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Lennox GWB84-175E, GWB84-205E, GWB84-235E, GWB84-E Non-Condensing Boiler Installation guide

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PN 240012889, Rev. A [07/31/2020]
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
THESE INSTRUCTIONS MUST BE
AFFIXED ON OR ADJACENT TO THE
BOILER.
GWB84-060E, GWB84-095E,
GWB84-120E, GWB84-150E,
GWB84-175E, GWB84-205E,
GWB84-235E
GAS FIRED BOILER
INSTALLATION
INSTRUCTIONS
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
GAS-FIRED HOT WATER BOILERS
These Gas-Fired Water boilers are low pressure,

     


      
     


Tested For 100 psi.



For Natural Gas Or Propane
WARNING





supplier.
!
2
VERIFY CONTENTS RECEIVED
Fully Assembled Boiler Vent Damper Draft Hood
Pump (Optional)
*Drain Valve *ASME Safety Relief Valve *Tridicator
*Black Iron Fittings
(see parts list for sizes
and use)



Document Package *Junction Box *Circulator Harness
Information and specications outlined in this manual in eect at the
time of printing of this manual. Manufacturer Manufacturer reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.

PN 240012889 Rev. A [07/31/2020]
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
For Parts lists see manual 240012891 included with your boiler literature package.
3
TABLE OF CONTENTS
1 - Physical Data ........................................................................................................................ 4
2 - Safety Symbols And Warnings ............................................................................................... 5
3 - Locating The Boiler ............................................................................................................... 7
 .................................................................................................................. 7
 ................................................................................................... 7
3.3 Boiler Location Considerations ............................................................................................................ 8
4 - Connecting Supply And Return Piping ................................................................................... 9
4.1 Connection Locations ........................................................................................................................ 9

.........................................................................................................9
 .................................................................................................................. 10
 ............................................................................................................................ 11
 ..................................................................................................... 11
 .......................................................................................................................... 12
5- Ventilation & Combustion Air ............................................................................................... 19
6 - Vent System Modication .................................................................................................... 20
7 - Vent Installation ................................................................................................................. 21
 ....................................................................................................................... 21
................................................................................................................................. 21
 ........................................................................................................................ 21
7.4 Vent Pipe ....................................................................................................................................... 21
8 - Vent Damper Installation & Instructions ............................................................................. 22
 ................................................................................................................................. 22
9 - Connecting Gas Service ....................................................................................................... 24
9.1 General ......................................................................................................................................... 24
 .............................................................................................................24
10 - Electrical ........................................................................................................................... 25
10.1 Electrical Wiring ............................................................................................................................ 25
 .................................................................................................................. 25
11 - Wiring Diagrams .............................................................................................................. 26
12 - Lighting Instructions ......................................................................................................... 28
12.1
8
8
12.3  .......................................................................................... 28
13 - Normal Sequence Of Operation ......................................................................................... 29
13.1 General ....................................................................................................................................... 29
14 - General Maintenance And Care Instructions......................................................................30
 .......................................................................................................................... 30
 .......................................................................................................... 30
 ..................................................................................................................... 31
 ...................................................................................................................... 32
15 - Ratings And Capacities ...................................................................................................... 33
Appendix A - Control Function .................................................................................................. 34
........................................................................................................................... 34
Appendix B-1 - Vent Damper Installation ................................................................................. 38
Appendix B-2 - Vent Damper Harness ...................................................................................... 38
Appendix B-3 - Vent Damper Troubleshooting .......................................................................... 39
PN 240012889 Rev. A [07/31/2020]
4
1 - PHYSICAL DATA
Model
GWB84-060E GWB84-095E GWB84-120E GWB84-150E GWB84-175E GWB84-205E GWB84-235E
# Sections 3456789
A  13-³/"13-¹/ 16-/"19"21-/ 27-¹/ 27-¹/
340 mm 340 mm 411 mm 483 mm 555 mm  
B 6-
³/
"6-
³/
"8-¹/" 9-¹/ 10-¹5/"13-
³/
"13-
³/
"
171 mm  206 mm 241 mm 278 mm  
C 32-¹/" 32-¹/" 32-¹/" 32-¹/" 32-¹/" 32-¹/" 32-¹/"
      
D 6" 6" 6-¹/ 6-¹/ 7" 7" 7"
153  153      
E 22" 22" 22" 22" 22" 22" 22"
      
F 26" 26" 26" 26" 26" 26" 26"
      
G  4" 5" 6" 6" 7" 7" 7"
      
 1-
¹/
" NPT 1-
¹/
" NPT 1-
¹/
" NPT 1-
¹/
" NPT 1-
¹/
" NPT 1-
¹/
" NPT 1-
¹/
" NPT
 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 3/4" NPT 3/4" NPT
 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT
Drain Valve NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT
       
       
       
       
PN 240012889 Rev. A [07/31/2020]
Figure 1 - Dimensions
Front View 
 "B"
"C"
"D"
"G"
2"
(50.8 mm)
"F"
"
(549.3 mm)
7"
(117.8mm)
12¹/"
(317.5 mm )
23" (584mm)
7¹/" (181mm)
16³/" (416mm)
"E"
Gas Valve
5
2 - SAFETY SYMBOLS AND WARNINGS
CAUTION


!!
WARNING


!
DANGER


!






2.1. Safety Information
WARNING


these instructions could result in death or serious

and accessories.
!
CAUTION






!!
NOTICE
Used to address practices not related to personal

WARNING




!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!







tap or draw their own bath.




• 
• 




• 

• 
• 
DANGER
!
Water
Temperature
Seng
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:




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WARNING


liquids.









!
WARNING
















silica/.








!
2 - SAFETY SYMBOLS AND WARNINGS
2.2 For Your Safety 2.2 For Your Safety




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1.


National Fuel Gas Code
Natural Gas and Propane
Installation Code

Standard for Controls and Safety
Devices for Automatically red Boilers

2.


National Fuel Gas Code

Natural Gas and Propane
Installation Code,

3.



4.9.
4.





5.



6.



7.


8.
Do not
install boiler on carpeting.
9.



10.


11.

TOP ...................................... 
 .................................. 
 ................. 
 ............. 

 ............... 





below.
3 - LOCATING THE BOILER
Minimum Clearances to Combustible Construction
(as seen from above)
3.1 Installation Requirements
3.2 Clearance and Service Requirements
1.

servicing and cleaning.
2.

enough to allow largest boiler part to enter, or to

heater.
3.

CAUTION


!!
WARNING



!
2"
6"
BOILER
18"
2"
Front
PN 240012889 Rev. A [07/31/2020]
8
3.3 Boiler Location Considerations
• 

• 

• 
electrical service.
• 


• 
wet.
• 
boiler as desired.
• 
3 - LOCATING THE BOILER
Items to Avoid Products Which May Contain These
Items Areas Where These Items May Be
Found








Carbon Tetrachloride







Cat litter



Paint, Varnish, Turpentine, etc.



Photo processing plants









Other















Table 3-1: CONTAMINANTS
• 



PN 240012889 Rev. A [07/31/2020]
9
4 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4-1 - Safety Relief Valve
WARNING





!




4 . 2 S a f e t y R e l i e f V a l v e I n s t a l l a t i o n
See Figure 4-1
4.1 Connection Locations
• 


boiler with water.
• 
boiler, as desired.
• 
tapping, as desired.
• ASME relief valve may be located o unused
supply tapping IN UPRIGHT POSITION ONLY.
• 

on near boiler piping using contractor supplied tees
with no valves.
WARNING





!
WARNING



these instructions could result in death or serious

!
Check local codes for maximum
distance from oor or allowable
safe point of discharge.
RELIEF VALVE


DISCHARGE
LINE
WARNING

installed with spindle in upright position only,


!
 



B. 

discharge line;
C. 


D. 


E. 
discharge line;
F. 

G. be as short and straight as possible;
 
 




PN 240012889 Rev. A [07/31/2020]
10
4 - CONNECTING SUPPLY AND RETURN PIPING
4.3 Flush and Rinse System




WARNING
• 

• 


• 

• 

• 
water.
• 


• 

• 

NOTICE






4.4 Water Treatment









• I

      

  
  
  
• 

•          



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PN 240012889 Rev. A [07/31/2020]
4 - CONNECTING SUPPLY AND RETURN PIPING
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4 - CONNECTING SUPPLY AND RETURN PIPING
4.5 Supply and Return Requirements
1.




2.






3.



4.



5.


4.6 Special Conditions
• 



• Boiler installed above radiation level (or as required

pressure switch is provided in boiler.
• 


• 




       

Note
WARNING






!
6.






 




and 4-4 page 13-14.
B. 



NOTE#1:     

is obtained.
NOTE#2: 

7.

shown in Figures 4-2 through 4-7. 

Guide.
8.

Warning, Page 9 and Figure 4-1.
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12
4 - CONNECTING SUPPLY AND RETURN PIPING

acceptable practice.
BACK FLOW VALVE
PIPING LEGEND:
Figure 4-2 -
Circulators Mounted on Supply System, Boiler Used In Conguration with Chiller
System. See Special Conditions, Below
DRAIN
PN 240012889 Rev. A [07/31/2020]
13
Figure 4-3 - Bypass Piping With Automatic Mixing Valve
BACK FLOW VALVE
PIPING LEGEND:
4 - CONNECTING SUPPLY AND RETURN PIPING
PURGE
VALVE
DRAIN
VALVE





PN 240012889 Rev. A [07/31/2020]
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4 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4-4 - Bypass Piping - Fixed Low Temp Only With Zone Valve
BACK FLOW VALVE
PIPING LEGEND:



**
* 

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4 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4-5 - Bypass Piping (4-Way Valve Option With Circulator On Supply side)
BACK FLOW VALVE
PIPING LEGEND:






PN 240012889 Rev. A [07/31/2020]
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4 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4-6 - Single Zone System With DHW Priority
BACK FLOW VALVE
PIPING LEGEND:



Back Flow
Valve
Drain
Valve
Purge
Valve
PN 240012889 Rev. A [07/31/2020]
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4 - CONNECTING SUPPLY AND RETURN PIPING
BACK FLOW VALVE
PIPING LEGEND:
Figure 4-7 - Multi Zone System With Zone Valves And DHW Priority (With Zone Valve)

Valve to
Drain
Cold
Water

Optional



Water







Valve
1



Note
Note 

an anti-scald valve. Local codes






Water


Note




1
PN 240012889 Rev. A [07/31/2020]
18
5- VENTILATION & COMBUSTION AIR
Room Cubic Feet Volume
#
Sections
Input
BTU/HR
Standard
Method
Known Air Inltration Rate Method (ACH - Air Changes Per Hour)
0.1 0.2 0.3 0.4 0.5 0.6
3 59,000 2950 12390 6195 4130 3098 2478 2065
4 92,500 4625 19425 9712.5 6475 4856 3885 3238
5 120,000 6000 25200 12600 8400 6300 5040 4200
6 149,000 7450 31290 15645 10430 7823 6258 5215
7 175,000 8800 36960 18480 12320 9240 7392 6160
8 205,000 10250 43050 21525 14350 10763 8610 7175
9 235,000 11750 49350 24675 16450 12338 9870 8225
Table 5-1 - Space With Boiler Only
5.1 Requirements


National Fuel Gas Code
Natural Gas and Propane Installation
Code
building codes.








• 

• 
per
[(BTU/





• 


 



31,000
B. 



 3 


• 

 


enclosure.




in enclosure.


[(BTU/

appliances in enclosure.
B. 




• 

• 



• 


• 

• 

or structure where boiler is installed, including air

WARNING



Do not obstruct air openings. Follow instructions




!
[(BTU/
PN 240012889 Rev. A [07/31/2020]
19




6 - VENT SYSTEM MODIFICATION





1.


2.




3.

windows and all doors between the space in which the








4.
Place in operation the appliance being inspected. Follow


5.



pipe.
6.

7.






8.


the National Fuel gas Code
and/or the Natural Gas and Propane Installation Code,




National Fuel Gas Code
and/or the Natural Gas and Propane Installation Code,

9.

with all aplliances operating.
6.1
Removal Of Existing Boiler From Venting System
Figure 6-1 -
Typical Masonry Chimney Requirements
See NFPA for Installation Specications
Type B Vent Masonry Chimney Requirements
PN 240012889 Rev. A [07/31/2020]
20
7 - VENT INSTALLATION
WARNING







!
WARNING


!
7.1 Check Your Chimney



Chimney Sizing



codes.



1.



a. 
unheated space.
b. 

2.



a. enclosed in a chase, or
b. 

3.

boiler and water heater.
4.


5.

1.



2.



7.2 Requirements
7.3 Chimney Inspection

and in good condition.


The National Fuel Gas Code,
7.4 Vent Pipe
• 

• 
sagging.
• 

• Vent pipe through crawl space, use double wall vent
pipe.
• 


NOTICE





listing.
3.


National Fuel Gas Code

 Natural Fuel Gas and Propane
Installation Code

4.






inch.
5.





National Fuel Gas Code,







PN 240012889 Rev. A [07/31/2020]
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