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