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Lennox GCWB95W-150, Installation Instructions Manual, Page: 2 / 64

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Lennox GCWB95W-150 Installation Instructions Manual Download Page 2

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240012994 Rev. B  [08/31/2020]

VERIFY CONTENTS RECEIVED

* Verify proper unit size before use.

Fully Assembled Boiler

Metal  Wall  Bracket                    

w/  4  ea  Wall  Screws                 

and Plugs           

30 PSI Safety Relief Valve

        

Temperature Pressure 

Gauge

4 ea - 17x24x2 Gaskets

Includes Essential           

Documents and Warranty

11x17 Wire Diagrams

Drain Valve

*5 GPM Flow Restrictor 205 

Combi - Factory Installed

Used for  Valve 

Connections

Document Package

Wall Mount Template

*Manifold 

Template

  

For Parts lists see manual 240012996 included with your boiler literature package.

Summary of Contents for GCWB95W-150

Page 1: ...ndards 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 Ame...

Page 2: ...0 PSI Safety Relief Valve Temperature Pressure Gauge 4 ea 17x24x2 Gaskets Includes Essential Documents and Warranty 11x17 Wire Diagrams Drain Valve 5 GPM Flow Restrictor 205 Combi Factory Installed Us...

Page 3: ...gement Of 0 10v Input 37 9 Start Up Procedure 39 9 1 Central Heating System Connections Combi 38 9 2 System Start Up 39 9 3 Fill Condensate Trap With Water 39 9 4 Control Panel 40 9 5 Prior To Commiss...

Page 4: ...tem temperature 176 F 80 C 176 F 80 C Pressure Relief Valve Setting 30 00 psi 2 11 bar 30 00 psi 2 11 bar Expansion Tank Minimum Size pre charge press 2 2 gal at 11 6 psi 10 0 L at 0 8 bar 2 2 gal at...

Page 5: ...CAL DATA Front View All Models Top View All Models 205 COMBI Bottom View Dimensions 150 COMBI Bottom View Dimensions D E I G C B F H B A Vent Connector Combustion Air 5 31 2 31 2 6 6 9 7 41 2 7 51 2 3...

Page 6: ...ish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never l...

Page 7: ...output available for domestic hot water GCWB95W 150 136 000 btu h 40 kW capable of providing 3 5 U S gpm 13 2 liters min with a temperature rise of 70 F 39 C GCWB95W 205 180 000 btu h 53 kW capable of...

Page 8: ...changer 12 Water Safety Thermostat 13 NTC Heating sensor Flow Return QTY 2 1 Shown for clarity 14 Flue Sensor 15 Pressure Switch 16 Coaxial Connector 17 Heat Exchanger Temperature Protector 18 Heat Ex...

Page 9: ...1 Water Safety Thermostat 12 Flue Sensor 13 Coaxial Connector 14 Heat Exchanger Temperature Protector 15 Heat Exchanger 16 Burner Door Temperature Sensor 17 Burner not shown 18 Ignition Electrode 19 F...

Page 10: ...weight of the boiler Room sealed boiler installed in a room containing bath or shower shall be installed so person using bath or shower cannot touch any electrical switch or boiler control utilizing l...

Page 11: ...30 in 763 mm 150 13 9 16 in 345 mm 4 2 Clearances 205 211 2in 571 5 mm 1 1 3 4 3 4 in in 45 mm 45 mm Left Side View of Boiler Front View of Boiler Service Clearances Combustible Clearances 1 3 4 in 45...

Page 12: ...ial flue See sizing below 150 4 3 8 110 mm diameter 205 5 5 16 135 mm diameter 6 Pre pipe supply and return water connections with factory fittings before wall mounting 7 Mount boiler on wall using wa...

Page 13: ...ith thermal insulation shall be prohibited Failure to follow these instructions could result in death or serious injury Note Follow venting manufacturer s equivalent lengths for specialty fittings Fig...

Page 14: ...liances remaining connected to common venting system are located and other spaces of building Turn on clothes dryer and any appliance not connected to common venting system Turn on exhaust fans such a...

Page 15: ...all vent systems shall be from same manufacturer and compatible with the vent pipe See list for approved Manufacturers Installation shall conform to requirements of authority having jurisdiction or i...

Page 16: ...into intake air vent and pass them through hole in wall Check all measurements before cutting Clearance to combustible materials is zero when using coaxial vent system After installing venting use cal...

Page 17: ...8 181 mm Max 14 356 mm Maintain 12 305 mm US 18 457 mm Canada clearance above highest anticipated snow level 24 610 mm above roof or ground Ground Anticipated Snow Line 18 Vertical Clearance to venti...

Page 18: ...ne venting an adapter kit is available C Twin Pipe Separated Flue Exhaust and combustion air intake are not located in same general location D Twin Pipe Common Atmospheric Zone Termination Exhaust and...

Page 19: ...uld not be used in outdoor applications Follow venting manufacturer s instructions for applying the securing mechanism on twin pipe polypropylene venting Example for Natalini venting system See Figure...

Page 20: ...305 mm Min 84 2 2 m Max vertical separation between combustion air intake and vent of different appliances 15 381 mm Max horizontal length of vent Min vent intake between different appliances 12 305...

Page 21: ...and combustion air of other boilers required in all multiple boiler installations FIGURE 5 22 2 60 mm ONLY Twin Pipe Side Wall Vent CAN BE USED ON ALL SIZES 3 80 mm Min 24 610 mm Max Separation See Gr...

Page 22: ...sed on equivalent straight runs only Include rigid pipe and fittings in overall equivalent length calculations Flexible venting installations use single wall polypropylene to pass flue gasses to base...

Page 23: ...6 456 mm H Clearance to each side of center line extended above meter regulator assembly 3 ft 0 9 m within a height of 15 ft 4 5 m above the meter regulator assembly 3 ft 0 9 m I Clearance to service...

Page 24: ...Use field source condensate pump designated for use with condensing boiler if boiler located below disposal point Condensate pump should have overflow switch Condensate from Boiler is slightly acidic...

Page 25: ...valves are not installed install them to properly clean the system When purging installations that include standing iron radiators and systems with manual vents at high points start with nearest manua...

Page 26: ...elbow s if used close to safety relief valve outlet and downstream of union if used Terminate pipe with plain end not threaded Check Local Codes For Check Local Codes For Maximum Distance To Floor Ma...

Page 27: ...ield supplied external control Boiler control allows domestic hot water prioritization WARNING Burn and scald hazard Verify all plastic caps are removed from boiler connections Failure to follow these...

Page 28: ...PLACE ISOLATION VALVE BEFORE TEE OR LWCO Note 1 To Drain Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return 5 gpm Limiter Factory Installed...

Page 29: ...EC or Canadian Electrical Code CEC Locate LWCO sensing device in the supply piping above the minimum height of boiler See Figure 6 6 Piping Diagram Position control in HORIZONTAL piping to assure prop...

Page 30: ...ing potable water before entering the boiler The strainer prevents any sedimentation and debris from your water supply piping from entering the boiler Debris carried from the water supply will clog DH...

Page 31: ...will acknowledge the presence of the flame in the combustion chamber and send a signal to the control board Temperature sensors will send a signal to the control board allowing the control board to in...

Page 32: ...SA National Fuel Gas Code ANSI Z223 1 NFPA 54 Canada Natural Gas and Propane Installation Code CAN CSA B149 1 GAS SUPPLY REQUIRED MODEL NATURAL GAS A LIQUID PROPANE E GCWB95W 150 143 ft3 h 4 00 m3 h 6...

Page 33: ...leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods that can prov...

Page 34: ...IGURE 8 1 Electric Knockouts Bottom Of Boiler Illustration shown size 150 illustration is for location purposes wiring knockouts found same general location on all sizes 8 ELECTRICAL CONNECTIONS Note...

Page 35: ...n supply is connected to terminal block M1 which is high voltage 120V 60Hz Fuses 3 15 A 250 V Fast Acting are incorporated in the power supply terminal block To check or replace fuse pull out black fu...

Page 36: ...apply 24 volts between 6 and 7 A Room End Switch 8 7 Optional Electrical Connections A 1K Ohm 1K Outdoor Temperature Sensor To connect this accessory see figure 8 5 terminals 4 5 and instructions supp...

Page 37: ...86 860 7 140 60 23 7 80 800 31 1 105 980 8 154 68 28 0 95 500 36 7 125 100 9 167 75 32 3 110 200 42 3 144 220 10 176 80 36 6 125 000 48 1 164 000 The functions with 0 10V regulator are activated by me...

Page 38: ...4 22 2 mm 1 25 4 mm D Cold DHW inlet tap system filling connection for Combi 1 2 15 9 mm 3 4 NPT E Gas shutoff connection 3 4 22 2 mm F Boiler Fast Fill External to Boiler NA G DHW outlet 1 2 15 9 mm...

Page 39: ...boiler drain may be open until water flows out Close drain as soon as water appears During initial system air purge open valve connected to top left of heat exchanger see figure 9 1 Open 4 full turns...

Page 40: ...rmation 06 Heating return temperature F C 16 Manufacturing information 07 Thermo fuse status 000 001 17 Fan speed i17 x100 08 Not used 18 Manufacturing information DHW temperature adjustment to increa...

Page 41: ...tic Calibration Function Manual Calibration may be necessary if combustion is not within specified range After furel type is detected confirm P02 is set for the desired fuel type by checking the param...

Page 42: ...is interrupted by power blackout start function again when power is restored Press and together and hold at same time for at least 6 seconds B If display shows fault E118 low pressure in hydraulic ci...

Page 43: ...erforms combustion control cycles In this phase CO values higher than 400 ppm can occur for brief periods of time 9 START UP PROCEDURE Automatically calculated from the PCB 9 13 Check Firing Rate 1 Me...

Page 44: ...tting optional 00 no function is associated 01 close contact with a room thermostat request other than ECR thermostat 02 close contact with a ECR room thermostat request 03 relay for indicating low wa...

Page 45: ...ut 0 100 00 P16 Maximum CH set point C 00 176 F 80 C 01 113 F 45 C 00 P17 Pump overrun time in heating mode 01 240 minutes 03 P18 Burner ignition delay in CH mode 00 10 minutes 00 10 seconds 03 P19 Ma...

Page 46: ...Boiler Model PARAMETER P13 Heating Output Btu h KW 150 20 400 6 0 0 23 800 7 0 3 27 200 8 0 6 30 700 9 0 9 34 100 10 0 12 40 900 12 0 18 47 700 14 0 24 54 500 16 0 29 61 400 18 0 35 68 200 20 0 41 75...

Page 47: ...ling stage the combustion fan comes on at ignition speed closing the air pressure switch allowing power to spark generator and gas valve creating ignition in the combustion chamber 3 Flame sensor ackn...

Page 48: ...ath or serious injury Note Verify proper operation after servicing Note Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe trouble free op...

Page 49: ...in death or serious injury CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Failure to follow these instructions could re...

Page 50: ...o comply will result in death or serious injury 11 4 Draining the Boiler turn boiler off isolate electrical supply close boiler gas service cock allow boiler to cool drain boiler through onboard drain...

Page 51: ...em to achieve temperature difference across heating supply and return pipes at the boiler Check system for proper volume and pressure See page 4 for acceptable volume and pressure Turn off boiler Thor...

Page 52: ...e as indicated in the Combustion Table Components replaced Primary heat exchanger Fan Gas valve Gas orifice Burner Flame sensing electrode Spark electrode 11 10 User Information Advise and demonstrate...

Page 53: ...owance 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 Max...

Page 54: ...3048 m GCWB95W 205 113 20 3 105 95 0 141 20 3 120 17 Max CH Supply temp 176 F 80 C for GCWB9 150 Max DHW temp 140 F 60 C GCWB9 150 Max DHW Flow rate 3 5 gpm 13 2 l min GCWB9 205 Max DHW flow rate 5 0...

Page 55: ...circulation of water and pump 118 Hydraulic pressure too low Refill heating system by opening cold water tap 117 Hydraulic pressure too high Relieve pressure via relief valve or drain Ensure water fee...

Page 56: ...the combustion levels E70 Flame signal problem micro interruption of the flame signal Check cable and integrity of the sensing electrode verify the continuity between burner and earth E73 Combustion a...

Page 57: ...ET ANOMALY P32 C00 P33 C01 P34 C02 P35 C03 P36 C04 P37 C05 P38 C06 RESET ANOMALY P39 C07 P40 C08 P41 C09 FAILURE CODE NUMBER OF TIMES OCCURRED SYSTEM STATUS CODES 0 STANDBY 1 DHW ON 2 CHIMNEY SWEEP AC...

Page 58: ...ls made of or surfaced with wood compressed paper plant fibers or other materials capable of being ignited and burned Such material shall be considered combustible even though flame proofed fire retar...

Page 59: ...nstallation testing repair or servicing of appliances and equipment Experienced in such work Familiar with all precautions required Complies with all requirements of authority having jurisdiction SAFE...

Page 60: ...60 240012994 Rev B 08 31 2020 APPENDIX A WIRING DIAGRAMS A 3 MODEL 150 Combi...

Page 61: ...61 240012994 Rev B 08 31 2020 APPENDIX A WIRING DIAGRAMS A 4 MODEL 205 Combi...

Page 62: ...62 240012994 Rev B 08 31 2020 NOTES...

Page 63: ...___ Measured BTU HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person In...

Page 64: ...s provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An e...

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