must be plugged
with the 2 ½” plugs (furnished).
4. Recommended near boiler piping for gravity
return systems is shown in Figure 5. This
FRESH AIR DUCT CAPACITIES (Btuh)
1 Square Inch per 4,000 Btuh
100% Free
Area
75% Free
Area
25% Free
Area
Fresh Air
Duct Size
¼” Wire
Mesh
Metal
Louvers
Wood
Louvers
3” x 12” 144,000 108,000 36,000
8” x 8” 256,000 192,000 64,000
8” x 12” 384,000 288,000 96,000
8½” x 16” 512,000 384,000 128,000
Figure #3A
FRESH AIR DUCT CAPACITIES (Btuh)
1 Square Inch per 2,000 Btuh
100% Free
Area
75% Free
Area
25% Free
Area
Fresh Air
Duct Size
¼” Wire
Mesh
Metal
Louvers
Wood
Louvers
3” x 12” 72,000 54,000 18,000
8” x 8” 128,000 96,000 32,000
8” x 12” 192,000 144,000 48,000
8½” x 16” 256,000 192,000 64,000
Figure #3B
FRESH AIR DUCT CAPACITIES (Btuh)
1 Square Inch per 3,000 Btuh
100% Free
Area
75% Free
Area
25% Free
Area
Fresh Air
Duct Size
¼” Wire
Mesh
Metal
Louvers
Wood
Louvers
3” x 12” 108,000 81,000 27,000
8” x 8” 192,000 144,000 48,000
8” x 12” 288,000 216,000 72,000
8½” x 16” 384,000 288,000 96,000
Figure #4
FRESH AIR FOR COMBUSTION
2. One permanent opening commencing with
12 inches of the top of the enclosure, shall
be permitted where the equipment has clear-
ance of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
The opening shall directly communicate with
the outdoors or shall communicate through
a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely com-
municate with the outdoors, and shall have a
minimum free area of:
a) 1 sq. inch per 3000 Btu per hour of the
total input of all equipment located in the
enclosure (See Figure 4), and
b) Not less than the sum of the areas of all
vent connectors in the conned space.

8
RECOMMENDED NEAR BOILER PIPING USING ONE SUPPLY TAPPING
con 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.
5. For installers choosing to use both supply tap-
pings, 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  tted with header offsets or
swing joints, or be equipped with expansion
joints, so that thermal expansion and contrac-
tion 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 take-
offs must never be between two risers.
6. System takeoffs from the header must never
be bullheaded. If the steam main goes in two
directions, there must be two takeoffs from the
header, one for each main.
Figure #5
INSTALLATION — SYSTEM PIPING

9
RECOMMENDED NEAR BOILER PIPING USING TWO SUPPLY TAPPINGS
7. All boilers in gravity return systems must be
equipped with a Hartford Loop as shown in
Figures 5 and 6A.
8. 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.
9. Steam riser(s) and header shall be 2 ½” pipe size.
10.Equalizer line shall be minimum 1 ½” size.
11.The near boiler piping shall include a 2 ½” tee
with a plug located on the supply line as shown
for skimming (i.e. surface blowdown).
12.The near boiler piping shall include a 1 ½” ball
valve in the return piping as shown for bottom
blowdown and draining.
13.For gravity return systems, the bottom of the
lowest 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 “Di-
mension A.”
14.For pumped return systems, follow the con-
densate pump or boiler feed pump manufac-
turer’s instructions for proper installation and
hookup.
15.In connecting the cold water supply to the
water inlet 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.
INSTALLATION — SYSTEM PIPING
Figure #6A

10
COMMON NEAR BOILER PIPING MISTAKES
CHILLED WATER PIPING
FOR USE WITH COOLING UNITS
A.This boiler, when used in connection with
chilled water systems, must be installed so
that the chilled water is piped in parallel with
the heating boiler. Appropriate valves must be
used to prevent the chilled water from entering
the heating boiler (Figure 7).
B.When this boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air circulation, the pip-
ing system shall be equipped with ow control
valves or other automatic means to prevent
gravity circulation of the boiler water during the
cooling cycle.
Figure #6B
INSTALLATION — SYSTEM PIPING
Figure #7

11
CHIMNEY AND VENT PIPE CONNECTION
For boilers for connection to gas vents or chimneys, vent installations shall be
in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI
Z223.1-latest revision and applicable provisions of the local building codes.
CHECK YOUR CHIMNEY
This is a very important pat of your heating sys-
tem. 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 provi-
sions of the National Fuel Gas Code and local
building codes. Figure 8 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.
CHIMNEY SIZING
Chimney sizing and all other aspects of the vent
installation must be in accordance with Part 7 of
the National Fuel Gas Code, ANSI Z223.1-latest
revision, and applicable provisions of the local
building codes.
CONNECTING THE VENT DAMPER AND
VENT CONNECTOR
Refer to Figure 1 ue diagram for the size and
location of the vent (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 ½ square inch
hold (approximately ¾” diameter). On boil-
ers 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.
1. Position furnished vent damper on top of ue
outlet collar. Fasten damper securely to ue
outlet collar with sheet metal screws. Make
sure damper blade has clearance to operate
inside of diverter.
AS AN OPTION:
The damper may be installed in any horizontal or ver-
tical position, closer to the ue outlet collar preferred.
Follow the diagrams – Figures 9, 10, and 11.
2. Install the vent damper to service only the sin-
gle 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.
3. The damper must be in the open position when
appliance main burners are operating.
4. The boiler is equipped with a factory wired har-
ness that plugs into the vent damper. The ther-
mostat must be connected to the black wires
marked 24 Volt
thermostat on
the boiler.
5. Vent pipe must be
same size as the
ue outlet collar.
6. Slope pipe up
from boiler to
chimney not less
than ¼” per foot.
7. Run pipe as
directly as pos-
sible with as
few elbows as
possible.
8. Do not connect to
replace ue.
9. End of vent pipe
must be flush
with inside face
of chimney ue.
Use a sealed-in
thimble for the
chimney con-
nection.
10. Horizontal run should not be longer than ¾
the chimney height (HT) (Figure 8).
TYPICAL MASONRY
CHIMNEY REQUIREMENTS
Figure #8

12
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom ex-
hausts, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close
replace dampers.
4. Place in operation the appliance being inspect-
ed. Follow the lighting instructions. Adjust ther-
mostat so appliance will operate continuously.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use
the ame of a match or candle, or smoke from
a cigarette, cigar, or pipe.
6. After it has been determined that each ap-
pliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans, replace dampers, and any other gas-
burning appliance to their previous conditions
of use.
7. Any improper operation of the common venting
system should be corrected so that the installa-
tion conforms with the National Fuel Gas Code,
ANSI Z223.1-latest revision. When resizing
any portion of the common venting system,
the common venting system should be resized
to approach the minimum size as determined
using the appropriate tables in Part 11 in the
National Fuel Gas Code, ANSI Z223.1-latest
revision.
For boilers for connection to gas vents or
chimneys, vent installations shall be in ac-
cordance with Part 7, Venting of Equipment,
of the National Fuel Gas Code, ANSI Z223.1-
latest revision and applicable provisions of
the local building codes.
Vent connectors serving appliances vented by
natural draft shall not be connected into any
portion of mechanical draft systems operating
under positive pressure.
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 parti-
tion, 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 ac-
cordance with their listing.
REMOVING EXISTING BOILER FROM
COMMON VENTING SYSTEM
When an existing boiler is removed from a com-
mon 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 appli-
ance remaining connected to the common vent-
ing system placed in operation, while the other
appliances remaining connected to the 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 deciencies 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
CHIMNEY AND VENT PIPE CONNECTION

13
VENT DAMPER OPERATION
ROTATION ROTATION
OPEN
CLOSED
FLUE GAS FLOW FLUE GAS FLOW
CLOSED
OPEN
DAMPER CLOSED DAMPER OPEN
SHOWING OPEN AND CLOSED POSITION
VENT DAMPER POSITION INDICATOR
For safe, efcient operation, the vent damper and
all ue product carrying areas of the appliance must
be checked annually by you, 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:
1. When the boiler is off, check that the vent damper
positions indicator points to the closed position,
Figure 11.
2. Turn the thermostat or controller up to call for heat
and check the vent damper indicator points to the
open position, Figure 11.
3. Turn the thermostat or controller down again and
check that the damper position indicator returns to
the closed position.
4. If you have central air conditioning, set the thermo-
stat to COOL and turn it down to call for cooling.
Cooling system should operate.
5. Return thermostat to desired position.
The vent damper must be inspected at least once a
year by a trained, experienced service technician.
The name of the person who originally installed your
vent damper is shown on the installation label.
MANUAL OPERATION OF THE VENT DAMPER
The vent damper may be placed in the open posi-
tion to permit burner operation by using the “HOLD
DAMPER OPEN” switch, located on the damper con-
troller. The thermostat will control the burner ring as
before, while the damper will remain open.
DO NOT turn damper open manually or motor dam-
age will result. Set switch to “AUTOMATIC OPERA-
TION” to close vent damper during burner off cycle.
For further information, and for a vent camper trouble
shooting guide, refer to the manual that was packaged
with the vent damper.
TYPICAL INSTALLATION FOR VENT DAMPER
NOTE CAUTION AND FOOTNOTES
1. Install the vent damper to service only the single appli-
ance for which it is intended. If improperly installed, a
hazardous condition, such as an explosion or carbon
monoxide poisoning, could result.
2. Do not install the vent damper on vent pipe curve.
3. Do not run wires near high temperature surfaces. Use
stand-off brackets if necessary.
Figure #10
Figure #11
Figure #9

14
GAS SUPPLY PIPING
CHECK GAS SUPPLY
The gas pipe to your boiler must be the correct
size for the length of the run and for the Btu per
hour input of all gas utilization equipment con-
nected to it. See Figure 12 for the proper size.
Be sure your gas line complies with local codes
and gas company requirements.
The boiler and its individual shut-off valve must
be disconnected from the gas supply piping sys-
tem during any pressure testing of that system at
test pressures in excess of ½ psig (3.5 kPa).
This boiler must be isolated from the gas sup-
ply piping system by closing its individual manual
shut-off valve during any pressure testing of the
gas supply piping system at test pressures equal
to or less than ½ psig (3.5 kPa).
CONNECTING THE GAS PIPING
Refer to Figure 13 for the general layout at the
boiler. It shows the basic  ttings you will need. The
gas line enters the boiler from the right side.
The following rules apply:
1. Use only those piping materials and joining
methods listed as acceptable by the authority
having jurisdiction or in the absence of such
requirements, by the National Fuel Gas Code,
ANSI Z223.1-latest revision.
2. Use pipe joint compound suitable for LP gas
on male threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas con-
trols.
5. Use two pipe wrenches when making the
connection to the gas valve to keep it from
turning.
6. Install a manual shut-off valve in vertical pipe
about 5 feet above  oor.
7. Tighten all joints securely.
8. Propane – gas connections should only be
made by a licensed propane installer.
9. Two-stage regulation should be used by the
propane installer.
10.Propane – gas piping should be checked out
by the propane installer.
CHECKING THE GAS PIPING
Upon completion of piping, check immediately for
gas leaks. Open the manual shut-off valve. Test for
leaks by applying soap suds (or a liquid detergent) to
each joint. Bubbles forming indicate a leak. COR-
RECT EVEN THE SMALLEST LEAK AT ONCE.
Never use a match or open fl ame to test for leaks
*Outside diameter
The length of pipe or tubing should be measured from the gas meter
or propane second stage regulator.
GAS PIPING AT BOILER
GAS PIPE SIZES
NATURAL GAS
Length
of Pipe
– Ft.
Pipe Capacity – Btu Per Hour Input
Includes Fittings
1/2”3/4” 1” 1 1/4”
20 92,000 190,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000
PROPANE GAS
Length
of Pipe
– Ft.
Pipe Capacity – Btu Per Hour Input
Includes Fittings
Copper Tubing* Iron Pipe
5/8”3/4”1/2”3/4”
20 131,000 216,000 189,000 393,000
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000
Figure #12
Figure #13
WARNING
!
!

15
ELECTRICAL WIRING
Set heat anticipator at 0.4 amps for boilers
equipped with standing pilot, and at 0.6 amps for
boilers equipped with intermittent ignition. The
24 Volt thermostat leads shall be connected to
the two wires tagged “24 Volt thermostat” on the
boiler. For boilers with 67D-1 oat type low water
cut-off, the two wires are black. One wire is lo-
cated on the secondary of the 24 Volt transformer,
the second wire is located on the pressure limit
control. For boilers with PS-802 probe type low
water cut-off, one wire is green and is located on
terminal B or the PS-802, the second wire is black
and located on the pressure limit control.
ELECTRONIC THERMOSTATS
Certain types of electronic thermostats may lose
their memory or shut down. With 67D-1 oat type
low water cut-offs, this may occur each time the
thermostat calls for heat, due to the internal circuit
in the vent damper. With PS-802 probe type low
water cut-offs, this may occur each time the low
water cut-off detects a low water condition. If this
is the case, an isolation relay is required for the
thermostat circuit. A 24 bolt single pole single
throw (SPST) normally open (N.O.) relay is re-
quired, such as the Honeywell R8222A or equiva-
lent. Wire as shown in Figures 14A or 14B.
VENT DAMPER
The boiler is equipped with a factory wired
harness with 4 pin molex plug, that plugs into the
4 pin molex receptacle inside the vent damper
operator.
The vent damper must be connected for the
boiler to operate. Wiring diagrams follow for the
various different models.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
ELECTRIC POWER SUPPLY
All electrical work must conform to local codes,
as well as the National Electrical Code, ANSI/
NFPA-70, latest revision.
Run a separate 120 Volt circuit from a separate
over-current protective device in your electrical ser-
vice entrance panel. This should be a 15 ampere
circuit. Locate a shut-off switch at the boiler. It must
be turned off during any maintenance. Connect 120
Volt electrical supply to the primary leads on the
24 Volt transformer. Solder and tape or securely
fasten these connections with wire nuts.
The boiler, when installed, must be electrically
grounded in accordance with the requirements of
the authority having jurisdiction or, in the absence of
such requirements, with the National Electrical Code,
ANSI/NFPA No. 70-latest revision. Run a 14 gauge
or heavier copper wire from the boiler to a grounded
connection in the service panel or a properly driven
and electrically grounded ground rod.
INSTALL YOUR THERMOSTAT
The thermostat location has an important effect
on the operation of your boiler system. BE SURE
TO FOLLOW THE INSTRUCTIONS INCLUDED
WITH YOUR THERMOSTAT.
Locate the thermostat about ve feet above
the oor on an
inside wall. It
may be mount-
ed directly
on the wal l
or on a verti-
cally mounted
outlet box.
It should be
sensing av-
erage room
temperature,
so avoid the
following:
Turnoffelectricpoweratfuseboxbeforemakinganyline
Voltage connections. Follow local electrical codes.
WARNING
!
!
THERMOSTAT LOCATIONS TO AVOID
DEAD SPOTS:
Comers and
alcoves Behind doors
COLD SPOTS: HOT SPOTS:
Concealed pipes
or ducts
Concealed pipes
Fireplace
Stairwells - drafts TV sets
Radios
Unheated rooms
on
other side of wall
Lamps
Direct sunlight
Kitchens
CAUTION
!
!

16
ISOLATION RELAY WIRING FOR STEAM BOILERS WITH FLOAT TYPE
LOW WATER CUT OFF AND USING AN ELECTRONIC THERMOSTAT
ISOLATION RELAY WRITING FOR STEAM BOILERS WITH PROBE TYPE
LOW WATER CUT OFF AND USING AN ELECTRONIC THERMOSTAT
Figure #14A
Figure #14B

17
WIRING DIAGRAMS FOR BOILERS WITH PS-802 PROBE TYPE LOW WATER CUT-OFF
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.
INTERMITTENT IGNITION

18
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.
WIRING DIAGRAMS FOR BOILERS WITH PS-802 PROBE TYPE LOW WATER CUT-OFF
STANDING PILOT

19
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.
WIRING DIAGRAMS FOR BOILERS WITH 67D-1FLOAT TYPE LOW WATER CUT-OFF
INTERMITTENT IGNITION

20
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.
WIRING DIAGRAMS FOR BOILERS WITH 67D-1FLOAT TYPE LOW WATER CUT-OFF
STANDING PILOT