Lennox GCWB95F-150 User manual
240012999 Rev. A [08/31/2020]
RETAIN THESE INSTRUCTIONS
FOR
FUTURE REFERENCE
These instructions must be axed
on or adjacent to the boiler.
CONDENSING
GAS BOILER
INSTALLATION
INSTRUCTIONS
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
GAS-FIRED HOT WATER BOILERS
These Gas-Fired Water boilers are low pressure, Design
Certied 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.
GCWB95F-150
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
supplier.
2
Fully Assembled Boiler 30 PSI Safety Relief Valve
Temperature Pressure
Gauge (2" Shank) G3/4 NPT Ball Gas
Shuto Valve
2 ea - 1/2" AFM Gaskets
DHW Optional Pipe
Heat Only Boiler Copper Flush Bushing
1/2” x 1/4” NPT Copper Tee
1-1/24” x 1-1/4 “x 1/2” Used for Valve
Connections
Includes Essential
Documents and Warranty
Document Package
VERIFY CONTENTS RECEIVED
Threaded End
Non-Threaded End
Copper Tee
NOTICE
is not UP the TP
For Parts lists see manual 240013001 included with your boiler literature package.
240012999 REV A, [08/31/2020]
3
Verify Contents Received......................................2
Table Of Contents.................................................3
Physical Data........................................................4
1 - Important Information....................................6
2 - Introduction....................................................7
3 - Component Listing...........................................8
4 - Locating Boiler................................................9
4.1 Boiler Location Considerations........................9
4.2 Floor Location...............................................9
4.3 Clearances .................................................10
5 - Combustion Air And Vent Piping....................11
5.1 General ......................................................11
System ............................................................11
...................................................12
..........................13
..........................................13
..........................14
......................14
........................................16
..... 17
... 20
......................................22
6 - Hydronic Piping.............................................23
6.1 General ......................................................23
6.2 Special Conditions........................................23
.....................24
..................................................24
..............................................24
........... 26
................................28
6.8 Domestic Hot Water Mode .............................28
6.9 Frost Protection Mode...................................28
6.10 Pump Protection.........................................28
7 - Gas Supply Piping .........................................29
7.1 General ......................................................29
..................................30
.................................................30
8 - Electrical Connections...................................31
8.1 General ......................................................31
8.2 Install Room Thermostat...............................31
8.3 Electrical Connections...................................31
8.4 Access To Connection Block ...........................32
8.5 Main Supply Connection................................32
................................33
8.7 Optional Electrical Connections ......................33
..........................34
9 - Start Up Procedure........................................35
35
9.2 System Start Up ..........................................36
9.3 Fill Condensate Trap With Water.....................36
9.4 Control Panel...............................................37
...............................38
............... 38
.......................38
..........................39
9.9 De-Aeration Function....................................39
9.10 Commission Set Up (Gas) ...........................39
2Adjust)........ 40
2%) ... 40
.......................................40
41
.....................................41
9.17 Description Of Parameters ...........................42
............ 43
10 - Operating Instructions................................44
Supply .............................................................44
10.2 Boiler Operation.........................................44
..................................44
10.4 Domestic Hot Water Mode ...........................44
10.5 Frost Protection..........................................44
10.6 Pump........................................................44
...... 44
11 - General Maintenance And Cleaning .............45
............. 45
............ 46
....... 46
.....................................47
........................47
..................................48
.....................48
...................................48
...........................................48
11.10 User Information ......................................49
11.11 Safety Flue Thermostat -
Do Not
Device...........................................................................49
................. 49
11.13 Replacement Parts....................................49
12 - Ratings And Capacities................................50
..................................50
............. 50
............ 50
.....................................50
13 - Trouble Shooting.........................................51
.... 51
........... 53
14 - Glossary......................................................54
Appendix A - Wiring Diagrams............................56
TABLE OF CONTENTS
240012999 REV A, [08/31/2020]
4
Dimensions
Central Heating (Sealed System) 150
Max System Pressure 30.00 psi
Min System Pressure 7.25
Max System temperature 176°F
30.00
press.) 2.2
[10.0 L at
Recommended System Pressure (cold)
Domestic Hot Water (Sealed System) 150
Max Inlet Water Pressure
Min Inlet Water Pressure
Max DHW Temperature
DHW Water Content
SYSTEM
PHYSICAL DATA
DIMENSIONS 150
Depth
Condensate Trap Connection 3/4"NPT
System Supply
DHW Outlet
Gas Connection
DHW (Cold Water) Inlet
System Return
External to Boiler
Primary Water Content
* Or use Propress®
240012999 REV A, [08/31/2020]
5
PHYSICAL DATA
240012999 REV A, [08/31/2020]
Top View
All Models
Front View
All Models Right Side View
All Models
Left Side View
All Models
1.62
1.62
1.62
1.62
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. [628 mm]
2.22 in.2.22 in.
[56.4 mm][56.4 mm]
9.13 in.9.13 in.
[232 mm][232 mm] 7.92 in.7.92 in.
[201 mm][201 mm]6.63 in.6.63 in.
[168 mm][168 mm]
4.35 in.4.35 in.
[111 mm][111 mm]
6.12 in.6.12 in.
[156 mm][156 mm]
2.90 in.2.90 in.
[74 mm][74 mm]
7.31 in.7.31 in.
[186 mm][186 mm]
1.80 in.1.80 in.
[46 mm][46 mm]
43.65 in.43.65 in.
[1.1 m][1.1 m] 40.23 in.40.23 in.
[1.0 m][1.0 m] 37.20 in.37.20 in.
[.95 m][.95 m]
2.99 in.2.99 in.
[76 mm][76 mm] 3.15 in.3.15 in.
[80 mm][80 mm]
10 in.10 in.
[255 mm][255 mm]
6.56 in.6.56 in.
[167 mm][167 mm] 4.35 in.4.35 in.
[110 mm][110 mm]
6.63 in.6.63 in.
[168 mm][168 mm]
6.47 in.6.47 in.
[165 mm][165 mm]
42.03 in.42.03 in.
[1.0 m][1.0 m]
17.46 in.17.46 in.
[443 mm][443 mm]
1.63 in.1.63 in.
[41 mm][41 mm]
6
CAUTION
could result in minor or moderate injury.
!!
WARNING
could result in death or serious injury.
!
DANGER
WILL result in death or serious injury.
!
injury or death.
1. Safety Information
WARNING
instructions could result in death or serious injury.
Use only manufacturer recommended parts and
accessories.
!
CAUTION
personal protection equipment to include safety
in minor or moderate injury.
!!
NOTICE
Used to address practices not related to personal
injury.
WARNING
Fire, explosion, asphyxiation and electrical shock
serious injury. Read this manual and understand all
!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!
and cause permanent injury.
•
•
to manufacturer's recommendations and
instructions.
•
•
•
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note:
of the time for an adult.
1 - IMPORTANT INFORMATION
WARNING
!
240012999 REV A, [08/31/2020]
7
Information and specications outlined in this manual in eect at the
time of printing of this manual. Manufacturer reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
2.5 Designated Use
• GCWB95F-150
• Indoor installation.
•
•
outdoors.
•
(LP/propane).
2.6 The unit MUST NOT:
•
•
•
•
•
2.7 Operational Features
• GCWB95F-150 - Modulates input to provide CH
•
GCWB95F-150
temperature rise of 70°F/39°C.
•
• Optional Outdoor Temperature Reset.
•
•
2 - Introduction
2.1 Installation shall conform to requirements of authority
UNITED STATES
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
.
• National Electrical Code, NFPA 70.
CANADA
• Natural Gas and Propane Installation Code, CAN/CSA
B149.1.
• Canadian Electrical Code, Part I, Safety Standard for
Electrical Installations, CSA C22.1
2.2
installation shall conform to Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
2.3 Requirements for Commonwealth of
Massachusetts:
2.4 Manufacturer recommends use of Carbon
Monoxide monitor may be requirement of local
jurisdiction.
2 - INTRODUCTION
240012999 REV A, [08/31/2020]
8
3 - COMPONENT LISTING
ITEM
NO.
1Coaxial Connector
2Flue Sensor
3
4
5Flame Detection Electrode
6Air/Gas Blend Manifold
7
8Fan
9
10 DHW Priority Sensor
11
12 Boiler Drain Tap
13
14 Cold Water DHW Inlet Tap
15 Gas Inlet
16 DHW Outlet
17
18 Condensate Connection
19
20 NTC DHW Sensor
21
22
23
24 Water Safety Thermostat
25
26
27
28
9
16
27
2
25
24
19
4
1
26
3
6
5
7
8
28
10
11
12
14 13
15
17
18
20
21
22
23
240012999 REV A, [08/31/2020]
UTICA BOILER GCWB95F-150
9
4.1 Boiler Location Considerations
•
• Approved for installation in closets or alcove provided
clearances are met.
•
service (circulator replacement, condensate trap,
control replacement, etc.).
• Access to outdoors to meet minimum and maximum
section 6.
• Disposal of condensate. See section 6.
•
•
electrical service. See sections 5, 7 and 8.
•
•
•
•
•
or compartment.
• Requires fresh air intake piped from outdoors.
WARNING
serious injury.
!
4 - LOCATING BOILER
4.2 Floor Location
•
truck. Insert dolly or hand truck under left hand side of
•
•
and as close to vent and air intake terminals as
•
• Boiler is approved for installation in closets and
This boiler shall NOT be
installed on carpeting.
•
•
•
WARNING
could result in death or serious injury.
!
WARNING
installation could result in death or serious
injury. Read these instructions and understand all
!
240012999 REV A, [08/31/2020]
10
protection clearances.
Minimum ClearanceMinimum Clearance
17 ¾ in. [450 mm ]17 ¾ in. [450 mm ]
From Front of BoilerFrom Front of Boiler
13.58 in /
345.00 mm
1212 inin
[305 mm][305 mm]
17 in
[450 mm]
8 ⅝in [220 mm]
40 in
[1.02 m]
150
13 in
[345 mm]
4.3 Clearances
11 inin
[45 mm][45 mm]
of Boiler
Boiler
Service Clearances
4 - LOCATING BOILER
1 in
[45 mm]
17in
BackBack
Closet Installation
1 in
[45 mm]
1in
[45 mm]
1in
[45 mm]
[450 mm]
0in
[0 mm]
0in
[0 mm]
0in
[0 mm]
0in
[0 mm]
Combustible Clearances
TABLE 1: BOILER CLEARANCES
Dimension Combustible
Materials (1)
Manufacturer
Recommended for
Service(1)(2)
Top
0" (0 cm) 8-5/8" (220 mm)
Left Side
1-3/4" (45 mm) 12" (305 mm)
1-3/4" (45 mm) 1-3/4" (45 mm)
Front
0" (0 mm) 17-3/4"(450 mm)
Back
0" (0 mm) 0" (0 mm)
Bottom
0" (0 mm) 0"(0 mm)
0" (0 mm) 6" (160 mm)
(1) Required distances measured from boiler jacket.
(2) Service, proper operation clearance recommendation.
* Allowance for piping and venting not included.
240012999 REV A, [08/31/2020]
11
WARNING
installation could result in death or serious
injury. Read these instructions and understand all
!
•
•
•
in Canada, or UL 1738 in the U.S.
•
D1785, ANSI/ASTM F441, ANSI/ASTM F493.
•
•
•
•
•
•
of manufacturer's instruction use pipe hooks, pipe straps,
contraction of pipe.
•
WARNING
or serious injury.
!
5 - COMBUSTION AIR AND VENT PIPING
NOTICE
•
•
manufacturer’s instructions.
•
•
•
• Manufacturer requires use of an approved mechanical
polypropylene vent system.
5.2 Removal of Existing Boiler From Common Vent
System
•
•
could cause an unsafe condition.
•
•
continuously.
•
•
use.
•
Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane
Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and
Propane Installation Code, CAN/CSA B149.1.
5.1 General
•
»U.S. ANSI Z223.1 /NFPA 54 in the United States
»CSA B149.1 in Canada.
240012999 REV A, [08/31/2020]
12
5.3 Denitions
1.
Coaxial piping – Exhaust and air intake pipe have a
common axis.
2.
Twin Pipe – Exhaust and intake air are separate pipes,
Figure 5-1 - Venting Support
5 - COMBUSTION AIR AND VENT PIPING
or tees.
240012999 REV A, [08/31/2020]
13
5.4 Approved Venting Materials
5.5 Vent Termination
•
coaxial vent kit.
• Separate vent terminal from air inlet terminal to prevent
•
pollutants.
•
Vent Material Options
150
1
2
exhaust.
3
exhaust.
4
polypropylene on air intake.
5
vent pipe. See list for approved Manufacturers.
• USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54.
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
WARNING
death or serious injury.
!
WARNING
instructions could result in death, or serious injury.
!
WARNING
•
•
result in death, or serious injury.
•
!
1.
2.
Boiler shall not support any type of vent system.
3.
components must conform to ASTM and ANSI standards.
In Canada ULC S636 and in the USA UL 1738 schedule 40
4.
Manufacturer requires use of a mechanical fastener at
polypropylene vent system.
Approved Polypropylene Manufacturers
* Natalini
®
*Centrotherm
* Z-Flex
®
manufacturers.
5 - COMBUSTION AIR AND VENT PIPING
240012999 REV A, [08/31/2020]
14
1-3/4" (45mm)
3/4" (19mm)
5.6 Coaxial Venting Instructions
Coaxial Pipe Vent Lengths
Boiler Size 150
4"/2"
Maximum Minimum
Natalini 6 ft
®
Centrotherm
Coaxial Elbows - Equivalent length
45°
90°
•
•
•
•
•
system.
•
•
Figure 5-2 - Coaxial Screw Placement
5.7 Coaxial Vent Screw Placement - See Figure 5-2
WARNING
death or serious injury.
!
WT = Wall Thickness
FIGURE 5-3 - Coaxial Venting Horizontal or Vertical
5 - COMBUSTION AIR AND VENT PIPING
240012999 REV A, [08/31/2020]
15
FIGURE 5-6 Side Wall Coaxial Venting
Min. 8" (181 mm)
Max. 14" (356 mm)
Maintain 12"(305 mm)
US (18"(457 mm)
Canada) clearance
Ground
Anticipated
Clearance to
FIGURE 5-4 Roof Mount Coaxial Venting
Maintain 12"(305 mm)
US (18"(457 mm)
Canada) clearance
Anticipated
FIGURE 5-5 - Coaxial Vertical Exhaust -
12" (305 mm)
Minimum Separation
Manufacturer
Recommends
Greater Separation
FIGURE 5-7 - Coaxial Horizontal Exhaust -
Multiple
Appliances Multiple
Appliances
24" (610 mm)
Min. Separation
Manufacturer
Recommends
Greater Separation
5 - COMBUSTION AIR AND VENT PIPING
240012999 REV A, [08/31/2020]
16
Twin Pipe Vent Lengths
Boiler Size 150
3"
2"
All
Maximum Minimum
L1 85 ft
6 ft
L2
170 ft
12 ft.
Single Wall Elbows - Equivalent Length
3" [80 mm] 2" [60 mm]
FIGURE 5-8 - 3"/ 80 mm Twin Pipe Separated
Horizontal Flue Termination
5.8 Twin Pipe Systems
A.
Twin Pipe CPVC System
approved for air intake.
B.
Twin Pipe Polypropylene System
C.
Twin Pipe Separated Flue
D.
Twin Pipe - Common Atmospheric Zone
Termination
FIGURE 5-9 - 3" / 80 mm Twin Pipe Separated
Horizontal Flue Termination
This
Termination
on
3"/ 80 mm
vent
only
FIGURE 5-10 - 2" / 60 mm & 3" / 80 mm Twin Pipe
Separated Horizontal Flue Termination With Tee On
Exhaust
Grade, Snow
& Ice
Maintain 12"(305 mm) US, 18"(457 mm)
5 - COMBUSTION AIR AND VENT PIPING
WARNING
Installation Instructions completely and understand all
!
This
Termination
on
3"/ 80 mm
vent
only
This
Termination
2" / 60 mm &
3"/ 80 mm
vent only
When using charts below
See Vent Material Options - page 13
240012999 REV A, [08/31/2020]
17
WARNING
Installation Instructions completely and understand all
!
Example for Natalini venting system.
1.
2.
other.
3.
shoulder of the female end of the pipe stops the clamp
4.
Insert the male end of of the second pipe into the clamp
5.
place.
5.9 Securing Twin Pipe Polypropylene Venting
Figure 5-11 - Natalini Clamp
UP
UP
UP
NOTICE
240012999 REV A, [08/31/2020]
18
FIGURE 5-14 - (2" / 60 mm & 3" / 80 mm) Twin Pipe
Roof Vent
15"
(381 mm)
Max.
Vent Combustion
Air
12" (305 mm) US,
18" (458 mm) Canada Min.
Roof Line
12" (305 mm) Min.
FIGURE 5-16 - (3" / 80 mm ONLY) Horizontal Twin
Pipe, Exhaust and Intake
12" (305 mm)
Minimum Separation
Manufacturer
Recommends
Greater Separation
4
[120
12" (305 mm)
See Grade,
See Grade,
FIGURE 5-15 - (3" / 80 mm ONLY) Single Wall
Exhaust Kit and Air Intake Minimum Distance Center
to Center
Roof
Terminations
12" (305 mm) Min.
same appliance.
12" (305 mm) Min. 84" (2.2 m) Max. vertical
12" (305 mm).
outside exposure is 10 ft.(3.05 m).
Ground
Level
FIGURE 5-12 - Twin Pipe on Roof Combustion Air On
Sidewall
FIGURE 5-13 - Twin Pipe Flue On Sidewall,
Combustion Air On Roof CAN BE USED ON ALL SIZES
This
termination
used on
3"/ 80 mm
vent pipe
only
5 - COMBUSTION AIR AND VENT PIPING
This
termination
used on
3"/ 80 mm
vent pipe
only
240012999 REV A, [08/31/2020]
19
FIGURE 5-17 -( 3" / 80 mm ONLY) Twin Pipe Side
Wall Vent (Multiple Appliances)
12" (305 mm) Min.
Separation
Manufacturer Recommends
Greater Separation
See Grade,
FIGURE 5-19 - (3" / 80 mm ONLY) Twin Pipe Side
Wall Vent
3" (76 mm) Min.
24" (610 mm) Max.
Separation
12"(305 mm)Min.
12" (305 mm) Min.
24" (610 mm) Max.
Bottom Of
Separation 24"
Min.
See Grade,
FIGURE 5-18 - (3" / 80 mm ONLY) Twin Pipe Side
Wall with 45° Vent
3" (76 mm) Min.
24" (610 mm) Max.
Separation
12" (305 mm) Min.
24" (610 mm) Max.
Separation
Separation 24"
Min.
See Grade,
FIGURE 5-22 - 2" / 60 mm & 3" / 80 mm Twin Pipe
Side Wall Vent
3" (77 mm) Min.
24" (610 mm) Max.
Separation
See Grade,
FIGURE 5-20 - 2" /60 mm & 3" / 80 mm Vent Pipe
with T
See Grade,
3" (77 mm) Min.
24" (610 mm) Max.
Separation
6" (153 mm) Min.
24" (610 mm) Max.
Separation
FIGURE 5-21 - 2" / 60 mm & 3" / 80 mm Vent Pipe
with Tee
See Grade,
FIGURE 5-23 - 2" / 60 mm & 3" / 80 mm Twin Pipe
Side Wall Vent
3" (77 mm) Min.
24" (610 mm) Max.
Separation
See Grade,
6" (153 mm) Min.
24" (610 mm) Max.
Separation
3" (77 mm) Min.
24" (610 mm) Max.
Separation
5 - COMBUSTION AIR AND VENT PIPING
This
termination
used on
3"/ 80 mm
vent pipe only
This termination
used on
3"/ 80 mm vent
pipe only
This termination
used on
3"/ 80 mm vent
pipe only
240012999 REV A, [08/31/2020]
20
5.10 (3" /80 mm Only) Flexible Vent System
Flexible Pipe Vent Lengths
Boiler Size 150
3” [80 mm] Diameter Pipe
Minimum Minimum Maximum
Natalini Exhaust
Intake
DuraVent®Exhaust
Intake
Centrotherm Exhaust
Intake
Z-Dens Exhaust NA NA
Intake
Single Wall Elbows - Equivalent Length
45° bend
90° bend
•
•
top.
•
•
•
and clearances to maintain.
•
FIGURE 5-24 - (3" / 80 mm Only) Flexible Venting
System
Air
5 - COMBUSTION AIR AND VENT PIPING
NOTICE
Condensate Tee
Note Prime trap before nal assembly of vent
240012999 REV A, [08/31/2020]
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