Lennox GWM-050IE Installation Instructions Manual

Text of Lennox GWM-050IE User Guide:

• 41 _ _ _ _ _ Lockout Alarm A 0 0 Blocking too long error Enter Installer Menu, Boiler Status. Scroll to most recent Lockout Alarm or Blocking Error. Diagnose corrective action using appropriate Troubleshooting Tree. Is harness connected to Gas Valve? Is harness connected to Control Module J13? NOYES _ P _ _ _ Lockout Alarm A 0 5 GV re

• Lennox GWM-050IE, 45 13 - TROUBLE SHOOTING Follow OPERATING INSTRUCTIONS to initiate boiler operation. Enter Installer Menu, Boiler Status, Flame Signal. Is flame signal greater than 3.7 uA? _ P _ _ _ Lockout Alarm A 2 4 3 flame failures Inspect harness connection Flame Sensor. Is connection clean and secure? NO Replace Flame Sensor or harness Remove Flame Sensor. Is rod free of contamination? Clean or replace Flame Sensor Replace Control Module Replace Flame Sensor and Burner YES YES YES NO NO Inspect burner through sight glass.

• Lennox GWM-050IE, 63 APPENDIX A - CONTROL MODULE User Interface Display Explanation Installer Menu Boiler Status STATUS ▲ Ign i t i on At tempts Su c c e s fu l 4267 Fai led 21 ▼ Control module logs successful and failed ignition attempts. Information accessed in ‘Ignition Attempts’ Screen as shown. Ignition attempts are stored in non-volatile memory and are retained in event of power failure. Figure A-1 Typical Ignition Cycle Following control features are implemented to ensure safe and reliable operation of Combust

• Lennox GWM-050IE, 68 APPENDIX A - CONTROL MODULE User Interface Display Explanation CH Settings CH SETT I NGS ▲ Boos t Funct ion Temp 10°F Time 20min ▼ Outdoor reset boost function increases CH set point by increment (‘Temp’) if CH demand continues beyond pre-set time limit (‘Time’). CH set point will continue to increase until set point reaches 195°F / 91°C Allowable Temperature Increment: 0..36 °F (0..20 °C) Default Temperature increment: 0 °F (10 °C) Allowable Time Delay: 1..120 minutes Default Time Delay: 20 minutes CH SETT I NGS ▲

• Lennox GWM-050IE, 8 3 - COMPONENT LISTING FIGURE 3-3 Boiler Components (View from Front of Boiler) GAS SHUTOFF GAS SHUTOFF VALVE VALVE (SHOWN IN OPEN POSITION) VENT CONNECTOR COMBUSTION COMBUSTION AIR AIR BLOWER BLOWER GAS (CONTROL) GAS (CONTROL) VALVE VALVE LOW WATER LOW WATER CUTOFF CUTOFF HIGH TEMPERATURE SUPPLY SWITCH SAFETY RELIEF VALVE AIR VENT AIR VENT COMBUSTION AIR INLET NOTE: See Section 5 For Piping Instructions HEAT EXCHANGER HEAT EXCHANGER PUMP PUMP CONDENSATE COLLECTOR RETURN WATER RETURN WATER FROM HEATIN

• 26 7-2 Manual Main Gas Shutoff Valve Outside Boiler Jacket 7.3 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. • Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manua

• Lennox GWM-050IE, 66 User Interface Display Explanation CH Settings CH SETT I NGS CH mod e MODE:1 CH w i t h thermostat ▼ 4. Central Heating (CH) modes available: • CH Mode = 0 ‘CH with Thermostat’ • Boiler will attempt to satisfy CH demand while CH thermostat input is closed. • Boiler will modulate its fi ring rate to maintain CH set point and match system heat load. • CH set point adjusted in ‘Settings’ submenu under ‘User Menu’ • CH Mode = 1 ‘CH with Thermostat and Outdoor Reset’ • Boiler will attempt to satisfy CH deman

• Lennox GWM-050IE, 59 1.4 Sequence of Operation Operational State User Interface Display Explanation If fl ame detected before Gas Valve opens during ignition boiler will lockout. Please refer to troubleshooting guide. Gas Valve energized to deliver air/fuel to burner. If fl ame undetected after 3 seconds boiler will de-energize Gas Valve and enter post purge mode for 30 seconds. Ignition attempted 5 times before lockout. Boiler will run provided all operational and safety devices are within limits Refer to for more information. Control module adjusts fi ring rate according to heating demand. When Boiler detects demand met, will enter post

• 20 1"(2.54cm) Maximum Combustion Air Vent 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 Maintain 12" clearance above highest anticipated snow level or grade * See Note Below Vent Combustion Air 1" (2.54cm) Maximum Roof overhang 36"(0.9m) Minimum Maintain 12"(30cm) clearance above highest anticipated snow level or grade 12" (30cm) Minimum

• Lennox GWM-050IE, 44 13 - TROUBLE SHOOTING Measure resistance across High Temperature Supply Switch terminals 2 and 4? Does resistance match supply water temperature (see table)? Is supply water temperature less than 185°F (91°C)? _ _ _ _ _ Lockout Alarm A 1 8 Max Temp Error Disconnect harness from High Temperature Supply Switch and Control Module J13. Continuity from J13-5 to Switch 1? Continuity from J13-6 to Switch 3? YES NO YES NO Replace wire(s) YES NO Is High Temperature Supply Switch open (no continuity

• Lennox GWM-050IE, 62 User Interface Display Explanation Installer Menu Installer Menu INS TALLER MENU  Bo i l e r S t a tus Bo i l e r Con f i g CH Se t t i n g s DHW Se t t i ng s Casca de Se t t i ngs Sys t em Tes t The Installer Menu structure includes: Installer Menu can be accessed by simultaneously holding ‘Menu’ and ‘Enter’ keys for 5 seconds. • ‘Boiler Status’ submenu – User monitors detailed boiler status parameters such as fl ame signal, fan speeds and stored error codes. • ‘Boiler Confi g’ submenu – Modifi es general boiler set

• Lennox GWM-050IE, 6 3.1 Component Listing 1. User Interface (see Appendix A) - Displays information regarding boiler condition. Allows adjustment of boiler operating parameters. NOTE: Does not replace thermostat used to control central heating space. 2. Combustion Air Inlet (2"/3" ) (see page 7 & 8) 3. Return Water From Heating System (In) Return Water From Heating System (In) (see (see page 8) page 8) - - Connection supplied at bottom of boiler. Connection supplied at bottom of boiler. 4. Low Voltage Terminal S

• Lennox GWM-050IE, 40 13 - TROUBLE SHOOTING Go to Page 41 Go to Page 45 Go to Page 42 Go to Page 41 Go to Page 43 Go to Page 44 Go to Page 45 Go to Page 46 Go to Page 47 Go to Page 47 Go to Page 48 Go to Page 49 Go to Page 49 Go to Page 50 Go to Page 51 Go to Page 51 Go to Page 52 Go to Page 52 Replace Control Module Replace Control Module Replace Gas Valve Replace Control Module Replace Gas Valve Replace Control Module Replace Control Module Replace Control Module Replace Control Module Error Clears in 1-2 minutes Repl

• 47 13 - TROUBLE SHOOTING Is correct harness connected to return sensor (2 Brown Wires)? NOYES _ _ _ _ _ Blocking Error E 4 0 Return Temp Disconnect harness from Return Water Sensor. Measure resistance using digital ohm meter. Is resistance between 950 to 33,000 ohms? Is Heat Exchanger Pump oriented properly? (Pump Arrow pointing down?) YES N

• Lennox GWM-050IE, 4 1.1 Designated Use • Hot water heating boiler. • Indoor installation. • Closet or alcove installation. • Direct vent boiler. • For use with natural gas or liquefi ed petroleum gases (LP/propane). 1.2 The unit MUST NOT: • Directly heat potable water. Indirect heating is acceptable. • Heat water with non-hydronic heating system chemicals present (example, swimming pool water). • Exceed 50 psig (344 kPa) system pressure. • Exceed 195°F (90.5°C) system design temperature. 1.3 Operational Features • Modulating: 20-100%. • Integral Dual Limit. • Integral Low Water Cutoff (with test button). • Outdoor Temperature Reset. • Integral Multiple Boiler Control. 1 - I

• Lennox GWM-050IE, 14 5 - HYDRONIC PIPING 5-5 TWO-PIPE ZONED SYSTEM WITH VALVES 5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS Heat exchanger ball valve open (as shipped) Heat exchanger ball valve open (as shipped) DHW Pump CH/System Pump DHW Pump Zone Pump 3/8"/10mm Open End Wrench 3/8"/10mm Open End Wrench

• Lennox GWM-050IE, 24 6 - COMBUSTION AIR AND VENT PIPING 6.6 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. • Canada - CSA or ULC certifi ed PVC/CPVC pipe, fi ttings and cement. • Attach PVC tee provided with boiler and fi eld sourced piping to condensate drain at bottom of boiler. See Figure 6-1. • Slope condensate drain pipe minimum 1/4" per foot (21mm/m) away from boiler. • Use fi eld sourc

• Lennox GWM-050IE, 27 WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. ! 8 - ELECTRICAL CONNECTIONS 8-2 LINE VOLTAGE CONNECTIONS NOTICE Wiring diagrams can be found in Section 14 of this Manual. 8.1 General Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to: • USA- National Electrical Code, ANSI/NFPA 70. • Canada - Canadian Electrical Code

• Lennox GWM-050IE, 56 15 - GLOSSARY • QUALIFIED AGENCY - Any individual, fi rm, corporation, or company engaged in and responsible for: • Installation, testing, or replacement of gas piping, or connection, installation, 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. • SAFETY RELIEF VALVE - Valve designed to relieve pressure in hot water supply system wh

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