Lennox International Inc Boiler Gas Fired Hot Water Boiler User Manual

INSTALLATION  
INSTRUCTIONS  
PRODUCT LITERATURE  
Lennox Industries Inc.  
Dallas, Texas  
GWB8-262E-2  
GWB8-245E-2  
GWB8-299E-2  
GWB8-280E-2  
GAS FIRED BOILER  
RETAIN THESE INSTRUCTIONS FOR  
FUTURE REFERENCE  
These instructions must be afxed on  
or adjacent to the boiler.  
!
WARNING  
Improper installation, adjustment,  
alteration, service, or maintenance  
can cause injury or property damage.  
Refer to this manual. For assistance  
or additional information consult a  
qualied installer, service agency, or  
the gas supplier.  
This boiler cannot be used with all types of  
chimneys. Read these instructions carefully  
before installing.  
GAS-FIRED HOT WATER BOILERS  
These Gas-Fired Water boilers are low pressure,  
sectional cast iron boilers Design Certied 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. Certied for  
Natural gas or Propane  
P/N# 240009276, Rev. A [03/2012]  
2 - BOILER RATINGS AND CAPACITIES  
Table 2 - Ratings and Capacities  
† NATURAL GAS  
† PROPANE GAS  
AFUE  
(2)  
(2)  
HIGH  
NET  
HIGH  
ALTITUDE  
INPUT  
(3) Mbh  
BOILER MODEL  
NUMBER(1)  
NET AHRI  
HEATING  
CAPACITY  
(3)Mbh  
INTERMITTENT  
IGNITION  
WITH VENT  
DAMPER  
Input  
(3) Mbh  
Heating  
Capacity  
(3) Mbh  
ALTITUDE INPUT  
AHRI  
RATING  
Water,  
(3) Mbh  
RATING  
Water,  
(3) Mbh  
(3)Mbh  
INPUT  
(3) Mbh  
GWB8-262E-2  
GWB8-299E-2  
GWB8-245E-2  
GWB8-280E-2  
262.5  
299  
220  
251  
191  
218  
83.9  
83.7  
83.9  
83.7  
236  
269  
245  
280  
206  
235  
179  
204  
220  
252  
Input rating for sea level to 2,000 ft. (610m) above sea level.  
• United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m)  
above sea level.  
• *Canada, 2000 ft (610m) to 4500 (1350m) above sea level, reduce input per table. Over 4500 ft  
(1350m) above sea level. Contact Provincial authority having jurisdiction.  
+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.  
(2)  
Net AHRI Water rating shown based on piping and pickup allowance of 1.15. Consult manufacturer before  
selecting boiler for installations having unusual piping and pickup requirements, such as intermittent  
system operation, extensive piping systems, etc.  
Mbh = 1,000 Btuh = British Thermal Unit Per Hour  
(3)  
- Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or  
terminal units. Net AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on  
AHRI Standard as published by The Hydronics Institute.  
- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated  
heat loss of the building.  
- Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.  
BOILERS FOR USE AT HIGH ALTITUDE  
Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level.  
For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner  
orice 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  
orice sizing information.  
In Canada, a high altitude conversion kit is available to convert to altitudes of 2,000 to 4,500 feet above sea  
level. Please consult your dealer.  
3
3 - TABLE OF CONTENTS  
KEEP THIS MANUAL NEAR BOILER  
1 - Dimensions....................................................2  
2 - Ratings And Capacities....................................3  
3 - Table of Contents............................................4  
4 - Installation Procedure .....................................5  
5 - Ventilation & Combustion Air............................6  
6 - Connecting Supply And Return Piping................7  
7 - Chimney And Vent Pipe Connection................. 11  
8 - Vent Damper Operation................................. 14  
9 - Gas Supply Piping......................................... 15  
10 - Electrical Wiring.......................................... 15  
11 - Wiring Diagrams......................................... 16  
12 - General Instructions.................................... 19  
13 - Lighting Instructions ................................... 20  
14 - Operating Your Boiler .................................. 21  
15 - Maintaining Your Boiler................................ 23  
16 - Service Hints.............................................. 24  
17 - Equipment And Optional Accessories ............ 25  
Appendix A - Control Module............................... 27  
RETAIN FOR FUTURE REFERENCE  
IMPORTANT: Read the following instructions  
COMPLETELY before installing!!  
!
WARNING  
Fire, explosion, asphyxiation and electrical shock  
hazard. Improper installation could result in death  
or serious injury. Read this manual and understand  
all requirements before beginning installation.  
WARNING  
!
Keep boiler area clear and free from combustible  
materials, gasoline and other ammable vapors  
and liquids.  
DO NOT obstruct air openings to the boiler room.  
Modication, substitution or elimination of factory  
equipped, supplied or specied components may  
result in personal injury or loss of life.  
TO THE OWNER - Installation and service of this  
boiler must be performed by a qualied installer.  
SAFETY SYMBOLS & WARNINGS  
The following dened symbols are used throughout this  
manual to notify the reader of potential hazards of varying  
risk levels.  
TO THE INSTALLER - Leave all instructions with  
boiler for future reference.  
When this product is installed in the  
Commonwealth of Massachusetts the installation  
must be performed by a Licensed Plumber or  
Licensed Gas Fitter.  
!
DANGER  
Indicates a hazardous situation which, if not avoided,  
WILL result in death or serious injury  
!
WARNING  
Indicates a hazardous situation which, if not avoided,  
could result in death or serious injury.  
!
CAUTION  
Indicates a hazardous situation which, if not avoided,  
could result in minor or moderate injury.  
NOTICE  
Used to address practices not related to personal  
injury.  
4
4 - INSTALLATION PROCEDURE  
!
!
WARNING  
WARNING  
Improper installation, adjustment, alteration, service  
or maintenance could result in death or serious  
injury.  
Fire hazard. Do not install boiler on combustible  
ooring 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  
ooring special base must be used. (See Replacement  
Parts Section.) Boiler can not be installed on  
carpeting.  
1. Installation must conform to the requirements of the  
authority having jurisdiction or, in the absence of such  
requirements, to the National Fuel Gas Code, ANSI  
Z223.1/NFPA 54, and/or Natural Gas and Propane  
Installation Code, CAN/CSA B149.1.  
2. Where required by the authority having jurisdiction, the  
installation must conform to the Standard for Controls  
and Safety Devices for Automatically red Boilers,  
ANSI/ASME CSD-1.  
Table 3 - MINIMUM CLEARANCE DIMENSIONS  
Inches  
(mm)  
Top  
6”  
6”  
(152mm)  
(152mm)  
(178mm)  
(152mm)  
(457mm)  
(152mm)  
(13mm)  
3. Boiler series is classied as a Category I. Vent  
installation shall be in accordance with "Venting of  
Equipment ," of the National Fuel Gas Code, ANSI  
Z223.1/NFPA 54, or "Venting Systems and Air Supply  
for Appliances," of the Natural Gas and Propane  
Installation Code, CAN/CSA B149.1, or applicable  
provisions of the local building codes.  
Rear  
Control Side  
Opposite Side  
Front  
7”  
6”  
18”  
6”  
Flue/Vent Connector  
Near Boiler Piping  
1/2”  
4. Boiler has met safe lighting and other performance  
criteria with the gas manifold and control assembly on  
the boiler per the latest revision of ANSI Z21.13/CGA  
4.9.  
NOTE: Greater clearances for access should supersede fire  
protection clearances.  
5. Install boiler such that gas ignition system components  
are protected from water (dripping, spraying, rain,  
etc.) during appliance operation and service, (circulator  
replacement, condensate trap, control replacement,  
etc.).  
* Denition of Alcove is three sided space with no wall in  
front of boiler. ANSI standard for alcove is 18 inches from  
front of appliance to leading edge of side walls as shown  
below.  
6. Locate boiler on level, solid base as near chimney as  
possible and centrally located with respect to heat  
distribution system as practical.  
Minimum Clearances to Combustible  
Construction (as seen from above)  
7. Allow 24 inches (610mm ) at front and right side for  
servicing and cleaning.  
6"  
8. When installed in utility room, door should be wide  
enough to allow largest boiler part to enter, or to  
permit replacement of another appliance such as water  
heater.  
6"  
7"  
Control  
Side  
BOILER  
Front  
18"  
5
5 - VENTILATION & COMBUSTION AIR  
Provide combustion air and ventilation air in accordance  
• All Outdoor Air. Provide permanent opening(s)  
communicating directly or by ducts with outdoors.  
with the section “Air for Combustion and Ventilation,” of the  
National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections  
8.2, 8.3 or 8.4 of Natural Gas and Propane Installation  
Code, CAN/CSA B149.1, or applicable provisions of local  
building codes.  
A. Two Permanent Opening Method. Provide opening  
commencing within 12 inches of top and second  
opening commencing within 12 inches of bottom of  
enclosure.  
Provide make-up air where exhaust fans, clothes dryers,  
and kitchen ventilation equipment interfere with proper  
operation.  
Direct communication with outdoors or  
communicating through vertical ducts. Provide  
minimum free area of 1 in² per 4 Mbh of total  
input rating of all appliances in enclosure.  
National Fuel Gas Code recognizes several methods  
of obtaining adequate ventilation and combustion air.  
Requirements of the authority having jurisdiction may  
override these methods.  
Communicating through horizontal ducts.  
Provide minimum free area of 1 in² per 2  
Mbh of total input rating of all appliances in  
enclosure.  
• Engineered Installations. Must be approved by  
authority having jurisdiction.  
B. One Permanent Opening Method. Provide opening  
commencing within 12 inches of top of enclosure.  
Provide minimum clearance of 1 inch on sides/back  
and 6 inches on front of boiler (does not supersede  
clearance to combustible materials).  
• Mechanical Air Supply. Provide minimum of 0.35  
cfm per Mbh for all appliances located within space.  
Additional requirements where exhaust fans installed.  
Interlock each appliance to mechanical air supply  
system to prevent main burner operation when  
mechanical air supply system not operating.  
• Refer to National Fuel Gas Code for additional  
requirements for louvers, grilles, screens and air  
ducts.  
• All Indoor Air. Calculate minimum allowable room  
volume for all appliances in space. Use a different  
method if minimum volume not available.  
• Combination Indoor and Outdoor Air. Refer to National  
Fuel Gas Code for application information.  
A. Standard Method. Cannot be used if known air  
inltration rate is less than 0.40 air changes per  
hour. See Table 4 for space with boiler only. Use  
equation for multiple appliances.  
Canada  
National Gas and Propane Installation Code Requires  
providing air supply in accordance with:  
Volume 50 ft3 x Total Input [Mbh]  
• Section 8.2 and 8.3 when combination of appliances  
has a total input of up to and including 400 Mbh (120  
kW).  
B. Known Air Inltration Rate. See Table 4 for  
space with boiler only. Use equation for multiple  
appliances. Do not use an air inltration rate  
(ACH) greater than 0.60.  
• Section 8.4 when combination of appliances has total  
input exceeding 400 Mbh (120 kW).  
• Refer to Natural Gas and Propane Installation Code  
for specic air supply requirements for enclosure  
or structure where boiler is installed, including air  
supply openings and ducts.  
Volume 21 ft3ACH x Total Input [Mbh]  
C. Refer to National Fuel Gas Code for opening  
requirements between connected indoor spaces.  
Table 4 - Minimum Room Volume, Indoor Air Only*  
Room Cubic Feet Volume  
Known Air Inltration Rate Method (Air Changes Per Hour)  
Standard  
Method  
Input Mbh  
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
262.5  
299  
13125  
14950  
55125  
62790  
27563  
31395  
18375  
20930  
13781  
15698  
11025  
12558  
9188  
10465  
* Table values based on boiler only. Add volume for any additional appliances.  
6
6 - CONNECTING SUPPLY AND RETURN PIPING  
!
WARNING  
Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,  
scalding, or water damage due to discharge of steam and/or hot water during operation.  
Discharge line shall:  
• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum  
distance from oor or allowable safe point of discharge;  
• be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge  
line;  
• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or  
place any obstruction in discharge line;  
• terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;  
• allow complete drainage of the valve and the discharge line;  
• be independently supported and securely anchored to avoid applied stress on the relief valve;  
• be as short and straight as possible;  
• terminate with plain end (not threaded);  
• be constructed of material suitable for exposure to temperatures of 375°F (191°C); or greater.  
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation  
requirements.  
Figure 2 - Safety Relief Valve  
RELIEF VALVE  
DISCHARGE  
LINE  
Check local  
codes for  
maximum  
distance  
from oor  
or allowable  
safe point of  
discharge.  
7
6 - CONNECTING SUPPLY AND RETURN PIPING  
Verify clean water supply is available to water inlet  
!
WARNING  
valve. Install sand strainer when water supply is from  
a well or pump.  
Burn and scald hazard. Safety relief valve could  
discharge steam or hot water during operation. In-  
stall discharge piping per these instructions.  
Install hot water boiler above radiation level or as  
required by Authority having jurisdiction install low  
water cutoff device at time of installation. Periodic  
inspection is necessary, as is ushing of oat type  
devices, per manufacturers specic instruction.  
1. Boiler is shipped assembled. Install discharge piping  
from safety relief valve. See Warning, Page 7.  
2. Install temperature pressure gauge.  
• Apply pipe sealant to threads on shaft of gauge.  
FOR USE WITH COOLING UNITS  
A. Boiler used in connection with refrigeration  
system, must be installed so that chilled medium  
is piped in parallel with heating boiler. Appropriate  
valves must be used to prevent chilled medium  
from entering heating boiler. See Figure 5 page 9.  
B. Boiler connected to heating coils located in air  
handling units where they may be exposed to  
refrigerated air circulation, piping system shall  
be equipped with ow control valves or other  
automatic means to prevent gravity circulation of  
boiler water during cooling cycle.  
• Thread gauge into supply water tee. See Figure 3.  
NOTICE  
DO NOT TIGHTEN GAUGE BY HAND!! Gauge should  
be tightened using crescent wrench or 9/16” open  
end wrench. See Figure 3.  
3. Connect supply and return lines to boiler. Connections  
may require additional ttings and parts, as shown on  
diagrams.  
LOW WATER TEMPERATURE AND LARGE WATER  
CONTENT SYSTEM (See Figures 6 and 7, Page 10.)  
Signicant condensation may form in boiler and/or  
venting system if boiler is operated for long period of  
time with return temperatures of less than 120° F.  
Figure 3 - Temperature Pressure Gauge  
Condensate is corrosive and can cause severe  
damage to boiler and venting system. Minimum  
design return water temperature to prevent  
condensation in boiler and venting is 120°F.  
Minimum high limit setting is 140°F.  
1. Boiler used in heating system where design water  
temperatures below 140°F are desired (e.g. radiant  
oor heating), 4-way mixing valve or suitable  
alternative is required to prevent low temperature  
return water from entering boiler. Follow mixing valve  
manufacturer’s instructions.  
2. Boiler connected to system having large water content  
(such as former gravity system), install system bypass.  
See Figures 6 and 7, page 10.  
3. If boiler water reset control is used to operate boiler,  
minimum reset supply water temperature setpoint  
must be at least 140°F, unless mixing valve is used as  
in (1) above.  
8
6 - CONNECTING SUPPLY AND RETURN PIPING  
Figure 4 - Typical Hot Water Piping  
Figure 5 - Chilled Water Piping  
9
6 - CONNECTING SUPPLY AND RETURN PIPING  
Bypass Piping Required For High Mass (Large Water Content) Systems  
Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY  
Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN  
10  
7 - CHIMNEY AND VENT PIPE CONNECTION  
Connecting The Vent Damper And Vent  
WARNING  
!
Connector  
Refer to Figure 1, page 2 for size and location of vent  
(ue opening).  
Boiler and venting installations shall be performed  
by a qualied 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 re or to asphyxiation from poisonous gases such  
as carbon monoxide with is odorless and invisible.  
NOTICE  
Damper blade on furnished vent damper has 1/2  
square inch hole (approximately 3/4” diameter).  
Boilers equipped with intermittent ignition, hole  
should be plugged by using plug supplied with vent  
damper.  
Boilers connecting to gas vents or chimneys, vent  
installations shall be in accordance with “Venting of  
Equipment, of the National Fuel Gas Code, ANSI  
Z223.1/NFPA 54 or “Venting Systems and Air Supply  
for Appliances,” of the Natural Gas and Propane  
Installation Code, CAN/CSA B149.1, or applicable  
provisions of the local building codes.  
1. Position furnished vent damper on top of ue outlet  
collar. Fasten damper securely to ue outlet collar with  
sheet metal screws. Verify damper blade has clearance  
to operate inside of diverter. Do not modify either draft  
diverter or vent damper during installation.  
Check Your Chimney  
It must be clean, right size, properly constructed and  
in good condition.  
As An Option  
Damper may be installed in horizontal or vertical  
position, closer to ue outlet collar preferred. See  
Figures 8, 9 and 10 and enclosed vent damper  
instructions.  
Chimney Sizing  
Chimney sizing, and vent installation must be in  
accordance with The National Fuel Gas Code, ANSI  
Z223.1/NFPA 54 or CAN/CSA B149.1, or applicable  
provisions of local building codes.  
2. Install vent damper to service only single boiler for  
which it is intended. Damper position indicator shall be  
in visible location following installation. Locate damper  
so it is accessible for servicing. See Figure 9.  
This is a high efciency boiler with low stack  
temperature. Following recommendations are in  
addition to requirements of the National Fuel Gas  
Code.  
3. Damper must be in the open position when appliance  
main burners are operating.  
1. Type B double wall vent pipe is recommended for  
vent connector. Single wall vent connectors should  
not be used unless following conditions are true:  
4. Boiler is equipped with factory wired harness that plugs  
into vent damper.  
a) Except for basement, boiler is not installed in  
unheated space.  
5. Slope pipe up from boiler to chimney not less than 1/4”  
per foot.  
b) Total horizontal portion of vent connector, not  
including elbows is less than 5 feet in length.  
6. Run pipe as directly as possible with as few elbows as  
2. Outside chimneys (i.e. chimneys exposed to  
outdoors below roof line) should not be used unless  
they are:  
possible.  
7. Do not connect to replace ue.  
8. End of vent pipe must be ush with inside face of  
chimney ue. Use a sealed-in thimble for chimney  
connection.  
a) enclosed in a chase, or  
b) lined with type B vent pipe, or listed exible  
vent liner, or other certied chimney lining system.  
3. Where possible it is recommended to common vent  
boiler and water heater.  
Fasten sections of vent pipe with sheet metal screws  
to make piping rigid. Support horizontal potions of  
vent system to prevent sagging. Use stovepipe wires  
every 5’ to support pipe from above. Use double wall  
vent pipe if vent pipe must go through crawl space.  
Where vent pipe passes through combustible wall  
or partition, use ventilated metal thimble. Thimble  
should be 4 inches larger in diameter than vent pipe.  
4. For multiple boiler installations, consult boiler  
manufacturer for venting recommendations.  
11  
7 - CHIMNEY AND VENT PIPE CONNECTION  
5. Test for spillage at the draft hood relief opening after  
WARNING  
!
5 minutes of main burner operation. Use the ame of  
a match or candle, or smoke from a cigarette, cigar or  
pipe.  
Boiler and venting installations shall be performed  
by a qualied 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 re or to asphyxiation from poisonous gases such  
as carbon monoxide with is odorless and invisible.  
6. After it has been determined that each appliance  
remaining connected to the common venting system  
properly vents when tested as outlined above, return  
doors, windows, exhaust fans, replace dampers and  
any other gas-burning appliance to their previous  
conditions of use.  
!
WARNING  
7. Any improper operation of the common venting system  
should be corrected so the installation conforms with  
the National Fuel gas Code, ANSI Z223.1/NFPA 54,  
and/or the Natural Gas and Propane Installation Code,  
CAN/CSA B149.1. When re-sizing any portion of the  
common venting system, the common venting system  
should be re-sized to approach the minimum size  
determined using the appropriate tables in Chapter 13  
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,  
and/or the Natural Gas and Propane Installation Code,  
CAN/CSA B149.1.  
Do not connect boiler to any portion of mechanical  
draft system operating under positive pressure.  
Minimum Vent Pipe Clearance  
Wood and other combustible materials must not be  
closer than 6” from any surface of single wall metal  
vent pipe. Listed Type B vent pipe or other listed  
venting systems shall be installed in accordance with  
their listing.  
Removing Existing Boiler From Common  
Venting System  
When an existing boiler is removed from common  
venting system, common venting system is likely to be  
too large for proper venting of appliances remaining  
connected to it.  
At time of removal of existing boiler, following steps  
shall be followed with each appliance remaining  
connected to the common venting system placed  
in operation, while other appliances remaining  
connected to common venting system are not in  
operation.  
1. Seal any unused openings in the common venting  
system.  
2. Visually inspect the venting system for proper size and  
horizontal pitch and determine there is no blockage or  
restriction, leakage, corrosion and other deciencies  
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 replace dampers.  
4. Place in operation the appliance being inspected. Follow  
the lighting instructions. Adjust thermostat so appliance  
will operate continuously.  
12  
8 - VENT DAMPER OPERATION  
Figure 8 - Vent Damper Installation  
Figure 9 - Vent Damper Placement  
Annually check vent damper and all ue product  
carrying areas of appliance, with particular attention  
given to deterioration from corrosion or other  
sources. If you see corrosion or other deterioration,  
contact your heating contractor for repairs. Check  
vent damper operation as follows:  
For further information, and vent damper  
troubleshooting guide, refer to manual packaged with  
vent damper.  
Inspect vent damper at least once a year by a  
qualied service technician.  
• When boiler is off, check vent damper positions  
indicator points to closed position, Figure 10.  
• Turn thermostat or controller up to call for heat and  
check vent damper indicator points to open position.  
Figure 10 - Vent Damper Position Indicator  
• Turn thermostat or controller down again and check  
damper position indicator returns to closed position.  
Vent Damper Manual Operation  
Vent damper may be placed in open position to  
permit burner operation by using “HOLD DAMPER  
OPEN” switch, located on damper controller.  
Thermostat will control burner ring as before, while  
damper will remain open. DO NOT turn damper  
open manually or motor damage will result. Set  
switch to “AUTOMATIC OPERATION” to close vent  
damper during burner off cycle.  
13  
9 - GAS SUPPLY PIPING  
Pressure test over 1/2 psig (3.5 kPa). Disconnect  
boiler and its individual gas shutoff valve from gas  
supply system.  
!
CAUTION  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
Pressure test at 1/2 psig (3.5 kPa) or less. Isolate  
boiler from gas supply system by closing manual gas  
shutoff valve.  
• Do not touch any electrical switch; do not use  
any phone in your building.  
Locate leakage using gas detector, noncorrosive  
detection uid, or other leak detection method  
acceptable to authority having jurisdiction. Do  
not use matches, candles, open ames, or other  
methods providing ignition source.  
• Immediately call your gas supplier from a  
neighbor’s phone. Follow gas supplier’s  
instructions.  
• If you cannot reach your gas supplier, call the re  
department.  
Correct leaks immediately and retest.  
CHECK GAS SUPPLY  
Table 5 - Gas Pipe Sizes  
NATURAL GAS  
Gas pipe to your boiler must be correct size for  
length of run and for total BTU per hour input of all  
gas utilization equipment connected to it. See Table  
5 for proper size. Be sure your gas line complies with  
local codes and gas company requirements.  
Pipe Capacity - BTU Per Hour Input  
Includes Fittings  
Length of  
Pipe - FT  
½”  
¾”  
1”  
1¼”  
CONNECTING THE GAS PIPING See Figure 11.  
Gas line enters boiler from right side.  
20  
40  
60  
92,000  
63,000  
50,000  
190,000  
130,000  
105,000  
350,000  
245,000  
195,000  
625,000  
445,000  
365,000  
• Use piping materials and joining methods acceptable  
to authority having jurisdiction. In absence of such  
requirements:  
• USA - National Fuel gas Code, ANSI Z223.1/NFPA 54  
PROPANE GAS  
• Canada - Natural Gas and Propane Installation Code,  
CAN/CSA B149.1  
Pipe Capacity - BTU Per Hour Input  
Includes Fittings  
• Use pipe joint compound suitable for LP gas on male  
threads only.  
Copper Tubing *  
Iron Pipe  
Length of  
Pipe - FT  
”  
¾”  
½”  
¾”  
• Use ground joint unions.  
20  
40  
60  
131,000  
90,000  
72,000  
216,000  
145,000  
121,000  
189,000  
129,000  
103,000  
393,000  
267,000  
217,000  
• Install sediment trap upstream of gas controls.  
• Use two pipe wrenches when making connection to gas  
valve to keep it from turning.  
* Outside diameter  
Measure length of pipe or tubing from gas meter or  
propane second stage regulator.  
• Install manual shut-off valve in vertical pipe about 5  
feet above oor.  
Figure 11 - Gas Piping  
• Tighten all joints securely.  
• Propane gas connections should only be made by  
licensed propane installer.  
• Two-stage regulation should be used by propane  
installer.  
• Propane gas piping should be checked out by propane  
installer.  
CHECKING GAS PIPING  
!
DANGER  
Fire Hazard. Do not use matches, candles, open  
ames, or other methods providing ignition source.  
Failure to comply will result in death or serious  
injury.  
Pressure test boiler and gas connection before placing  
boiler in operation.  
14  
10 - ELECTRICAL WIRING  
VENT DAMPER WIRING  
!
WARNING  
Boiler is equipped with factory wired harness with 4 pin  
molex plug, that plugs into 4 pin molex receptacle inside  
vent damper operator.  
Electrical shock hazard. Turn OFF electrical power  
supply at service panel before making electrical  
connections. Failure to do so could result in death  
or serious injury.  
Vent damper must be connected for boiler to operate.  
If any of the original wire as supplied with this  
appliance must be replaced,  
It must be replaced with type 105°C thermoplastic  
wire or its equivalent.  
NOTICE  
Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and  
dangerous operation. Verify proper operation after  
servicing.  
Electrically bond boiler to ground in accordance with  
requirements of authority having jurisdiction. Refer to:  
• USA- National Electrical Code, ANSI/NFPA 70.  
• Canada - Canadian Electrical Code, Part I, CSA C22.1:  
Safety Standard for Electrical Installations.  
ELECTRIC POWER SUPPLY  
Run separate 120 volt circuit from separate over  
current protective device in electrical service entrance  
panel. This should be a 15 ampere circuit. Locate  
shut-off switch at boiler. It must be turned off during  
any maintenance. Connect 120 volt power supply to  
control leads L1 (HOT) and L2.  
Run a 14 gauge or heavier copper wire from boiler  
to grounded connection in service panel or properly  
driven and electrically grounded ground rod.  
THERMOSTAT INSTALLATION  
1. Thermostat should be installed on an inside wall about  
four feet above the oor.  
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 xtures,  
televisions, a replace, 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 nal adjustment of the thermostat  
are packaged with the thermostat (adjusting heating  
anticipator, calibration, etc.)  
Set heat anticipator at .2 amps. 24 volt thermostat  
connects to aquastat terminals T and TV.  
15  
11 - WIRING DIAGRAMS  
Figure 12 - Integrated High Limit Electronic Ignition Control (240008781)  
!
WARNING  
Modication, substitution or elimination of factory  
equipped, supplied or specied components may  
result in personal injury or loss of life.  
I
Inducer is not an option.  
16  
11 - WIRING DIAGRAMS  
Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)  
17  
11 - WIRING DIAGRAMS  
Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)  
18  
12 -GENERAL INSTRUCTIONS  
FILLING SYSTEM WITH WATER  
NOTICE  
Never run water in a hot empty boiler.  
• Close air vents on all radiation units. Open valves to  
these units.  
• Verify boiler and expansion tank drain valves are closed.  
• Air bleed screw on tank drain tting 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 ow 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 lling of  
your system.  
• If your system is closed expansion tank system, you  
may leave it open to rell 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  
ll valve should compensate for this. Instructions are  
packaged with the valve.  
19  
13 - LIGHTING INSTRUCTIONS  
5. Remove lower front panel.  
!
WARNING  
6. Rotate the gas control knob clockwise  
“OFF.  
to  
If you do not follow these instructions  
exactly, a re or explosion may result  
causing property damage, personal injury  
or loss of life.  
• This appliance is equipped with an ignition device  
which automatically lights burner. Do NOT try to  
light this burner by hand.  
Figure 15 - Automatic Gas Valve  
WIRING  
PRESSURE REGULATOR ADJUSTMENT  
(UNDER CAP SCREW)  
TERMINALS (2)  
OUTLET  
PRESSURE  
TAP  
INLET  
PRESSURE  
TAP  
GROUND  
TERMINALS  
(2)  
• Before operating smell all around appliance area  
for gas. Be sure to smell next to oor because  
some gas is heavier than air and will settle to the  
oor.  
OUTLET  
INLET  
ON  
PILOT  
OFF  
OUTLET  
Use only your hand to turn the gas shutoff  
valve. Never use tools. If valve will not turn  
by hand, do not try to repair it, call a qualied  
service technician. Force or attempted repair may  
result in re or explosion.  
PILOT ADJUSTMENT  
(UNDER CAP SCREW)  
GAS CONTROL KNOB  
7. Wait ve (5) minutes to clear out any gas. Then  
smell for gas, including near the oor. If you smell  
gas, STOP! Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s instructions.  
If you don’t smell gas, go to next step.  
Do not use this appliance if any part has  
been under water. Immediately call a qualied  
service technician to inspect appliance and to  
replace any part of control system and any gas  
control which has been under water.  
8. Rotate gas control knob counterclockwise  
“ON.  
to  
LIGHTING PROCEDURE FOR BOILER WITH  
INTERMITTENT PILOT SYSTEM  
9. Replace lower front panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
For Your Safety, Read Before Operating!!  
A. This appliance is equipped with an ignition device  
which automatically lights the pilot. Do not try to light  
appliance by hand.  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and call  
your service technician or gas supplier.  
!
CAUTION  
TO TURN OFF GAS TO APPLIANCE  
WHAT TO DO IF YOU SMELL GAS  
1. Set the thermostat to lowest setting.  
• Do not try to light any appliance.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
• Do not touch any electrical switches; do not use  
any phone in your building.  
3. Push in gas control knob slightly and turn  
• Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s  
instructions.  
clockwise  
to “OFF” Do not force.  
• If you cannot reach your gas supplier, call the re  
department.  
1. STOP! Read the safety information above.  
2. Set the thermostat to lowest setting.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition device  
which automatically lights the pilot. Do not try to  
light the pilot by hand.  
20  
14 - OPERATING YOUR BOILER  
Figure 16 - Pilot Flame  
AUTOMATIC GAS VALVE  
Automatic Gas Valve opens or closes according to  
heat requirements of thermostat and temperature  
limit control. It closes if pilot goes out. Each  
individual control must be operating correctly before  
any gas can pass to burners. Any one control can  
hold gas supply from burner regardless of demand of  
any other control.  
SAFETY PILOT  
Safety Pilot prevents ow of gas to burner if pilot  
goes out, or will not ignite.  
GAS VALVE SAFETY SHUTDOWN TEST  
Ignition system safety shutoff device must be tested after  
placing boiler in operation.  
RELIGHT  
Electric and gas shall be off for 5 minutes before  
relighting.  
MAIN BURNER(S)  
• Main burners do not require primary air adjustment and  
are not equipped with primary air shutters.  
THERMOSTAT  
• Main burner ames form sharp blue inner cones in softer  
blue outer mantel, with no yellow.  
Keep it set at desired room temperature. If windows  
are to be opened or heat is not needed, move  
thermostat pointer to lower setting.  
• Puffs of air from blowing on ame or stamping on oor  
will cause ames to turn orange momentarily. This is  
not unusual. Remain still when observing main burner  
ames.  
NOTICE  
In event of failure of any component, system  
will not operate or will go into safety lockout.  
System is completely self-checking. On  
every call for heat, each component must  
be functioning properly to permit operation.  
Safety lockout system has to be reset by  
turning thermostat to lowest setting for one  
minute, then back to normal setting.  
• If ame appearance is not correct, check main burner  
orices, burner throat and ame ports for dust and  
lint obstruction. It may be necessary to remove rollout  
shield to observe main burner ames. Replace rollout  
shield after observation. Refer to Figure 17.  
Figure 17 - Burner  
ADJUST PILOT BURNER  
Pilot ame should surround 3/8” to 1/2” of the pilot  
sensor. See Figure 16. If ame needs adjusting, do it  
as follows:  
1. Remove screw cover over pilot adjusting screw.  
2. Insert small screwdriver and adjust ame as needed.  
Turn screw counterclockwise to increase ame, clockwise  
to decrease.  
ADJUST LIMIT CONTROLS  
3. Replace screw cover over pilot adjusting screw.  
Instructions for each control are included with  
controls. Settings can be changed. Refer to  
Appendix A page 27 for information.  
21  
14 - OPERATING YOUR BOILER  
CHECK THERMOSTAT OPERATION  
A. When set above temperature indicated on  
thermostat, boiler should ignite.  
B. Verify thermostat turns boiler off when room  
temperature reaches selected setting and starts  
boiler operating when room temperature falls a  
few degrees.  
C. After setting limit control to limit setting, check to  
see if it shuts off gas supply to burners. Turn your  
thermostat up to call for heat and let boiler run  
until temperature of water reaches limit setting.  
Gas valve should shut off and circulator running  
until thermostat is satised, or water cools enough  
to restart burners through limit control.  
D. Set thermostat for desired temperature. Conditions  
in your home and location of thermostat will govern  
this setting.  
22  
15 - MAINTAINING YOUR BOILER  
BURNERS  
CLEANING YOUR BOILER AND BURNERS  
Beginning of heating season visually check pilot and main  
burner ames. See Figure 16.  
Flue passages between sections should be examined yearly  
and cleaned if necessary.  
To clean:  
SAFETY RELIEF VALVE  
• Remove burners, pilot, and vent pipe.  
Refer to page 7 for important information. To test safety  
relief valve refer to valve manufacturer’s instructions  
packaged with relief valve. Call Technical Support if  
• Remove top and front jacket panels.  
• Remove two screws attaching intermediate front panel  
to left and right side jacket panels.  
manufacturer’s instruction are not located.  
• Remove draft diverter and intermediate front panel  
together.  
EXPANSION TANK  
• Carefully remove cerafelt gasket strips.  
Tank may become waterlogged, or may receive excess  
of air. Frequent automatic opening of safety relief  
valve indicates water logging. High boiler temperature  
accompanied by unusually low radiation unit temperature  
(and “knocking”) indicates excess air in tank.  
• Clean passageways between sections with exible  
handle wire brush. Remove dirt from bottom of boiler  
and from between sections by vacuuming.  
• Verify all ame ports in burners are open and clear.  
Shake out or blow out all loose dirt in burners.  
To correct:  
1. Close valve between boiler and tank. Drain tank until  
• Reseal seams between adjacent sections as necessary  
with 400° F RTV silicone sealant.  
empty.  
2. Check all tank plugs and ttings. Tighten as necessary.  
• Reassemble all parts.  
3. Open valve between boiler and tank. Water will rise to  
normal height in tank if you have automatic ll valve  
(otherwise, manually rell system).  
• Verify tightness of pilot connections and condition of  
burner ames after reassembly. See Figures 16 and 17,  
pages 21.  
• Verify vent pipe connections to chimney are secure and  
no obstructions are present.  
BOILER FLUE PASSAGES  
Recommend following checked annually by qualied service  
agent.  
HOUSEKEEPING  
ue passages  
• Keep boiler area clear and free from combustible  
materials, gasoline and other ammable vapors and  
liquids.  
• burner adjustment  
• operation of controls  
• Keep boiler area clear of debris and other materials  
obstructing ow of combustion and ventilation air.  
Before start of each season (or whenever system has been  
shut down for some time) recheck whole system for leaks  
and recheck boiler and vent pipe for leaks. Replace or patch  
any boiler seals that are faulty.  
VENT PIPE  
Venting and piping should be checked at least once a  
season. If vent piping shows any sign of leaking, replace  
immediately.  
WATER SYSTEM  
If system is to remain out of service during freezing weath-  
er, always drain it completely (water left in to freeze will  
crack pipes and/or boiler).  
23  
16 - SERVICE HINTS  
EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO  
!
CAUTION  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not touch any electrical switch; do not use any  
phone in your building.  
• Immediately call your gas supplier from a neighbor’s  
phone. Follow the gas supplier’s instructions.  
• If you cannot reach your gas supplier, call the re  
department.  
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .  
You may avoid inconvenience and service calls by checking these points before you call for service.  
Possible Cause  
What to do  
Thermostat is not set correctly Reset thermostat above room temperature  
Burner is not operating properlyCheck ame. If it is yellow, burner is not getting enough air.  
Or, if ame is blue and noisy and seems to lift off burner,  
burner is getting too much air. Contact your service technician.  
No electric power to boiler  
Check over current protection. Verify electric power supply circuit is  
“ON.  
Controls out of adjustment  
Radiators not heating  
Reset according to instructions.  
Open radiator vents to expel air. Check ow control valve (if  
used). It may be in closed position.  
Circulating pump not running Check over current protection. Check relay operation.  
Poor electrical contact  
Rollout switch blown  
Check all control terminals and wire joints.  
Have your service agent check heat exchanged for blockage.  
Replace rollout switch with exact replacement.  
Blocked vent blown  
Have your service agent check venting system and chimney  
for blockage, or down draft condition. Reset blocked vent.  
Vent damper not operating  
Consult troubleshooting guide in Efkal manual, packaged with  
vent damper.  
IF BURNER IS NOISY . . .  
Possible Cause  
What to do  
Gas input amount is incorrect Contact your service agent.  
RELIEF VALVE LEAKING . . .  
Possible Cause  
Dirt on seat  
What to do  
Open valve manually. Allow water to run and clear valve seat.  
Water logged expansion tank Drain tank, see instructions.  
HAVE YOUR SERVICE AGENT CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.  
24  
17 - EQUIPMENT AND OPTIONAL ACCESSORIES  
AUTOMATIC FILL VALVE  
EXPANSION TANK  
Expanding water ows into expansion tank. Tank should  
be correct size. Tank is lled with air. As water expands it  
compresses air in the tank to form air pressure cushion.  
This “spring-like” cushion serves to maintain correct  
operating water pressure regardless of water temperature.  
This assures “full measure” of water, even in highest  
radiation unit of system. It also prevents blowing off of  
safety relief valve. Air in tank in beginning (with system  
lled with cold water) is sufcient for proper operation.  
Tank also serves as trap for excess air in system. Air  
would cause gurgling in pipes and in efcient circulation in  
radiators if left in system.  
For a safe, efcient operation, hot water system must be  
completely lled with water. Adding new water, when  
needed can be done manually (by use of hand valve in  
water supply line). Requires regular attention to system’s  
needs. Automatic ll valve accomplishes this without atten-  
tion. Install in supply line on hot water boilers only. Valve  
operates through water pressure differentials. It does not  
require electrical connection.  
DRAIN VALVE  
Manual valve provides means of draining all water from  
boiler and system. It is often installed in 3/4” tapping at  
bottom of end boiler section. Or it can be installed in tee  
where return line enters boiler.  
It is possible for tank to become “waterlogged” (lled with  
water). It can also become overlled with air. This can hap-  
pen after lling system with new water. Fittings provided on  
tank and in line to tank are for bleeding off excess water or  
air.  
WATER TEMPERATURE CONTROL  
Water temperature limit control in relay is adjustable  
When installing this tank, it is important:  
and may be set as necessary. It may be set as low as  
104°F (40°C), or as high as 220°F (104°C). This depends  
on type and amount of radiation involved and weather  
conditions.  
1. Tank be higher than boiler top.  
2. Pipe to tank continuously rises up to tank (so air  
can “bubble” up to it).  
DIAPHRAGM TYPE EXPANSION TANK  
CIRCULATING PUMP  
Diaphragm type expansion tank takes place of conventional  
expansion tank. Carefully read instructions packed with  
your tank assembly.  
Every forced hot-water system requires circulating pump.  
Separate pump or zone valve is required for each zone,  
if you have a two or more zone system. Pump must have  
capacity to provide circulation required by your system.  
Pump is connected into main just ahead of boiler. It is also  
wired to electrical system.  
Tank comes with 10-12 pounds per square inch air charge.  
This is the same as pressure produced in system by  
automatic ll valve. When system is rst lled, tank will  
contain little or no water.  
As water is heated its pressure increases. It expands into  
tank, compressing air in tank. Compressed air cushion  
permits water in system to expand as temperature  
changes. Diaphragm type tank can be mounted on air  
purger tting or at any convenient place in supply or return  
line.  
VENT DAMPER  
This product is automatic, motorized stack damper  
developed to increase efciency of heating system by  
reducing standby losses from heating apparatus and  
conditioned air space. Damper closes chimney vent  
when burner is off and fully opens it when combustion is  
required.  
AIR ELIMINATING FITTING (AIR PURGER)  
Air purger is used to remove excess air from system. It  
is installed in supply line. It will eliminate air from water  
before it reaches radiators and bleed off this air.  
MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR  
DIAPHRAGM TYPE EXPANSION TANK  
Before system is lled with water, there is air in pipes and  
radiation units. Some of it will be trapped as system is  
lled . It is possible to eliminate most of this air through  
air vent on radiation units. Main air vent will speed and  
simplify this. Install on highest point in supply main when  
all radiation is below top of boiler.  
25  
17 - EQUIPMENT AND OPTIONAL ACCESSORIES  
BLOCKED VENT SAFETY SWITCH  
ROLLOUT SWITCH  
(FLAME ROLLOUT SAFETY SHUTOFF)  
(BLOCKED VENT SAFETY SHUTOFF)  
Rollout switch is temperature-sensitive fuse link device.  
Located on boiler base just outside re box. In event of  
heat exchanger ueway blockage causing ame to roll  
out of re box, fuse does not change in appearance when  
blown.  
Blocked vent safety switch is manual reset disc thermostat  
with xed setpoint (340°F (171°C)), and normally closed  
contacts. It is located at relief opening of integral draft diverter.  
In event of chimney or venting system blockage causing  
products of combustion to spill out of relief opening, blocked  
vent disc heats up and blocked vent contacts open, shutting  
down ow of gas to main burners by removing power to gas  
valve.  
If rollout switch blows, it must be replaced with exact  
replacement. Check heat exchanger ueways for blockage  
when restoring system to operating condition. DO NOT  
operate system without rollout switch.  
In event blocked vent contacts open, reset button on back  
of switch will pop up. Blocked vent safety switch must be  
reset manually, after switch has cooled off, by pushing  
reset button down. Check venting system and chimney for  
blockage when restoring system to operating condition. DO  
NOT operate boiler without Blocked vent safety switch.  
26  
APPENDIX A - CONTROL MODULE  
A.1 Installation Environment Considerations A.3 Adjusting Settings  
To discourage unauthorized changing of settings, procedure  
to enter adjustment mode is required.  
!
WARNING  
If you do not follow these instructions  
exactly, a re or explosion may result  
causing property damage, personal injury  
or loss of life.  
To enter adjustment mode, press UP, DOWN, and I buttons  
simultaneously for three seconds. Press and release I  
button until parameter requiring adjustment is displayed.  
See Figure 12, page 16.  
о “SP_” Setpoint (180 °F default setting; adjustable  
Do not use this appliance if any part has  
been under water. Immediately call a qualied  
service technician to inspect appliance and to  
replace any part of control system and any gas  
control which has been under water.  
between 130 and 220 °F)  
о “Df_” Setpoint Differential (15 °F default setting;  
adjustable between 10 and 30 °F)  
о “°F_” Degrees Fahrenheit  
• Do not allow water to drip on controls. Prevent  
condensation by allowing air circulation around  
module and gas control.  
Press UP or DOWN button until parameter has reached  
desired value. After 60 seconds without any button inputs,  
control automatically returns to READ mode.  
• Do not use corrosive chemicals around or on  
module or gas control.  
A.4 Display  
In RUN mode, status items and parameters are viewable.  
• Controls can be damaged by excessively high  
temperatures. Verify adequate air circulation around  
control is maintained when installing boiler.  
Example, to display setpoint, control ashs “sp” (setpoint)  
followed by temperature (i.e., 135), followed by °F or °C.  
To read settings, press and release I key to nd parameter  
of interest.  
A.2 Electrical Connections  
Example, press and release I until setpoint (sp) is  
displayed, followed by three-digit number, i.e., 190,  
followed by °F or °C. Press I button again will display (S1T)  
Sensor 1 Temperature followed by three-digit number and  
corresponding degree designator.  
Connect Module Connectors Figure 14, Page 18  
• L1& L2 leads inside J-box using wire nuts. Secure J-  
box cover.  
• Circulator harness to circulator. Harness comes  
plugged into module with Molex® plug.  
See Display Readout.  
• Thermostat connection to yellow wires marked TT  
using wire nuts.  
Figure 18 - Display Readout  
• Ensure remaining Molex® plug connectors have not  
worked loose during transit.  
• Check sensing bulb is fully inserted in well and is not  
loose.  
• Refer to enclosed addendum for wiring instructions  
when using indirect hot water heater.  
27  
APPENDIX A - CONTROL MODULE  
module proceeds to start burner (see state codes list)  
A.5 Operation  
and heats water in boiler until setpoint temperature is  
achieved or thermostat is satised. .  
Module continuously monitors boiler water temperature and  
res or shuts off burner based on this temperature data.  
3. Burner is de-activated, ignition module completes heat-  
ing cycle, returns to idle and waits for temperature to  
drop again.  
1. When “Call for Heat” occurs, control enables circulator  
and monitors boiler water temperature to determine  
whether thermostat can be satised without ring  
burners.  
4. Circulator is turned on throughout “Call for Heat.”  
2. Control determines burner operation is required,  
Table 6 - Operation State Codes  
State  
Code  
Denition  
Explanation  
Number  
Idle  
Standby - no call for heat  
1
Heat request present. Boiler temperature sufciently high to run circulator  
pump only.  
Circulator  
4
6
Pre-purge  
Spark  
System is purging before ignition trial; includes Pilot Valve circuit diagnostics.  
System sparking. Flame is not present up to 13 seconds  
Flame signal is being established. Variation in signal is allowed during this  
state, ame must be stable at end of period  
7
Flame stabilization  
8
9
Running  
System is running. Flame signal must be present.  
System is purging at end of call for heat  
Post-Purge  
Successful ignition was not detected, and delay is called before retry.  
Retry Recycle Delay  
10  
Flame signal was lost during state 7 or 8, and delay is called before retry (32  
second delay)  
13  
14  
15  
Soft lock-out  
Hard lock-out  
Soft lockout duration is one hour, may override with manual reset.  
Manual reset is required for hard lockout  
Wait for limit to close  
Possible thermostat call for heat; limit switch is open.  
Flame signal sensed before trial for ignition. Appropriate alarm is sent.  
OR  
16  
17  
Flame out of sequence  
Flame signal sensed out of sequence during post purge. Appropriate alarm is s  
ent.  
OR  
Flame signal present when not expected. Appropriate alarm is sent.  
Pilot valve circuitry diagnostics during pre-purge.  
Pilot valve diagnostics  
Self check performed at start up, again at beginning of heat cycle, and during  
“Wait for Recovery “ State.  
Current leakage detection  
Self check performed at start up, again at beginning of heat cycle, and during  
“Wait for Recovery “ State  
Wait for recovery  
Control has signaled damper/pressure switch  
to close, and is waiting for completion.  
If damper/pressure switch does not close within 60 seconds, control goes to  
State 20.  
18  
19  
Wait for damper to open  
Damper is closed and control waits for damper to open.  
Checked at beginning of heat cycle before opening damper.  
If damper does not open in 60 seconds, control goes to State 21.  
Wait for damper to close  
Wait for damper to open  
(Failed close)  
Damper has not opened (end swich not closed) at beginning of heat cycle.  
Alarm message is sent, control is NOT in lockout.  
20  
21  
Wait for damper to close  
(Failed open)  
Damper has not closed despite actuator de-energized.  
Alarm message is sent, control is NOT in lockout.  
28  
APPENDIX A - CONTROL MODULE  
A.6 Boiler High Limit Temperature Controller  
A.7 Troubleshooting  
• When water temperature reaches setpoint, controller  
ends heating cycle.  
• Following service procedures are provided as general  
guide.  
• When water temperature drops below setpoint minus  
differential, controller restarts heat cycle to re-heat  
boiler water.  
• On lockout and retry models, meter readings between  
gas control and ignition module must be taken within  
trial for ignition period. Once ignition module shuts  
off, lockout models must be reset through key buttons  
and display. On retry models, wait for retry or reset at  
thermostat.  
• If water temperature exceeds maximum allowed  
temperature (220°F or 104°C), controller enters manual  
reset lockout state.  
• Check for correct installation and wiring before replacing  
any component.  
• For models having reset capability, press any onboard  
button or cycle power to reset.  
• Control module cannot be repaired. If it malfunctions, it  
must be replaced.  
Figure 20 - Basic Control Algorithm Example  
• Use only qualied service agent to service ignition  
systems.  
1. Perform checkout as rst step in troubleshooting.  
Check troubleshooting guide to pinpoint cause of problem.  
See Table 7 , page 30.  
2. If troubleshooting indicates ignition problem, see  
Ignition System Checks to isolate and correct the  
problem.  
3. Perform checkout procedure following troubleshooting  
guide again to verify system is operating normally.  
A.8 Troubleshooting Error Codes  
Integrated boiler control uses advanced diagnostic  
capability to assist in troubleshooting error conditions.  
Table 6 page 28 shows codes that could arise on integrated  
display during fault.  
Suggestions are provided in Table 6 for servicing these  
potential errors.  
29  
APPENDIX A - CONTROL MODULE  
Table 7 - Troubleshooting Error Codes  
Error  
Code  
Denition  
Consequence  
Number  
4
6
Flame current too low. Check for ame.  
Non critical alarm  
Soft lockout  
Flame sensed out of normal sequence (before opening or after closing gas valve).  
Gas valve relays welded. Five consecutive soft lockouts.  
18  
23  
Hard lockout  
Soft lockout  
Flame sensed during prepurge ( before gas valve signaled opened).  
Sensor 1 error. Temperature sensor in well is not reading correctly.  
Verify it is connected to board. Replace if necessary.  
32  
Wait for recovery  
55  
56  
57  
58  
59  
Atmospheric damper end switch failed to close (end switch contacts stuck open).  
Atmospheric damper end switch failed to open (end switch contacts stuck close).  
Igniter ame rod shorted to burner ground  
Wait for recovery  
Wait for recovery  
Wait for recovery  
Wait for recovery  
Wait for recovery  
Igniter ame rod shorted to burner ground. Repair or replace igniter.  
Line Voltage error - voltage out of specication high or low (15-37V (44-66Hz))  
Applies only to thermostats having on-board transformer.  
Polarity is wrong in this case.  
60  
Wait for recovery  
Thermostat input higher than threshold.  
Line voltage unstable - possibly too may heavy loads switching on and off causing  
erratic supply voltage.  
61  
62  
Wait for recovery  
Soft lockout  
Soft lockout: maximum number of retries exceeded.  
Soft lockout is reset after one hour if alarm reason disappears.  
Soft lockout: maximum number of recycles exceeded.  
63  
64  
Soft lockout  
Soft lockout  
Soft Lockout - electronics failure. On-board self diagnostics detected error.  
Over temperature error. Sensor measured temperature in excess of maximum  
allowable limit.  
65  
Soft lockout  
Note: Soft lockout time is 1 hour or manual reset. Hard lockout requires manual reset.  
STEP 2:  
A.9 Intermittent Pilot  
Verify ignition system grounding. Nuisance shutdowns are  
often caused poor or erratic grounding.  
Ignition System Checks  
Common ground is required for module and pilot burner/  
igniter sensor.  
STEP 1: Check ignition cable.  
• Verify ignition cable does not touch metal surfaces.  
— Check for good metal-to-metal contact between  
pilot burner bracket and the main burner.  
• Verify only factory supplied Ignition cable (or approved  
replacement) is used.  
— Check ground lead from GND (BURNER) terminal  
on module to pilot burner. Verify connections are  
clean and tight. If wire is damaged or deteriorated,  
replace with No. 14-18 gauge, moisture-resistant,  
thermoplastic insulated wire with 105°C [221°F]  
minimum rating.  
• Verify connections to ignition module and igniter or  
igniter-sensor are clean and tight.  
• Verify ignition cable provides good electrical continuity.  
— Check ceramic ame rod insulator for cracks or  
evidence of exposure to extreme heat, which can  
permit leakage to ground. Replace pilot burner/igniter  
sensor and provide shield if necessary.  
30  
APPENDIX A - CONTROL MODULE  
— If ame rod or bracket is bent out of position, restore  
• Recheck ignition sequence as follows.  
to correct position.  
— Reconnect main valve wire.  
STEP 3: Check spark ignition circuit.  
Disconnect ignition cable at SPARK terminal on module.  
— Adjust thermostat above room temperature.  
— Verify ignition sequence at burner.  
!
WARNING  
— If spark does not stop after pilot lights, replace  
module.  
Electrical shock hazard. Ignition circuit generates  
over 10,000 volts. Turn OFF electrical power  
supply at service panel before making electrical  
connections. Failure to do so could result in death  
or serious injury.  
— If main burner does not light or if main burner lights  
and system locks out, check module, ground wire and  
gas control as described in troubleshooting table. See  
Table 7, Page 30.  
Figure 19 - Troubleshooting Pilot Flame  
Energize module and listen for audible sparking noise.  
When operating normally, there should be buzzing noise  
turns on and off twice per second for duration of 1–7  
seconds, depending on model.  
STEP 4: Verify pilot and main burner light-off.  
• Initiate call for heat. Turn thermostat above room  
temperature. Ignition sequence may be delayed by  
thermal purge until boiler water temperature is below  
140°F (60°C)  
• Watch pilot burner during ignition sequence.  
— Verify ignition spark continues after pilot is lit.  
— Verify pilot lights and spark stops, verify main  
burner does not light.  
• If so, ensure adequate ame current as follows.  
Turn off boiler at circuit breaker or fuse box.  
— Clean ame rod with emery cloth.  
— Verify electrical connections are clean and tight.  
Replace damaged wire..  
— Check for cracked ceramic insulator, which can  
cause short to ground, and replace igniter-sensor if  
necessary.  
— At gas valve, disconnect main valve wire from MV  
terminal.  
Turn on power and set thermostat to call for heat. Pilot  
should light, main burner will remain off because main  
valve actuator is disconnected.  
— Check pilot ame. Verify it is blue, steady and  
envelops 3/8 to 1/2 in. [10 to 13 mm] of ame rod.  
See Figure 19 for possible ame problems and causes.  
— If necessary, adjust pilot ame by turning pilot  
adjustment screw on gas control clockwise to decrease  
or counterclockwise to increase pilot ame. Following  
adjustment, always replace pilot adjustment cover  
screw and tighten rmly to assure proper gas control  
operation. Figure 16, page 20.  
— Set temperature below room set-point to end call for  
heat.  
Correct Pilot Flame: 3/8 to 1/2 inch in ame.  
See Figure 16, Page 21.  
31  
PRODUCT LITERATURE  
Lennox Industries Inc.  
Dallas, Texas  
Manufactured by:  
ECR International, Inc.  
2201 Dwyer Avenue, Utica NY 13501  

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