Lennox GWB8-262E-2 User manual

P/N# 240009276, Rev. A [03/2012]
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.
Tested for 50 psi.ASME
Working Pressure
C.S.A. Certified for
Natural gas or Propane
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.
!
GWB8-262E-2
GWB8-245E-2
GWB8-299E-2
GWB8-280E-2

2
1 - DIMENSIONS
Table 1 - Dimensions
BOILER MODEL NUMBER
DIMENSIONS
(INCH.)
FLUE
DIAMETER “A” WIDTH
GWB8-245E-2/GWB8-262E-2 727½
GWB8-280E-2/GWB8-299E-2 7 30¾
Add 5½” to height for vent Damper.
Figure 1 - Dimensions

3
2 - BOILER RATINGS AND CAPACITIES
Table 2 - Ratings and Capacities
BOILER MODEL
NUMBER (1)
† NATURAL GAS † PROPANE GAS AFUE
Input
(3) Mbh Heating
Capacity
(3) Mbh
(2)
NET AHRI
RATING
Water,
(3) Mbh
HIGH
ALTITUDE
INPUT
(3) Mbh
INPUT
(3)Mbh
HEATING
CAPACITY
(3)Mbh
(2)
NET
AHRI
RATING
Water,
(3) Mbh
HIGH
ALTITUDE
INPUT
(3) Mbh
INTERMITTENT
IGNITION
WITH VENT
DAMPER
GWB8-262E-2 262.5 220 191
236
83.9
GWB8-299E-2 299 251 218
269
83.7
GWB8-245E-2 245 206 179
220
83.9
GWB8-280E-2 280 235 204
252
83.7
† Input rating for sea level to 2,000 ft. (610m) above sea level.
• United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m)
above sea level.
• *Canada, 2000 ft (610m) to 4500 (1350m) above sea level, reduce input per table. Over 4500 ft
(1350m) above sea level. Contact Provincial authority having jurisdiction.
+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.
(2) Net AHRI Water rating shown based on piping and pickup allowance of 1.15. Consult manufacturer before
selecting boiler for installations having unusual piping and pickup requirements, such as intermittent
system operation, extensive piping systems, etc.
(3) Mbh = 1,000 Btuh = British Thermal Unit Per Hour
- Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or
terminal units. Net AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on
AHRI Standard as published by The Hydronics Institute.
- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated
heat loss of the building.
- Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.
BOILERS FOR USE AT HIGH ALTITUDE
Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level.
For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner
orifice size.
For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000
feet above sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54, or manufacturer for correct
orifice sizing information.
In Canada, a high altitude conversion kit is available to convert to altitudes of 2,000 to 4,500 feet above sea
level. Please consult your dealer.

4
3 - TABLE OF CONTENTS
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 the boiler room.
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
TO THE OWNER - Installation and service of this
boiler must be performed by a qualified installer.
TO THE INSTALLER - Leave all instructions with
boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.
!
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.
!
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
!
1 - Dimensions....................................................2
2 - Ratings And Capacities ....................................3
3 - Table of Contents............................................4
4 - Installation Procedure ..................................... 5
5 - Ventilation & Combustion Air ............................6
6 - Connecting Supply And Return Piping ................7
7 - Chimney And Vent Pipe Connection ................. 11
8 - Vent Damper Operation ................................. 14
9 - Gas Supply Piping......................................... 15
10 - Electrical Wiring.......................................... 15
11 - Wiring Diagrams ......................................... 16
12 - General Instructions.................................... 19
13 - Lighting Instructions ................................... 20
14 - Operating Your Boiler .................................. 21
15 - Maintaining Your Boiler ................................ 23
16 - Service Hints.............................................. 24
17 - Equipment And Optional Accessories ............ 25
Appendix A - Control Module ............................... 27

5
4 - INSTALLATION PROCEDURE
Table 3 - MINIMUM CLEARANCE DIMENSIONS
Inches (mm)
Top 6” (152mm)
Rear 6” (152mm)
Control Side 7” (178mm)
Opposite Side 6” (152mm)
Front 18” (457mm)
Flue/Vent Connector 6” (152mm)
Near Boiler Piping 1/2” (13mm)
WARNING
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
!
WARNING
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
1. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
flooring special base must be used. (See Replacement
Parts Section.) Boiler can not be installed on
carpeting.
NOTE: Greater clearances for access should supersede fire
protection clearances.
* Definition of Alcove is three sided space with no wall in
front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.
1. Installation must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
2. Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically fired Boilers,
ANSI/ASME CSD-1.
3. Boiler series is classified as a Category I. Vent
installation shall be in accordance with "Venting of
Equipment ," of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or "Venting Systems and Air Supply
for Appliances," of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
4. Boiler has met safe lighting and other performance
criteria with the gas manifold and control assembly on
the boiler per the latest revision of ANSI Z21.13/CGA
4.9.
5. Install boiler such that gas ignition system components
are protected from water (dripping, spraying, rain,
etc.) during appliance operation and service, (circulator
replacement, condensate trap, control replacement,
etc.).
6. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
7. Allow 24 inches (610mm ) at front and right side for
servicing and cleaning.
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.
Minimum Clearances to Combustible
Construction (as seen from above)
6"
BOILER
18"
6"
Front
7"
Control
Side

6
5 - 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 jurisdiction.
• 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 allowable room
volume for all appliances in space. Use a different
method if minimum volume not available.
A. Standard Method. Cannot be used if known air
infiltration rate is less than 0.40 air changes per
hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.
Volume ≥50 ft3x Total Input [Mbh]
B. Known Air Infiltration Rate. See Table 4 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate
(ACH) greater than 0.60.
Volume ≥21 ft3⁄ACH x Total Input [Mbh]
C. Refer to National Fuel Gas Code for opening
requirements between connected indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
A. Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in² per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in² per 2
Mbh of total input rating of all appliances in
enclosure.
B. One Permanent Opening Method. Provide opening
commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides/back
and 6 inches on front of boiler (does not supersede
clearance to combustible materials).
• 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.
Canada
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).
• 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 4 - Minimum Room Volume, Indoor Air Only*
Room Cubic Feet Volume
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
262.5 13125 55125 27563 18375 13781 11025 9188
299 14950 62790 31395 20930 15698 12558 10465
* Table values based on boiler only. Add volume for any additional appliances.

7
6 - CONNECTING SUPPLY AND RETURN PIPING
RELIEF VALVE
DISCHARGE
LINE
Check local
codes for
maximum
distance
from floor
or allowable
safe point of
discharge.
WARNING
Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.
Discharge line shall:
• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from floor or allowable safe point of discharge;
• be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge
line;
• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or
place any obstruction in discharge line;
• terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;
• allow complete drainage of the valve and the discharge line;
• be independently supported and securely anchored to avoid applied stress on the relief valve;
• be as short and straight as possible;
• terminate with plain end (not threaded);
• be constructed of material suitable for exposure to temperatures of 375°F (191°C); or greater.
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.
!
Figure 2 - Safety Relief Valve

8
6 - CONNECTING SUPPLY AND RETURN PIPING
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation. In-
stall discharge piping per these instructions.
!
Figure 3 - Temperature Pressure Gauge
Verify clean water supply is available to water inlet
valve. Install sand strainer when water supply is from
a well or pump.
Install hot water boiler above radiation level or as
required by Authority having jurisdiction install low
water cutoff device at time of installation. Periodic
inspection is necessary, as is flushing of float type
devices, per manufacturers specific instruction.
FOR USE WITH COOLING UNITS
A. Boiler used in connection with refrigeration
system, must be installed so that chilled medium
is piped in parallel with heating boiler. Appropriate
valves must be used to prevent chilled medium
from entering heating boiler. See Figure 5 page 9.
B. Boiler connected to heating coils located in air
handling units where they may be exposed to
refrigerated air circulation, piping system shall
be equipped with flow control valves or other
automatic means to prevent gravity circulation of
boiler water during cooling cycle.
LOW WATER TEMPERATURE AND LARGE WATER
CONTENT SYSTEM (See Figures 6 and 7, Page 10.)
Significant condensation may form in boiler and/or
venting system if boiler is operated for long period of
time with return temperatures of less than 120° F.
Condensate is corrosive and can cause severe
damage to boiler and venting system. Minimum
design return water temperature to prevent
condensation in boiler and venting is 120°F.
Minimum high limit setting is 140°F.
1. Boiler used in heating system where design water
temperatures below 140°F are desired (e.g. radiant
floor heating), 4-way mixing valve or suitable
alternative is required to prevent low temperature
return water from entering boiler. Follow mixing valve
manufacturer’s instructions.
2. Boiler connected to system having large water content
(such as former gravity system), install system bypass.
See Figures 6 and 7, page 10.
3. If boiler water reset control is used to operate boiler,
minimum reset supply water temperature setpoint
must be at least 140°F, unless mixing valve is used as
in (1) above.
1. Boiler is shipped assembled. Install discharge piping
from safety relief valve. See Warning, Page 7.
2. Install temperature pressure gauge.
• Apply pipe sealant to threads on shaft of gauge.
• Thread gauge into supply water tee. See Figure 3.
NOTICE
DO NOT TIGHTEN GAUGE BY HAND!! Gauge should
be tightened using crescent wrench or 9/16” open
end wrench. See Figure 3.
3. Connect supply and return lines to boiler. Connections
may require additional fittings and parts, as shown on
diagrams.

9
Figure 5 - Chilled Water Piping
Figure 4 - Typical Hot Water Piping
6 - CONNECTING SUPPLY AND RETURN PIPING

10
Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY
Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN
Bypass Piping Required For High Mass (Large Water Content) Systems
6 - CONNECTING SUPPLY AND RETURN PIPING

11
Boilers connecting to gas vents or chimneys, vent
installations shall be in accordance with “Venting of
Equipment”, of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or “Venting Systems and Air Supply
for Appliances,” of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
Check Your Chimney
It must be clean, right size, properly constructed and
in good condition.
Chimney Sizing
Chimney sizing, and vent installation must be in
accordance with The National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or CAN/CSA B149.1, or applicable
provisions of local building codes.
This is a high efficiency boiler with low stack
temperature. Following recommendations are in
addition to requirements of the National Fuel Gas
Code.
1. Type B double wall vent pipe is recommended for
vent connector. Single wall vent connectors should
not be used unless following conditions are true:
a) Except for basement, boiler is not installed in
unheated space.
b) Total horizontal portion of vent connector, not
including elbows is less than 5 feet in length.
2. Outside chimneys (i.e. chimneys exposed to
outdoors below roof line) should not be used unless
they are:
a) enclosed in a chase, or
b) lined with type B vent pipe, or listed flexible
vent liner, or other certified chimney lining system.
3. Where possible it is recommended to common vent
boiler and water heater.
4. For multiple boiler installations, consult boiler
manufacturer for venting recommendations.
Connecting The Vent Damper And Vent
Connector
Refer to Figure 1, page 2 for size and location of vent
(flue opening).
NOTICE
Damper blade on furnished vent damper has 1/2
square inch hole (approximately 3/4” diameter).
Boilers equipped with intermittent ignition, hole
should be plugged by using plug supplied with vent
damper.
1. Position furnished vent damper on top of flue outlet
collar. Fasten damper securely to flue outlet collar with
sheet metal screws. Verify damper blade has clearance
to operate inside of diverter. Do not modify either draft
diverter or vent damper during installation.
As An Option
Damper may be installed in horizontal or vertical
position, closer to flue outlet collar preferred. See
Figures 8, 9 and 10 and enclosed vent damper
instructions.
2. Install vent damper to service only single boiler for
which it is intended. Damper position indicator shall be
in visible location following installation. Locate damper
so it is accessible for servicing. See Figure 9.
3. Damper must be in the open position when appliance
main burners are operating.
4. Boiler is equipped with factory wired harness that plugs
into vent damper.
5. Slope pipe up from boiler to chimney not less than 1/4”
per foot.
6. Run pipe as directly as possible with as few elbows as
possible.
7. Do not connect to fireplace flue.
8. End of vent pipe must be flush with inside face of
chimney flue. Use a sealed-in thimble for chimney
connection.
Fasten sections of vent pipe with sheet metal screws
to make piping rigid. Support horizontal potions of
vent system to prevent sagging. Use stovepipe wires
every 5’ to support pipe from above. Use double wall
vent pipe if vent pipe must go through crawl space.
Where vent pipe passes through combustible wall
or partition, use ventilated metal thimble. Thimble
should be 4 inches larger in diameter than vent pipe.
7 - CHIMNEY AND VENT PIPE CONNECTION
WARNING
Boiler and venting installations shall be performed
by a qualified expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to fire or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
!

12
Minimum Vent Pipe Clearance
Wood and other combustible materials must not be
closer than 6” from any surface of single wall metal
vent pipe. Listed Type B vent pipe or other listed
venting systems shall be installed in accordance with
their listing.
Removing Existing Boiler From Common
Venting System
When an existing boiler is removed from common
venting system, common venting system is likely to be
too large for proper venting of appliances remaining
connected to it.
At time of removal of existing boiler, following steps
shall be followed with each appliance remaining
connected to the common venting system placed
in operation, while other appliances remaining
connected to common venting system are not in
operation.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
7 - CHIMNEY AND VENT PIPE CONNECTION
5. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the 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.
WARNING
Boiler and venting installations shall be performed
by a qualified expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to fire or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
!
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
!

13
8 - VENT DAMPER OPERATION
Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement
Annually check vent damper and all flue product
carrying areas of appliance, with particular attention
given to deterioration from corrosion or other
sources. If you see corrosion or other deterioration,
contact your heating contractor for repairs. Check
vent damper operation as follows:
• When boiler is off, check vent damper positions
indicator points to closed position, Figure 10.
• Turn thermostat or controller up to call for heat and
check vent damper indicator points to open position.
• Turn thermostat or controller down again and check
damper position indicator returns to closed position.
Vent Damper Manual Operation
Vent damper may be placed in open position to
permit burner operation by using “HOLD DAMPER
OPEN” switch, located on damper controller.
Thermostat will control burner firing as before, while
damper will remain open. DO NOT turn damper
open manually or motor damage will result. Set
switch to “AUTOMATIC OPERATION” to close vent
damper during burner off cycle.
For further information, and vent damper
troubleshooting guide, refer to manual packaged with
vent damper.
Inspect vent damper at least once a year by a
qualified service technician.
Figure 10 - Vent Damper Position Indicator

14
9 - GAS SUPPLY PIPING
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.
!
!
CHECK GAS SUPPLY
Gas pipe to your boiler must be correct size for
length of run and for total BTU per hour input of all
gas utilization equipment connected to it. See Table
5 for proper size. Be sure your gas line complies with
local codes and gas company requirements.
CONNECTING THE GAS PIPING See Figure 11.
Gas line enters boiler from right side.
• 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
• Use pipe joint compound suitable for LP gas on male
threads only.
• Use ground joint unions.
• 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 above floor.
• Tighten all joints securely.
• Propane gas connections should only be made by
licensed propane installer.
• Two-stage regulation should be used by propane
installer.
• Propane gas piping should be checked out by propane
installer.
CHECKING GAS PIPING
DANGER
Fire Hazard. Do not use matches, candles, open
flames, or other methods providing ignition source.
Failure to comply will result in death or serious
injury.
!
Pressure test boiler and gas connection before placing
boiler in operation.
• 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.
• Locate leakage using gas detector, noncorrosive
detection fluid, or other leak detection method
acceptable to authority having jurisdiction. Do
not use matches, candles, open flames, or other
methods providing ignition source.
• Correct leaks immediately and retest.
NATURAL GAS
Pipe Capacity - BTU Per Hour Input
Includes Fittings
Length of
Pipe - FT 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
PROPANE GAS
Pipe Capacity - BTU Per Hour Input
Includes Fittings
Length of
Pipe - FT
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
* Outside diameter
Measure length of pipe or tubing from gas meter or
propane second stage regulator.
Table 5 - Gas Pipe Sizes
Figure 11 - Gas Piping

15
10 - ELECTRICAL WIRING
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:
• USA- National Electrical Code, ANSI/NFPA 70.
• Canada - Canadian Electrical Code, Part I, CSA C22.1:
Safety Standard for Electrical Installations.
ELECTRIC POWER SUPPLY
Run separate 120 volt circuit from separate over
current protective device in electrical service entrance
panel. This should be a 15 ampere circuit. Locate
shut-off switch at boiler. It must be turned off during
any maintenance. Connect 120 volt power supply to
control leads L1 (HOT) and L2.
Run a 14 gauge or heavier copper wire from boiler
to grounded connection in service panel or properly
driven and electrically grounded ground rod.
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall about
four feet above the floor.
2. NEVER install thermostat on outside wall.
3. Do not install a thermostat where it will be affected
by drafts, hot or cold pipes, sunlight, lighting fixtures,
televisions, a fireplace, or a chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop the
burners.
5. Instructions for the final adjustment of the thermostat
are packaged with the thermostat (adjusting heating
anticipator, calibration, etc.)
Set heat anticipator at .2 amps. 24 volt thermostat
connects to aquastat terminals T and TV.
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.
!
NOTICE
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
VENT DAMPER WIRING
Boiler is equipped with factory wired harness with 4 pin
molex plug, that plugs into 4 pin molex receptacle inside
vent damper operator.
Vent damper must be connected for boiler to operate.
If any of the original wire as supplied with this
appliance must be replaced,
It must be replaced with type 105°C thermoplastic
wire or its equivalent.

16
11 - WIRING DIAGRAMS
Figure 12 - Integrated High Limit Electronic Ignition Control (240008781)
I
Inducer is not an option.
WARNING
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
!

17
11 - WIRING DIAGRAMS
Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)

18
11 - WIRING DIAGRAMS
Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)

19
12 -GENERAL INSTRUCTIONS
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 it open. Start with
lowest radiation unit. Open air vent on this unit. When
all air has escaped and water starts to flow from vent,
close it.
• Go to next radiation unit, and repeat this process.
Repeat until you have covered every radiation units in
the system (ending up at highest unit in system).
• If your units have automatic vents, manual venting is
unnecessary but it will speed up the proper filling of
your system.
• If your system is closed expansion tank system, you
may leave it open to refill system automatically as
needed.
• Check temperature pressure gauge. Not position of hand
indicating pressure. This should be between 10 and 15
psi. Any lowering of this movable hand below 10 psi.
Will indicate loss of water due to leakage. Automatic
fill valve should compensate for this. Instructions are
packaged with the valve.
NOTICE
Never run water in a hot empty boiler.

20
13 - LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
OFF
ON
INLET
GAS CONTROL KNOB PILOT ADJUSTMENT
(UNDER CAP SCREW)
PILOT
OUTLET
OUTLET
WIRING
TERMINALS (2)
INLET
PRESSURE
TAP TERMINALS
(2)
GROUND
PRESSURE
TAP
PRESSURE REGULATOR ADJUSTMENT
(UNDER CAP SCREW)
OUTLET
5. Remove lower front panel.
6. Rotate the gas control knob clockwise to
“OFF”.
7. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions.
If you don’t smell gas, go to next step.
8. Rotate gas control knob counterclockwise to
“ON”.
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” and call
your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if
service is to be performed.
3. Push in gas control knob slightly and turn
clockwise to “OFF” Do not force.
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
service 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.
!
!
Figure 15 - Automatic Gas Valve