Lennox GCWB95W-205 Installation Instructions Manual
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Lennox GCWB95W-205 Installation Instructions Manual

Lennox GCWB95W-205 Installation Instructions Manual

Condensing wall mounted gas boiler
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PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
INSTALLATION
INSTRUCTIONS
GCWB95W-150
GCWB95W-205
CONDENSING
WALL MOUNTED 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.
WALL MOUNTED 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
240012994 Rev. B [08/31/2020]

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  • Page 1 INSTALLATION INSTRUCTIONS PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas GCWB95W-150 GCWB95W-205 CONDENSING WALL MOUNTED 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 Metal Wall Bracket Temperature Pressure Fully Assembled Boiler w/ 4 ea Wall Screws 30 PSI Safety Relief Valve Gauge and Plugs Includes Essential Documents and Warranty 4 ea - 17x24x2 Gaskets 11x17 Wire Diagrams *5 GPM Flow Restrictor 205 Used for Valve Drain Valve Document Package...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Verify Contents Received ..........2 9.4 Control Panel ............40 9.5 Prior To Commissioning: ........41 Table Of Contents ............3 9.6 Commissioning For The First Time: ......41 Physical Data..............4 9.7 Automatic Calibration Function ......41 1 - Important Information ..........6 9.8 Manual Calibration Function: .........42 9.9 Deaeration Function..........42 2 - Introduction .............7 9.10 Commission Set Up (Gas) - Changing The Type Of Gas 42...

  • Page 4: Physical Data

    PHYSICAL DATA Dimensions DIMENSIONS Height 30" [763 mm] 30 " [763 mm] Width 17 3/4 " [450 mm] 17 3/4 " [450 mm] Depth 13 9/16" [345 mm] 21 1/2" [571 mm] 13/16" [21 mm] 3/4" [19.1 mm] Condensate Trap Connection ID Hose 3/4”...
  • Page 5 PHYSICAL DATA Front View Top View All Models All Models Combustion Vent Connector 205 COMBI 150 COMBI Bottom View Bottom View Dimensions Dimensions 7" 5" 101/2" 31/2" 31/2" 51/2" 6" 6" 3" 41/2" 9" 51/2" 7" 9 1/2" 240012994 Rev. B [08/31/2020]...

  • 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

    2 - INTRODUCTION 2.5 Designated Use 2 - Introduction • GCWB9-150 and GCWB95W-205 provide both central heating and domestic hot water. 2.1 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: • Indoor installation.
  • Page 8 3 - COMPONENT LISTING LENNOX GCWB95W-150 ITEM Pump with Air Separator Boiler Drain Tap Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor Controlled Fast Fill Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor...
  • Page 9 3 - COMPONENT LISTING LENNOX GCWB95W-205 ITEM Pump Flow Sensor Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor DHW Heat Exchanger Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor NTC Heating sensor (Flow/Return)

  • Page 10: Locating Boiler

    4 - LOCATING BOILER WARNING TABLE 1: BOILER CLEARANCES Fire Hazard! Do not install on carpeting. Failure to Manufacturer Combustible follow these instructions could result in death or Dimension Recommended Materials serious injury. for Service (1)(2) 0" (0 cm) 8-5/8" (220 mm) 4.1 Boiler Location Considerations Left Side 1-3/4"...

  • Page 11: Clearances

    4 - LOCATING BOILER 4.2 Clearances Service Clearances 13 9/16 in 211/2 in [345 mm] [571.5 mm] Front View of Left Side View Boiler of Boiler 8 5/8 in [220 mm] 17 3/4 in 1 3/4 3/4 in in 1 3/4 3/4 in in 13.58 in / [45 mm] [45 mm]...

  • Page 12: Wall Mounting

    4 - LOCATING BOILER FIGURE 4-2 Wall Mount Bracket (Included) WARNING Fire, explosion, and asphyxiation hazard. Lift boiler using chassis. Do not use front jacket, vent piping, water or gas fittings to lift boiler as it may cause Center brackets. Avoid damage to the boiler and/or separation of the exhaust overhang on sides of piping.

  • Page 13: Combustion Air And Vent Piping

    5 - COMBUSTION AIR AND VENT PIPING • Venting shall be supported adjacent to each joint using WARNING steel strapping or equivalent. See Figure 5-1. Fire, explosion, and asphyxiation hazard. Improper • Support horizontal sections of vent pipe to prevent sags installation could result in death or serious capable of accumulating condensate.

  • Page 14: Removal Of Existing Boiler From Common Vent System

    5 - COMBUSTION AIR AND VENT PIPING 5.2 Removal of Existing Boiler From Common Vent 5.3 Definitions System Coaxial piping – Exhaust and air intake pipe have a When existing boiler is removed from common venting common axis. system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.

  • Page 15: Approved Venting Materials

    5 - COMBUSTION AIR AND VENT PIPING Venting shall be properly supported. WARNING Boiler shall not support any type of vent system. Manufacturer recommends this condensing boiler be All piping, glue, solvents, cleaners, fittings and vented with approved polypropylene venting material. components must conform to ASTM and ANSI standards.

  • Page 16: 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 17 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-4 Roof Mount Coaxial Venting FIGURE 5-6 Side Wall Coaxial Venting CAN BE USED ON ALL SIZES CAN BE USED ON ALL SIZES Maintain 12"(305 mm) US (18"(457 mm) Canada) clearance above highest anticipated snow level Anticipated 18"...

  • Page 18: Twin Pipe Systems

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-8 - 2"/60 mm & 3"/80 mm Twin Pipe WARNING Separated Horizontal Flue Termination Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe This Termination Installation Instructions completely and understand all can be used on: requirements before beginning installation.

  • Page 19: Securing Twin Pipe Polypropylene Venting

    5 - COMBUSTION AIR AND VENT PIPING 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. 5.9 Securing Twin Pipe Polypropylene Venting Venting manufacturer's use a device to secure Note single wall twin pipe polypropylene vent pieces...
  • Page 20 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 CAN BE USED ON ALL SIZES between combustion air intake and vent of same appliance.
  • Page 21 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-17 -Twin Pipe Side Wall Vent (Multiple FIGURE 5-20 - (2"/ 60 mm ONLY) Vent Pipe with T Appliances) CAN BE USED ON ALL SIZES This Termination Note: 3" shown for clarity. 12" between can be used on: vent and combustion air of other boilers 3"...

  • Page 22: 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 CAN BE USED ON ALL SIZES Flexible Pipe Minimum & Maximum Vent Lengths 3”...
  • Page 23 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 24: 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 25: Hydronic Piping

    6 - HYDRONIC PIPING 6.1 General Boiler rated at 50 psig (345 kPa) maximum Note • Primary/Secondary piping required. allowable working pressure. Boiler provided with • Install piping in accordance with authority having jurisdiction. 30 psig (206 kPa) safety relief valve. •...

  • Page 26: Safety Relief Valve And Air Vent

    6 - HYDRONIC PIPING FIGURE 6-2 Safety Relief Valve Discharge Piping 6.2 Special Conditions Do not expose boiler and condensate piping to Note freezing temperatures. Safety Relief Valve • System piping exposed to freezing conditions: Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system.

  • Page 27: Trim Piping

    6 - HYDRONIC PIPING 6.4 Trim Piping • Temperature - Pressure Gauge. Install temperature pressure gauge using piping provided with boiler. See Figure 6-1. • Some boiler models may have integral drain valve located inside jacket directly underneath pump. Install provided external drain valve as required.
  • Page 28 6 - HYDRONIC PIPING FIGURE 6-3 - Piping Diagram - LWCO Location Arrange piping to prevent Low Water Cutoff (LWCO) Note (See Figure 6-6 for detail) water dripping onto boiler. Position LWCO Above Illustrations are meant to Top of Boiler Note show system piping concept Purge Valve...

  • Page 29: External Optional Low Water Cut Off

    6 - HYDRONIC PIPING 6.6 External Optional Low Water Cut Off FIGURE 6-5 - 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 30: Manufacturer Recommendation - Strainer

    6 - HYDRONIC PIPING 6.7 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 31: Central Heating System

    6 - HYDRONIC PIPING 6.8 Central Heating System • Flow of water will operate the DHW flow switch which requests the 3 way valve to change position. This will allow Boiler is designed for use in a sealed central heating system. the pump to circulate the primary water through the DHW Design the system to operate with flow temperatures of up to plate heat exchanger.

  • Page 32: Gas Supply Piping

    (4.00 m (1.72 m CAUTION 191 ft 82 ft GCWB95W-205 (5.40 m (2.30 m WHAT TO DO IF YOU SMELL GAS • Boiler shall be isolated from the gas supply piping system • Do not try to light any appliance.

  • Page 33: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING NOTICE FIGURE 7-1 Sediment trap shall be located upstream of gas controls. 7.2 Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation. • Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

  • Page 34: Electrical Connections

    8 - ELECTRICAL CONNECTIONS DANGER Model Size Power Supply 120V - 60Hz Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz). Power Consumption 142 W 182 W Before making connections, verify appliance is Internal Fuse (Qty.

  • Page 35: 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 36: 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. Room End Dry contact only - do not apply 24 volts between 6 and 7.

  • Page 37: 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 38: Central Heating System Connections - Combi

    9 - START UP PROCEDURE 9.1 Central Heating System Connections - Combi GCWB95W-150 COMBI GCWB95W-205 COMBI LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4" [22.2 mm] 1" [25.4 mm] MANIFOLD Cold DHW inlet tap / system filling 1/2"...

  • Page 39: Start Up Procedure

    9 - START UP PROCEDURE 9.2 System Start Up FIGURE 9-1 Condensate Drain Assembly Follow all codes and regulations when filling the boiler. Model 205 shown (location similar in all sizes) Use drain taps to allow system to completely drain. Thoroughly flush the heating system before boiler is connected Pour and again after first heating season.

  • Page 40: 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 41: Prior To Commissioning

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

  • Page 42: Manual Calibration Function

    9 - START UP PROCEDURE 9.8 Manual Calibration Function: 9.9 Deaeration 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 43: Chimney Sweep Function (Co2 Adjust)

    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 A (Natural Gas) (Natural Gas) Gas E (LPG) CO2 % O2 %...

  • Page 44: 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 45 9 - START UP PROCEDURE FACTORY SETTINGS 9.15 Description Of Parameters: Factory Settings conti. 150-205 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 46: 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 47: 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. After a 3 minute anti-short cycling stage the combustion If you do not follow these instructions exactly, comes on at ignition speed, closing the air a fire or explosion may result causing property pressure switch, allowing power to spark generator and...

  • Page 48: 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 49: Maintenance And Routine Servicing

    11 - GENERAL MAINTENANCE AND CLEANING WARNING 11.2 Maintenance And Routine Servicing 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 50: 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 51: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model 150 Shown 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 52: User Information

    11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information 11.11 Safety Flue Thermostat - DO NOT disable this safety device. Advise and demonstrated to User the following important information: Safety Flue Thermostat found on the flue inside the boiler, interrupts flow of gas to the burner if the temperature A.

  • Page 53: Ratings And Capacities

    Maximum Minimum Rating Water, MBH GCWB95W-150 95.0 GCWB95W-205 29.5 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 54: High Altitude Ratings

    Model Number Capacity, AFUE, % Max Input, Min Input, Max Output, Min Output, Maximum Minimum MBH* 2,000-4,500 ft GCWB95W-150 95.0 (600m-1350m) GCWB95W-205 26.5 95.0 184.5 26.5 4,501-6,500 ft GCWB95W-205 24.1 95.0 24.1 (1372 m -1981 m) 6,501-10,000 ft GCWB95W-205 20.3 95.0...

  • Page 55: 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 56 13 - TROUBLE SHOOTING 13.1 Error Messages and Resetting the Boiler - continued Error Description Operation 162/317 Incorrect power supply frequency. Incorrect power supply frequency. Check pressure switch and cable. Flue pressure switch (contact open) Check obstruction on flue pipe 164/384 Fault flame (parasitic flame).

  • Page 57: 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 58: 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 59 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 60: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-3 MODEL 150 - Combi 240012994 Rev. B [08/31/2020]...

  • Page 61: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-4 MODEL 205 - Combi 240012994 Rev. B [08/31/2020]...
  • Page 62 NOTES 240012994 Rev. B [08/31/2020]...
  • Page 63 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 64 • 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...

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