Lennox GWB8-042IE-2 User manual

P/N# 240009135, Rev. C [06/2012]
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
These instructions must be affixed on
or adjacent to the boiler.
GAS FIRED BOILER
INSTALLATION
INSTRUCTIONS
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
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.
C.S.A. Certified
For Natural Gas Or Propane
Tested For 50 psi.
ASME
Working Pressure
WARNING
Improper installation, adjustment, alteration,
service, or maintenance could result in death
or serious injury. Refer to this manual for
assistance. For additional information consult
a qualified installer, service agency, or the gas
supplier.
!
GWB8-042IE-2, GWB8-075IE-2
GWB8-112IE-2, GWB8-150IE-2
GWB8-187IE-2, GWB8-225IE-2

2
Boiler Ratings & Capacities...................... 3
Dimensions ............................................. 4
Installation Procedure............................. 5
Ventilation & Combustion Air .................. 6
Installation System Piping ...................... 7
Vent Installation ................................... 10
Optional Horizontal Venting Instruction 13
Gas supply Piping .................................. 14
Electrical Wiring .................................... 16
Sequence of Operation .......................... 15
Wiring Diagrams ................................... 18
Starting Your Boiler............................... 19
Checking and Adjusting......................... 21
Maintaining Your Boiler ......................... 23
Service Hints ......................................... 24
Equipment & Optional Accessories ........ 25
Appendix A - Control Module ................. 27
A.1 Installation Environment Considerations.27
A.2 Electrical Connections.......................... 27
A.3 Adjusting Settings............................... 27
A.4 Display .............................................. 27
A.5 Operation .......................................... 28
A.6 Boiler High Limit Temperature Controller 29
A.7 Troubleshooting .................................. 29
A.8 Troubleshooting Error Codes................. 29
A.9 Intermittent Pilot ................................ 30
TABLE OF CONTENTS
Safety Symbols & Warnings
The following defined symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
NOTICE
Used to address practices not related to personal
injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
!
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
WARNING
Keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors
and liquids.
DO NOT obstruct air openings to 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.
TO THE INSTALLER - Leave all instructions with
boiler for future reference.
When this product is installed in Commonwealth of
Massachusetts installation must be performed by
Licensed Plumber or Licensed Gas Fitter.
!
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.
!

3
New York City MEA Number 484-84-E Vol. IV.
BOILER RATINGS & CAPACITIES
Model
Input
*Mbh
Heating
Capacity
*Mbh
**Net
AHRI
Rating
Water
*Mbh
AFUE
Vent Diameter (Inches)
To Chimney
(Category I)
Horizontal Vent
(Category III)
GWB8-042IE-2 42.5 36 31 84.4 4 3
GWB8-075IE-2 75.0 63 55 83.4 4 3
GWB8-112IE-2 112.5 94 82 83.0 4 3
GWB8-150IE-2 150.0 125 109 82.7 4 3
GWB8-187IE-2 187.5 155 135 82.3 4 4
GWB8-225IE-2 225.0 186 162 82.0 4 4
* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only.
• U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each
1,000 feet above sea level.
• Canada Only - Boilers may be used at high altitude (2,000-4500 feet/640-1350m) by using a certified
field conversion kit, resulting in a 10% de-rate. Contact Provincial authority having jurisdiction for
installations above 4500 ft (1350m)above sea level.+ Heating Capacity based on D.O.E. (Department
of Energy) test procedure.
** Net AHRI Water Ratings i ndicate amount of remaining heat input that can be used to heat the radiation
or terminal units. Net AHRI Ratings shown are based on an allowance of 1.15 Selection of
boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated
heat loss of building.
Manufacturer should be consulted before selecting a boiler for installations having unusual piping
and pickup requirements.
This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing.
These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron boilers Design Certified by C.S.A. (Canadian Standards
Association) for use with Natural and Propane Gases. Constructed and hydrostatically tested for maximum working pressure of 50 psi in
accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.
Boilers must stand on noncombustible floor. If installed on combustible floor, please refer to Repair Parts manual for appropriate
Combustible Floor Base part number.
Boilers For Use At High Altitude
Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level,
input ratings are reduced by change in main burner orifice size.
U.S.A. Only - For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above
sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1,
or manufacturer for correct orifice sizing information.
Canada Only - For altitudes in the range of 2,000-4,500 feet (610 - 1350m) above sea level, boilers may be field equipped for use
at high altitude by using a certified field conversion kit. The change in main burner orifice size results in the boiler’s input rating
being reduced by 10%.The conversion shall be carried out by a manufacturer’s authorized representative, in accordance with the
requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in accordance with the requirements of
CSA-B149 Natural Gas and Propane Installation Code. The certified field conversion kit includes a conversion data plate, which must be
attached to the boiler adjacent to the rating plate, indicating that the boiler has been converted for high altitude use. The conversion
data plate must be filled in with the correct conversion information.
For altitudes over 4500 feet (1350m), contact Provincial authority having jurisdiction.
Table 1 RATINGS NATURAL AND PROPANE GASES

4
DIMENSIONS
Model Width (A)
GWB8-042IE-2 11
GWB8-075IE-2 14-1/4
GWB8-112IE-2 17-1/2
GWB8-150IE-2 20-3/4
GWB8-187IE-2 24
GWB8-225IE-2 27-1/4

5
INSTALLATION PROCEDURE
WARNING
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
!
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/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1
2. Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
and Safety Devices for Automatically fired Boilers,
ANSI/ASME CSD-1.
3. This 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.
4. Boiler has met safe lighting and other performance
criteria with gas manifold and control assembly on
boiler per latest revision of ANSI Z21.13/CGA 4.9.
5. Install such that gas ignition system components are
protected from water (dripping, spraying, rain, etc.)
during appliance operation and service, (circulator
replacement, condensate trap, control replacement,
etc.).
6. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
7. Verify you have the right size boiler before starting
installation. See rating and capacity table.
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.
9. Boiler installed in building under construction, take
care to insure clean combustion air supply during
construction process. Airborne particulates such as
from drywall dust and from fiberglass insulation can
clog burner ports and cause incomplete combustion and
sooting.
NOTICE
Follow local regulations with respect to installation
of CO detectors.
Table 2 - BOILER MINIMUM CLEARANCE TO
COMBUSTIBLES
Unit Minimum
Clearances
Top 6” (152mm)
Rear 6” (152mm)
Control Side 8” (203mm)
Opposite Side 6” (152mm)
Front (Alcove) 18” (457mm)
Flue/Vent Connector 6” (152mm)
Near Boiler Piping 1/2” (13mm)
Set unit on concrete or other noncombustible material base or
floor. DO NOT INSTALL ON CARPETING.
Figure 1 - Minimum Clearances To Combustible
Construction
10. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
flooring special base must be used. (See Replacement
Parts Section.) Do Not Install Boiler on carpeting.
11. Verify boiler is supplied with correct type of gas, fresh
air for combustion, and suitable electrical supply.
WARNING
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
8”
Boiler
Rear
Front
Control Side
Opposite Side
18”
6”
6” 8”

6
VENTILATION & COMBUSTION AIR
Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections
8.2, 8.3 or 8.4 of Natural Gas and Propane Installation
Code, CAN/CSA B149.1, or applicable provisions of local
building codes.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
• Engineered Installations. Must be approved by
authority having jurisdictions.
• Mechanical Air Supply. Provide minimum of 0.35
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.
• All Indoor Air. Calculate minimum volume for all
appliances in space. Use a different method if
minimum volume not available.
оStandard Method. Cannot be used if known air
infiltration rate is less than 0.40 air changes per
hour. See Table 3 for space with boiler only. Use
equation for multiple appliances.
Volume ≥50 ft3x Total Input [Mbh]
оKnown Air Infiltration Rate. See Table 3 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate
(ACH) greater than 0.60.
Volume ≥15 ft3/ACH x Total Input [Mbh]
оRefer to National Fuel Gas Code for opening
requirements between connection indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
оTwo Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom
enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in2per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in2per 2
Mbh of total input rating of all appliances in
enclosure.
оOne Permanent Opening Method. Provide opening
commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides
and back and 6 inches on front of boiler (does not
supersede clearance to combustible materials).
оCombination Indoor and Outdoor Air. Refer to
National Fuel Gas Code for additional requirements
for louvers, grilles, screens and air ducts.
• Combination Indoor and Outdoor Air. Refer to
National Fuel Gas Code for application information.
National Gas and Propane Installation Code Requires
providing air supply in accordance with:
• Section 8.2 and 8.3 when combination of appliances
has a total input of up to and including 400 Mbh (120
kW).
оDoes not have draft control device.
• Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW).
• Refer to Natural Gas and Propane Installation Code
for specific air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.
Table 3- Air Infiltration Rate
Input Mbh Standard
Method
Known Air Infiltration Rate Method (Air Changes Per Hour)
0.1 0.2 0.3 0.4 0.5 0.6
42.5 2125 6375 3188 2125 1594 1275 1063
75 3750 11250 5625 3750 2813 2250 1875
112.5 5625 16875 8438 5625 4219 3375 2813
150 7500 22500 11250 7500 5625 4500 3750
187.5 9375 28125 14063 9375 7031 5625 4688
225 11250 33750 16875 11250 8438 6750 5625

7
1. Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements.
2. Install relief valve on 3/4” pipe nipple in tapped boiler
opening.
A. Pipe discharge line following guidelines in preceding
Warning. See Figure 2.
B. Discharge line pipe size shall be equal or greater
than that of relief valve outlet over entire length
of discharge line with no intervening shutoff valve
between safety relief valve and discharge to
atmosphere.
C. Discharge line shall terminate with plain end to
atmosphere where any discharge will be clearly
visible and is at no risk of freezing.
D. Discharge line shall be independently supported to
avoid applied stress on relief valve.
E. Installation shall allow complete drainage of relief
valve and discharge line.
3. Install Drain Valve on lower left side of boiler as
marked.
4. Install Temperature and Pressure Gauge into ¼”
bushing threaded in tee furnished with supply piping.
See Figures 3 and 4 .
5. Connect Supply and Return Lines to boiler. Figure 3 &
4. Connections may require certain additional fittings
and parts.
INSTALLATION SYSTEM PIPING
WARNING
Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.
Discharge line shall:
• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from 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; or greater.
Refer to local codes and appropriate ANSI/ASME Boiler and Pressure Vessel Code, Section IV, or Boiler,
Pressure Vessel and Pressure Piping Code, CSA B51 for additional installation requirements.
!
Check local codes
for maximum
distance from
floor or other
allowable safe
point of discharge
RELIEF VALVE
DISCHARGE
PIPING
Figure 2 - Safety Relief Valve Discharge Piping

8
Figure 3 - Forced Hot Water Typical Piping
Figure 4 - Forced Hot Water Typical Piping
With Zone Control Valve
INSTALLATION SYSTEM PIPING

9
• Install radiation units (panels, radiators or cabinets) and
supply and return mains first then make connections at
boiler.
• Verify clean water supply is available when connecting
cold water supply to water valve. Install sand strainer at
pump when water supply is from well or pump.
• Provide low water cutoff device when boiler is installed
above radiation level or as required by the Authority
having jurisdiction, either provide as part of boiler
or at time of boiler installation. Periodic inspection
is necessary, as is flushing of float type devices, per
manufacturers specific instructions.
• Boiler used in connection with refrigeration systems shall
be installed so chilled medium is piped in parallel with
heating boiler with appropriate valves to prevent chilled
medium from entering heating boiler. See
Figure 5 .
• Boiler connected to heating coils located in air handling
units 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.
INSTALLATION SYSTEM PIPING
Figure 5 - Piping Arrangements For Boiler When
Used In Connection With Refrigeration
System
Low Design Water Temperature Systems (Below
140°F) And Large Water Content Systems
Condensation is corrosive and can eventually cause severe
damage to boiler and venting system.
• Minimum design return water temperature to prevent
condensation in boiler and venting is 120°F. Minimum
high limit setting is 140°F.
• Boiler used in heating systems where design water
temperatures below 140°F are desired (e.g. radiant floor
heating), a 3-way or 4-way mixing valve or suitable
alternative is required to prevent low temperature return
water from entering boiler. When using mixing valve,
follow manufacturer’s installation instructions.
• Boiler connected to system having large water content
(such as former gravity system), suggest use of bypass
piping. See
Figure 6 .
Figure 6 - Bypass Piping

10
Check Your Chimney
Chimney must be clean, right size, properly constructed
and in GOOD CONDITION.
1. Installation must conform to requirements of the
authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes..
2. Boiler’s induced draft blower has 3” outlet. 3” X
4” increaser fitting is included in parts bag. Locate
increaser fitting on outlet of induced draft blower, and
secure gas-tight with bead of furnished silicone sealant.
Increaser fitting is required on this boiler for Category I
venting, and 4” is minimum permissible vent diameter.
This does not imply vent connector is intended to be 4”
diameter pipe. Vent connector shall be sized according
to appropriate venting tables in the National Fuel
Gas Code and may be required to be larger than 4”
diameter.
NOTICE
Boiler installation for chimney venting is not complete
unless increaser fitting is located and secured.
3. These are high efficiency boilers with low stack or
exhaust temperature.
4. Venting into masonry chimney without liner, line
chimney from top to bottom with either:
A. Listed Type B vent pipe
B. Listed flexible vent liner
C. Poured ceramic liner.
5. Outside chimneys should not be used unless they are
(choose one of the following):
A. Enclosed in a chase
B. Lined with Type B vent pipe
C. Use listed flexible vent liner
D. Use certified chimney lining system
6. Vent connector from boiler to chimney should run as
directly as possible with as few elbows as possible.
7. Where possible, it is recommended to common vent
water heater and boiler. Consult appropriate Vent
Sizing Tables in National Fuel Gas Code for specific
requirements of multiple appliance venting.
8. Boiler is only appliance connected to vent, Type B vent
pipe is recommended for vent connector.
9. Slope pipe up from boiler to chimney not less than 1/4”
per foot (21mm/m).
10. End of vent pipe must be flush with inside face of
chimney flue. Use sealed-in thimble for chimney
connection.
11. Fasten sections of vent pipe with sheet metal screws to
make piping rigid. Use stovepipe wires to support pipe
from above.
12. Do not connect to fireplace flue.
13. Do not install damper on this boiler.
Minimum Vent Pipe Clearance
• Use Type B vent pipe through crawl space. Where vent
pipe passes through combustible wall or partition, use
ventilated metal thimble. Thimble should be 4 inches
larger in diameter than vent pipe.
• Boiler installed with single wall vent, must have 6”
clearance between its surface and any combustible
material. New Type B gas vent or flexible liner must be
installed in accordance with instructions furnished with
vent. Maintain clearances as specified for vent pipe.
• Verify vent pipe is fire-stopped where it goes through
floor or ceiling. It should have approved vent cap with
clearances from roof. If clearances are less than shown
in have vent checked by local authorities. See Figure 7,
Page 11.
• Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.
VENT INSTALLATION

CHECK YOUR CHIMNEY
For boilers for connection 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 of the Natural Gas and Propane Installation
Code, CAN/CSA B149.1, or applicable provisions
of the local building codes.
Figure 7 - Type B Gas Vent
11
VENT INSTALLATION

12
Removing Existing Boiler From Common Venting
System
When an existing boiler is removed from a common
venting system, the common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it.
At the time of removal of an existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliance 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 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.
VENT INSTALLATION
5. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use flame of a match
or candle, or smoke from a cigarette, cigar, or pipe.
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.
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.
8. It is recommended that existing gas vents be checked
to be sure they meet local codes.

13
OPTIONAL HORIZONTAL VENTING INSTRUCTION
Horizontal venting with a power venter is an alternate
method of sidewall venting. This boiler is CSA listed for
sidewall venting with standard single wall galvanized or
Type B vent pipe when using the following power venter
kits, which were specifically sized for these boilers:
Table 4- Field Controls
Number Of
Boiler Sections
Field Controls
Power Venter
2, 3, 4, 5 SWG-4D
6, 7 SWG-5D
Some possible reasons for using a power venter for
sidewall venting:
1. May be preferred by local codes.
2. Need a vent piping run beyond 30’ (9.1m) (but not
more than 50’ (15.2m)).
3. The boiler installation site experiences gusting or high
winds. A power venter can help prevent the boiler from
short cycling due to gusting or high winds by providing
vent exhaust pressures greater than the boiler’s
induced draft blower alone.
4. When installers or homeowners prefer a negative
pressure vent system instead of a positive pressure
vent system.
5. May be more cost effective than stainless steel
venting, particularly at longer vent length.
The Field Controls power vent kit includes either a
SWG-II-4HD or SWG-II-5 power venter, a MG-1 4”
barometric draft controller, and the CK-43D controls kit.
Confirm that installing a power venter is an option allowed
by local codes. Follow the specific power venter installation
instructions issued with the power venter kits. Although
the power venter is equipped with its own fan, the fan on
the boiler remains in place and is unaltered when a power
venter is used.
When sidewall venting, flue gases must be vented to a
point in relation to the prevailing wind so that they may
freely disperse without being blown back at the building
causing discoloration, or into the building through doors or
windows causing odors. Also, under certain conditions flue
gases will condense, forming moisture. In such cases, steps
should be taken to prevent building materials at the vent
terminal from being damaged by the exhausted flue gas.
When installing single wall galvanized vent pipe for power
venting follow the specific power venter installation
instructions for layout, location of the barometric draft
control and termination connections.
When joining and sealing the single wall galvanized or Type
B vent piping, use RTV silicone sealant with a minimum
temperature rating of 400°F. For 3” vent pipe runs, be-
gin with the female end of the vent pipe over the boiler’s
induced draft blower outlet. For 4” vent pipe runs begin
with the galvanized 3” to 4” increaser fitting (included in
the boiler’s parts bag) over the induced draft blower outlet.
Then follow by placing the female end of the 4” vent pipe
over the increaser fitting.
When joining pieces of single wall galvanized vent pipe, a
substantial bead of silicone should be used at the joint to
insure a leak proof connection.

14
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 gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the fire
department.
!
!
Table 5 - Gas Pressures
PRESSURE GAS
NATURAL PROPANE
MIN. SUPPLY 5" w.c. 11" w.c.
MAX. SUPPLY 13.5" w.c. 13.5" w.c.
MANIFOLD 3.5" w.c. 10" w.c.
Verify minimum pressure while boiler is operating.
Verify maximum pressure when boiler is not operating
Connecting Gas Piping
Gas line enters boiler from right side. Flexible gas
connectors must never breach any boiler openings.
• 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
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
• All pipe compound must be resistant to liquefied
petroleum gas.
• Install ground joint union in gas supply line between
shut-off valve and boiler controls.
• Install sediment trap upstream of gas controls.
• Use two pipe wrenches when making connection to gas
valve to keep it from turning.
• Install manual shut-off valve in vertical pipe about 5 feet
(1.5m) above floor. See Figure 8.
• 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 check by propane installer.
Check Gas Supply
Gas pipe 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 6 & 7, Page 15 for proper size.
Be sure your gas line complies with local codes and gas
company requirements.
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.
!
Check Gas Piping
Pressure test boiler and gas connection before placing
boiler in operation.
• Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas
supply system.
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve. See Figure 8.
• Locate leakage using gas detector, noncorrosive
detection fluid, or other leak detection method
acceptable to authority having jurisdiction.
• Correct leaks immediately and retest.
GAS SUPPLY PIPING
Figure 8 - Gas Piping At Boiler

15
GAS SUPPLY PIPING
*Outside diameter:
Measure length of pipe or tubing from gas meter or propane
second stage regulator.
Table 6 - NATURAL GAS
Length of
Pipe - Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
½" ¾" 1" 1¼"
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
Table 7- PROPANE GAS
Length
of
Pipe - Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
Copper Tubing* Iron Pipe
⅝"¾"½"¾"
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

16
ELECTRICAL WIRING
Electrical Wiring
See wiring diagram Figure 10 page 18 for details.
Refer to Ladder Diagram from document envelope
received with boiler.
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.
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
Circulator harness is factory wired to control module.
Connect harness to circulator in field. See Figure 9.
WARNING
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.
!
Thermostat Installation
1. Thermostat should be installed on an inside wall about
four feet above the floor.
2. NEVER install a thermostat on an 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.)
6. Set heat anticipator at .2 amps. 24 volt thermostat
connects to yellow low voltage wires labled T.
Electric Power Supply
Run a separate 115 volt circuit from separate over current
protective device 15 ampere circuit in electrical service
entrance panel.
Connect 115 volt power supply to terminals L1 (HOT) and
L2 inside J box.
Run 14 gauge or heavier copper wire from boiler to
grounded connection in service panel or properly driven
and electrically grounded ground rod.
J BOX
L1 & L2
TRANSFORMER THERMOSTAT WIRES
R
R
TH
E
L
CIRCULATOR
HARNESS
CI
CI
CI
C
C
H
H
H
H
TRANSFORMER LINE VOLT
E
R LINE V
O
L
T
T
T
BLOWER
TRANSFORMER
SECONDARY
Figure 9 - Control Module Panel

17
Sequence of Operation - Figure 10, Page 18.
1. Thermostat calls for heat, control relay contacts.
2. Circulator pump is powered through terminals C1 and
C2. Control holds off burner and attempts to satisfy
thermostat with residual boiler heat.
3. Induced draft blower and transformer primary are
powered.
4. When blower gets up to speed and blower suction
pressure reaches pressure switch set point, pressure
switch contacts close sending 24 volts to pilot control
from transformer secondary.
5. Pilot gas valve opens and spark initiates to light pilot
burner.
6. When pilot flame is proven, spark drops out.
7. Main gas valve opens and pilot burner ignites main
burners.
8. If boiler water temperature reaches high limit set
point, high limit contacts open, cutting power to
blower and pilot control. Burners extinguish and blower
stops. Circulator pump continues to run as long as
the thermostat continues to call for heat. When boiler
water temperature drops past the high limit set point
and through the differential, high limit contacts close,
repeating steps 3-7.
9. If venting system becomes blocked, blower suction
pressure will drop below pressure switch set point,
opening pressure switch contacts and cutting power to
pilot control. Burners will extinguish, but blower will
remain powered as long as thermostat continues to call
for heat. If venting system clears, steps 4-7 will repeat.
10. Thermostat is satisfied, ending call for heat. Relay coil
is de-energized, opening contacts. Burners extinguish.
Blower and circulator pump stop.
SEQUENCE OF OPERATION

18
WIRING DIAGRAMS
Figure 10 - Control Module
Damper is not an option.

19
Filling System With Water
• 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 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 unit in
system. End at highest unit in system.
• If units have automatic vents, manual venting is
unnecessary but it will speed up proper filling of system.
• If system is closed expansion tank system, you may
have automatic fill valve. Leave it open to refill system
automatically as needed.
• Check temperature-pressure gauge. Note position of
hand indicating pressure. This should be between 10
and 15 psi. Any lowering of this movable hand below
10 psi indicates loss of water due to leakage. Automatic
fill valve should compensate for this. Instructions are
packaged with valve.
STARTING YOUR BOILER
NOTICE
Do not add water into hot empty boiler.

20
Operating Instructions.
1. STOP! Read Safety Information on previous page.
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 burner. Do not attempt to light
pilot by hand.
5. Remove burner access panel.
OFF
ON
INLET
GAS CONTROL KNOB
SHOWN IN "ON" POSITION
6. Depress gas control knob slightly and turn clockwise
to “OFF” position.
7. Wait five (5) minutes to clear out any gas. If you then
smell gas STOP! Follow WHAT TO DO IF YOU SMELL
GAS. If you don’t smell gas, go to next step.
8. Turn gas control knob counterclockwise to “ON.”
9. Turn on all electric power to the appliance.
10. Set thermostat to desired setting.
11. After visually inspecting the flame, replace lower front
panel.
12. If appliance will not operate after several tries, turn gas
control knob to “OFF” and call your service technician
or gas supplier.
To Turn Off Gas To The Appliance
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if servicing is
to be performed.
3. Depress gas control knob slightly and turn clockwise
to “OFF” position. Do not force.
STARTING YOUR BOILER
Figure 11 - Gas Control Knob
WARNING
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.
• 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.
• 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 ser-
vice technician. Force or attempted repair may
result in fire or explosion.
• 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.
!
LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM
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.
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switches; 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.
!
!