Lennox GCWB95F-150 Installation Instructions Manual
  1. Manuals
  2. Brands
  3. Lennox Manuals
  4. Boiler
  5. GCWB95F-150
  6. Installation instructions manual
Lennox GCWB95F-150 Installation Instructions Manual

Lennox GCWB95F-150 Installation Instructions Manual

Hide thumbs Also See for GCWB95F-150:
Table of Contents

Advertisement

Quick Links

PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
INSTALLATION
INSTRUCTIONS
GCWB95F-150
CONDENSING
GAS BOILER
RETAIN THESE INSTRUCTIONS
FUTURE REFERENCE
These instructions must be affixed
on or adjacent to the boiler.
WARNING
Improper installation, adjustment, alteration,
service, or maintenance could result in death
or serious injury. Refer to this manual for
assistance. For additional information consult
a qualified installer, service agency, or the gas
supplier.
GAS-FIRED HOT WATER BOILERS
These Gas-Fired Water boilers are low pressure, Design
Certified by CSA (Canadian Standards Association) for use
with Natural and Propane Gases. They are constructed
and hydrostatically tested for a maximum working pressure
of 50 psi (pounds per square inch) in accordance with
A.S.M.E. (American Society of Mechanical Engineers)
Boiler and Pressure Vessel Code Section IV Standards
for Heating Boilers.
FOR
240012999 Rev. A [08/31/2020]

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GCWB95F-150 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Lennox GCWB95F-150

Summary of Contents for Lennox GCWB95F-150

  • Page 1 INSTALLATION INSTRUCTIONS PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas GCWB95F-150 CONDENSING GAS BOILER RETAIN THESE INSTRUCTIONS FUTURE REFERENCE These instructions must be affixed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance could result in death or serious injury.

  • Page 2: Verify Contents Received

    VERIFY CONTENTS RECEIVED Temperature Pressure G3/4 NPT Ball Gas Fully Assembled Boiler 30 PSI Safety Relief Valve Gauge (2" Shank) Shutoff Valve 2 ea - 1/2" AFM Gaskets DHW Optional Pipe Copper Flush Bushing Copper Tee Used for Valve Heat Only Boiler 1/2”...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Verify Contents Received ........2 9.9 De-Aeration Function ........39 9.10 Commission Set Up (Gas) ......39 Table Of Contents ..........3 9.11 Chimney Sweep Function (Co Adjust) ..Physical Data............4 9.12 Combustion Adjustment Function (Co %) ... 1 - Important Information ........

  • Page 4: Physical Data

    PHYSICAL DATA Dimensions DIMENSIONS Height (Bottom of boiler top of safety Valve) 43.65" [1.09 m] Overall Width with Manifold 24.70" [628 mm] Depth 17.46" [444 mm] Condensate Trap Connection 3/4" NPT System Supply *11/4” Sweat Connection DHW Outlet *1/2” Sweat Connection Gas Connection 3/4”...
  • Page 5 PHYSICAL DATA Top View All Models 10.44 in. 10.44 in. [266 mm] [266 mm] 6.87 in. 6.87 in. [175 mm] [175 mm] 18.56 in. [472 mm] 18.56 in. [472 mm] 20.50 in. [521 mm] 20.50 in. [521 mm] 24.70 in. [628 mm] 24.70 in.

  • Page 6: Important Information

    1 - IMPORTANT INFORMATION 1. Safety Information FOR YOUR SAFETY READ BEFORE OPERATING DANGER Boiler installation shall be completed by qualified agency. See glossary for additional information. WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury.

  • Page 7: Introduction

    • Exceed 176°F (80°C) system design temperature. Installation by licensed plumber or gas fitter. 2.7 Operational Features • GCWB95F-150 - Modulates input to provide CH Turndown 5.7:1, DHW Turndown 7:1. 2.4 Manufacturer recommends use of Carbon Monoxide monitor may be requirement of local •...

  • Page 8: Component Listing

    3 - COMPONENT LISTING UTICA BOILER GCWB95F-150 ITEM Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator DHW Priority Sensor Flow Sensor with Water Filter and Flow Restrictor Boiler Drain Tap...

  • Page 9: Locating Boiler

    4 - LOCATING BOILER WARNING WARNING Fire Hazard! Do not install on carpeting. Failure to Fire, explosion, and asphyxiation hazard. Improper follow these instructions could result in death or installation could result in death or serious serious injury. injury. Read these instructions and understand all requirements before beginning installation.

  • Page 10: Clearances

    4 - LOCATING BOILER 4.3 Clearances TABLE 1: BOILER CLEARANCES Manufacturer Combustible Dimension Recommended for Materials Service (1)(2) 0" (0 cm) 8-5/8" (220 mm) Left Side 1-3/4" (45 mm) 12" (305 mm) Right Side 1-3/4" (45 mm) 1-3/4" (45 mm) Front 17-3/4"(450 mm) 0"...

  • Page 11: Combustion Air And Vent Piping

    5 - COMBUSTION AIR AND VENT PIPING • Support horizontal sections of vent pipe to prevent sags WARNING capable of accumulating condensate. Fire, explosion, and asphyxiation hazard. Improper • Assemble vent materials in accordance with venting installation could result in death or serious manufacturer’s instructions.

  • Page 12: Definitions

    5 - COMBUSTION AIR AND VENT PIPING Figure 5-1 - Venting Support 5.3 Definitions Coaxial piping – Exhaust and air intake pipe have a common axis. Twin Pipe – Exhaust and intake air are separate pipes, can be terminated using single wall terminals from the vent manufacturer or field built configuration using elbows or tees.

  • Page 13: Approved Venting Materials

    5 - COMBUSTION AIR AND VENT PIPING Venting shall be properly supported. 5.4 Approved Venting Materials Boiler shall not support any type of vent system. WARNING All piping, glue, solvents, cleaners, fittings and components must conform to ASTM and ANSI standards. Manufacturer recommends this condensing boiler be In Canada ULC S636 and in the USA UL 1738 schedule 40 vented with approved polypropylene venting material.

  • Page 14: Coaxial Venting Instructions

    5 - COMBUSTION AIR AND VENT PIPING 5.6 Coaxial Venting Instructions WARNING Maximum equivalent flue lengths for Coaxial venting are: Asphyxiation hazard. Before securing the screws Coaxial Pipe Vent Lengths ensure the pipe has been pushed in a minimum of (Includes first elbow and termination) 1-3/4"...
  • Page 15 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-4 Roof Mount Coaxial Venting FIGURE 5-6 Side Wall Coaxial Venting Maintain 12"(305 mm) US (18"(457 mm) Canada) clearance above highest anticipated snow level Anticipated 18" Vertical Snow Line 24" (610 mm) above Clearance to roof or ground ventilated soffit...

  • Page 16: Twin Pipe Systems

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-8 - 3"/ 80 mm Twin Pipe Separated WARNING Horizontal Flue Termination Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe Installation Instructions completely and understand all This requirements before beginning installation.

  • Page 17: Securing Twin Pipe Polypropylene Venting

    Figure 5-11 - Natalini Clamp WARNING Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe Installation Instructions completely and understand all requirements before beginning installation. NOTICE Venting manufacturer's use a device to secure single wall twin pipe polypropylene vent pieces to each other.
  • Page 18 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-14 - (2" / 60 mm & 3" / 80 mm) Twin Pipe 12" (305 mm) Min. horizontal separation  Roof Vent between combustion air intake and vent of same appliance. 12" (305 mm) Min. ...
  • Page 19 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-17 -( 3" / 80 mm ONLY) Twin Pipe Side FIGURE 5-20 - 2" /60 mm & 3" / 80 mm Vent Pipe Wall Vent (Multiple Appliances) with T This Note: 3" shown for clarity. 12" between vent and combustion air of other boilers termination 3"...

  • Page 20: 3" /80 Mm Only) Flexible Vent System

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-24 - (3" / 80 mm Only) Flexible Venting 5.10 (3" /80 mm Only) Flexible Vent System System Flexible Pipe Vent Lengths Boiler Size 3” [80 mm] Diameter Pipe Vent Size Vent Terminal Minimum Minimum Maximum...
  • Page 21 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-25 - Flue Terminal Location All vent pipe and combustion air pipe and fittings shall comply with the following: Use only manufacturer approved venting materials or venting materials primer and glue approved to: ULC S636 in Canada, or UL 1738 in the U.S.

  • Page 22: Condensate Piping

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-26 - Condensate Drain 5.11 Condensate Piping • Use materials acceptable to authority having jurisdiction. In absence of such authority: • USA - PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493. •...

  • Page 23: Hydronic Piping

    6 - HYDRONIC PIPING central heating systems. WARNING • Manufacturer recommends installation of magnetic dirt • Poison hazard. Ethylene glycol is toxic. Do not use separator in the hydronic system where there are cast iron ethylene glycol. or steel components, or where the previous boiler was a cast iron heat exchanger.

  • Page 24: Safety Relief Valve And Air Vent

    6 - HYDRONIC PIPING FIGURE 6-1 Safety Relief Valve WARNING Safety Relief Burn and scald hazard. Safety relief valve could Valve discharge steam or hot water during operation. Use pipe suitable for temperatures of 375°F (191°C) or greater. DO NOT use plastic pipe. Install discharge piping per these instructions.
  • Page 25 6 - HYDRONIC PIPING FIGURE 6-2 - Piping Diagram - LWCO Location Arrange piping to prevent Note water dripping onto boiler. Illustrations are meant to Note show system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction.

  • Page 26: External Optional Low Water Cut Off

    6 - HYDRONIC PIPING 6.6 External Optional Low Water Cut Off FIGURE 6-3 - Low Water Cutoff - Detail These guidelines are supplied when necessary to install an additional Low Water Cut Off (LWCO), for sensing a low water level condition in a boiler, as required by the Authority Having Jurisdiction.
  • Page 27 6 - HYDRONIC PIPING 6.5 Manufacturer Recommendation - Strainer Potable water Potable water Manufacturer Recommendation Manufacturer strongly recommends the use of a strainer filtering potable water before entering the boiler. The strainer prevents any sedimentation and debris from your water supply piping from entering the boiler.

  • Page 28: Central Heating System

    6 - HYDRONIC PIPING 6.7 Central Heating System • Combustion fan will then come on and begin to run at ignition speed. Boiler is designed for use in a sealed central heating system. • Once the fan reaches ignition speed the control board will Design the system to operate with flow temperatures of up to allow power to flow to the spark generator and gas valve 176°F (80°...

  • Page 29: Gas Supply Piping

    Model Do not use this boiler if any part has been under water. Call a qualified service technician before use. 143 ft3/h 61.15 ft3/h GCWB95F-150 (4.00 m3/h) (1.72 m3/h) CAUTION WHAT TO DO IF YOU SMELL GAS • Boiler shall be isolated from the gas supply piping system by closing its individual manual shutoff valve •...

  • Page 30: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING Figure 7-1 - Gas Piping NOTICE Sediment trap shall be located upstream of gas controls. NOTICE If overheating occurs or gas supply fails to shut off, do not turn off or disconnect electrical supply to pump. Shut off gas supply at location external to the boiler.

  • Page 31: Electrical Connections

    8 - ELECTRICAL CONNECTIONS Model Size DANGER Power Supply 120V - 60Hz Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz). 142 W Power Consumption Before making connections, verify appliance is Internal Fuse (Qty. 2) F3.15 A disconnected from power supply.

  • Page 32: Access To Connection Block

    8 - ELECTRICAL CONNECTIONS FIGURE 8-2 Terminal Block Locations DANGER Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz). Before making connections, verify appliance is disconnected from power supply. Respect the input polarity on terminal block M1: L (LINE) - N (NEUTRAL). Failure to follow these instructions WILL result in death or serious injury.

  • Page 33: Install Room End Switch

    8 - ELECTRICAL CONNECTIONS FIGURE 8-4 Thermostat Connections 8.6 Install Room thermostat Install room thermostat on inside wall. Do not install where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, sun rays or near a fireplace. Dry contact only - do not apply 24 volts between 6 and 7.

  • Page 34: Management Of 0-10V Input

    8 - ELECTRICAL CONNECTIONS 8.8 Management of 0-10V Input The functions with 0...10V regulator are activated by means of their parameters. When the function is enabled (P82=3) and P78=1, the input manages the heating set point temperature directly; when P78=2, the input manages the heating power input directly.

  • Page 35: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Central Heating System Connections - Combi GWCF150 COMBI LEGEND Heating supply connection 11/4” sweat DHW outlet 1/2" sweat Drain connection for condensate 3/4" NPT Gas shutoff connection 3/4" NPT Cold DHW inlet tap 1/2" sweat 11/4”...

  • Page 36: System Start Up

    9 - START UP PROCEDURE FIGURE 9-1 Condensate Drain Assembly 9.2 System Start Up Follow all codes and regulations when filling the boiler. Use drain taps to allow system to completely drain. HTEX Air Vent Thoroughly flush the heating system before boiler is connected Pour and again after first heating season.

  • Page 37: Control Panel

    9 - START UP PROCEDURE 9.4 Control Panel Press and hold for 1 second, to display information as shown in the table below. Press to exit. DESCRIPTION DESCRIPTION Secondary fault internal code Setpoint Central Heating (°F/°C) 10/11 Heating flow temperature (°F/°C) Manufacturing information Outdoor temperature (°F/°C) Flue sensor temperature (°F/°C)

  • Page 38: Prior To Commissioning

    9 - START UP PROCEDURE Boiler must not shutoff during calibration. NOTICE Note Open all heating zones in heating or DHW mode to ensure boiler does not shutoff. All connections shall be made and water added before performing this function. 9.7 Automatic Calibration Function Before performing this function verify there are no heat NOTICE...

  • Page 39: Manual Calibration Function

    9 - START UP PROCEDURE 9.8 Manual Calibration Function: 9.9 De-Aeration Function Manual Calibration phase starts at the end of the Automatic Used to eliminate air inside the heating circuit when boiler Calibration. is installed or after maintenance when water is drained from primary circuit.

  • Page 40: Chimney Sweep Function

    9 - START UP PROCEDURE 9.11 Chimney Sweep Function (CO Adjust) For correct boiler operation, content of (CO ) in the combustion flue must be within tolerances indicated in table below. COMBUSTION TABLE Gas A Gas E (LPG) (Natural Gas) CO2 % O2 % CO2 %...

  • Page 41: Description Of Parameters: Factory Settings

    9 - START UP PROCEDURE For Natural Gas : Table 9-2 Input Rate @ High Fire (MBH) 3600 x cu ft Input (MBH) seconds Approximate Rate @ Example: Natural Gas - Gas flow from 100% Fire (MBH) Meter = 2 cu ft Size Measured time = 72 seconds 3600 x 2 cu ft...

  • Page 42: Description Of Parameters

    9 - START UP PROCEDURE FACTORY SETTINGS 9.15 Description Of Parameters: Factory Settings conti. Outdoor temperature sensor input configuration 00= with outdoor temperature sensor connected, external temperature value has influence to calculate heating flow temperature set-point 01= with outdoor temperature sensor connected, display shows external temperature value (no influence) 02…05 = no function is associated 00..02 = No function is associated 03 = This is an input contact for CH request (e.g.

  • Page 43: Adjusting Maximum Heating Power

    9 - START UP PROCEDURE 9.16 Adjusting Maximum Heating Power Maximum boiler heating power can be reduced to suit requirements of heating system it serves. Table showing parameter P13 values according to desired maximum power model is shown for each single boiler. To access and edit P13 values, proceed as described in Section 9.15 Parameter Settings.

  • Page 44: Operating Instructions

    10 - OPERATING INSTRUCTIONS 10.3 Central Heating Mode FOR YOUR SAFETY READ BEFORE OPERATING With demand for heating, pump circulates water through WARNING the primary circuit. Combustion fan comes on at ignition speed, closing the If you do not follow these instructions exactly, air pressure switch, allowing power to spark generator and a fire or explosion may result causing property gas valve, creating ignition in the combustion chamber.

  • Page 45: General Maintenance And Cleaning

    11 - GENERAL MAINTENANCE AND CLEANING • Circulator pump and combustion air blower motor furnished DANGER with boiler are permanently lubricated from factory and require no further lubrication. Lubricate field sourced Before servicing, turn off electrical power to boiler at pumps and/or motors according to pump and/or motor service switch.

  • Page 46: Maintenance And Routine Servicing

    11 - GENERAL MAINTENANCE AND CLEANING 11.2 Maintenance And Routine Servicing WARNING Check and service boiler as necessary. Following service procedures must be performed by Frequency of servicing will depend upon installation qualified service agent. Boiler owner shall not attempt conditions and usage, manufacturer recommends annually.

  • Page 47: Draining The Boiler

    11 - GENERAL MAINTENANCE AND CLEANING DANGER Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury. 11.4 Draining the Boiler •...

  • Page 48: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model - GCWB95F-150 For special areas, where water is harder than 200 ppm or 12 grains/ gallon, install polyphosphate dispenser or equivalent treatment system, compliant with current regulations. 11.7 Cleaning The Cold Water Filter Boiler is fitted with cold water filter located on DHW hydraulic assembly (B).

  • Page 49: User Information

    11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information 11.13 Replacement Parts Advise and demonstrated to User the following important Perform Automatic Calibration procedure described in section information: 9.8 if one or more of the following components are replaced. Check and adjust CO2% value as indicated in the Combustion A.

  • Page 50: Ratings And Capacities

    Capacity, MBH * Maximum Minimum Rating Water, MBH GCWB95F-150 95.0 (1) 1000 Btu/hr (British Thermal Units Per Hour) (2) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures. (3) Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

  • Page 51: Trouble Shooting

    13 - TROUBLE SHOOTING 13.1 Error Messages And Resetting The Boiler Error Description Operation Gas valve connection fault Check cable PCB/gas valve and gas valve plug Outdoor sensor fault Check sensor and cable Verify all cables. Replace PCB. Gas valve command fault Call authorized SERVICE center Central Heating NTC sensor fault Check sensor and cable...
  • Page 52 13 - TROUBLE SHOOTING 13.1 Error Messages and Resetting the Boiler - continued Error Description Operation Check pressure switch and cable. Flue pressure switch (contact open) Check obstruction on flue pipe 164/384 Fault flame (parasitic flame). Check correct operation of T. gas valve. 165/385 Input voltage too low.

  • Page 53: Anomalies Table For The Installer

    13 - TROUBLE SHOOTING 13.2 Anomalies Table for the Installer - Use this table to report the anomaly values. SYSTEM STATUS CODES 0 STANDBY 1 DHW "ON" 2 CHIMNEY SWEEP ACTIVE 3 CH "ON" 4 PREHEAT "ON" 5 CH NO FROST "ON" 6 DHW NO FROST "ON"...

  • Page 54: Glossary

    14 - GLOSSARY • APPLIANCE - Device to convert gas into energy; term • DIRECT VENT BOILER - Boiler constructed and installed so includes any component, control, wiring, piping or tubing all combustion air is derived directly from outdoors and all required to be part of the device.
  • Page 55 14 - GLOSSARY • METRIC GAS METERS • TWO PIPE SYSTEM - Type of venting that allows for exhaust flue and intake air piping to be separated from each Natural Gas other. Fresh air may be drawn in at a different area from 127,116 x cu meters where flue terminal is located.

  • Page 56: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-2 MODELS GCWB95F-150 - Combi 240012999 REV A, [08/31/2020]...
  • Page 57 NOTES 240012999 REV A, [08/31/2020]...
  • Page 58 NOTES 240012999 REV A, [08/31/2020]...
  • Page 59 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________  Installation instructions have been followed  Checkout procedure and adjustments performed  Maintenance and Service issues reviewed with owner/ maintenance person  Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone...
  • Page 60 • This boiler is not used for any space heating • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas...

Table of Contents