Lennox GWM-050IE Installation Instructions Manual
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Lennox GWM-050IE Installation Instructions Manual

Wall mounted gas boiler
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PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
INSTALLATION
INSTRUCTIONS
GWM-050IE, GWM-075IE,
GWM-100IE, GWM-150IE,
GWM-200IE
WALL MOUNTED GAS
BOILER
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
These instructions must be affi xed
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 qualifi ed installer, service agency, or the gas
supplier.
WALL MOUNTED GAS-FIRED HOT WATER
BOILERS
These Gas-Fired Water boilers are low pressure,
stainless steel boilers Design Certifi ed 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.
PN# 240009475, Rev. A [07/2012]

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  • Page 1 INSTALLATION INSTRUCTIONS PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas GWM-050IE, GWM-075IE, GWM-100IE, GWM-150IE, GWM-200IE WALL MOUNTED GAS BOILER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions must be affi xed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance could result in death or serious injury.
  • Page 2 DIMENSIONS FIGURE 1-1 Dimensions Vent Connector Combustion Air Safety Relief Valve Connection (¾ NPT) Wall Hanging Bracket Table 1 : Physical Data Models 050/075/100 150/200 20" 23" Width (A) (508mm) (584mm) 31" 42" Height (B) (787mm) (1092mm) 14" 16.0" Supply Water (E) Depth (C) (356mm) (406mm)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 - Introduction ..........................4 2 - Important Safety Information ....................5 3 - Component Listing ........................6 4 - Locating Boiler ........................... 9 5 - Hydronic Piping ........................11 5.2 Special Conditions ........................11 5.3 Safety Relief Valve and Air Vent ....................11 5.4 Trim Piping ..........................

  • Page 4: Introduction

    1 - INTRODUCTION 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: •...

  • Page 5: Important Safety Information

    2 - IMPORTANT SAFETY INFORMATION 2.1 General 2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such Boiler installation shall be completed by qualifi ed agency. requirements: See glossary for additional information. • United States WARNING •...

  • Page 6: Component Listing

    3 - COMPONENT LISTING 3.1 Component Listing Gas (Control) Valve Gas (Control) Valve (see page 8) - Delivers - Delivers proper quantity of fuel to Combustion Air Blower. proper quantity of fuel to Combustion Air Blower. See section 7. See section 7. User Interface (see Appendix A) - Displays information regarding boiler condition.
  • Page 7 3 - COMPONENT LISTING FIGURE 3-1 Boiler Components (Viewed from Back of Boiler) NOTE: AIR VENT AIR VENT See Section 5-3 SAFETY RELIEF VALVE SAFETY RELIEF VALVE For Safety Relief Valve Piping VENT CONNECTOR Instructions COMBUSTION AIR INLET WALL WALL HANGING SUPPORT SUPPORT BRACKET...
  • Page 8 3 - COMPONENT LISTING FIGURE 3-3 Boiler Components (View from Front of Boiler) NOTE: See Section 5 See Section 5 See Section 5 AIR VENT AIR VENT For Piping For Piping SAFETY RELIEF VALVE SAFETY RELIEF VALVE SAFETY RELIEF VALVE Instructions Instructions VENT CONNECTOR...

  • Page 9: Locating Boiler

    4 - LOCATING BOILER FIGURE 4-1 Clearance to Combustible Materials Boiler Location Considerations • Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate. • Approved for installation in closets. • Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).
  • Page 10 4 - LOCATING BOILER Pre-pipe supply and return water connections with factory fi ttings before wall mounting. FIGURE 4-2 Wall Mount Bracket Engaged with Brack- 4.3 Wall Mounting et on Boiler Mount boiler on wall using wall mounting bracket included Center brackets.

  • Page 11: Hydronic Piping

    5 - HYDRONIC PIPING 5.1 General • Install piping in accordance with authority having jurisdiction. WARNING NOTICE • Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol. Use two (2) wrenches when tightening and fi tting to pipe boiler's threaded fi ttings. Boiler's internal •...

  • Page 12: Trim Piping

    5 - HYDRONIC PIPING • Install discharge piping from safety relief valve. See WARNING fi gure 5-2. Burn and scald hazard. Safety relief valve could • Use ¾" or larger pipe. discharge steam or hot water during operation. • Use pipe suitable for temperatures of 375°F (191°C) Install discharge piping per these instructions.
  • Page 13 5 - HYDRONIC PIPING Piping Legend NOTICE Illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. FIGURE 5-4 System Piping Safety Relief Valve System System Supply Return F L O O R Check Local Codes For Maximum Distance To Floor...
  • Page 14 5 - HYDRONIC PIPING 5-5 TWO-PIPE ZONED SYSTEM WITH VALVES Pump CH/System Heat exchanger Pump ball valve open (as shipped) 3/8"/10mm Open End Wrench 5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS Pump Heat exchanger ball valve open (as shipped) Zone Pump 3/8"/10mm Open End Wrench...
  • Page 15 5 - HYDRONIC PIPING 5-7A SINGLE BOILER USING PRIMARY/SECONDAY PUMPING 12"/305mm Max. apart 12"/305mm Existing closely spaced tees Max. apart in primary system loop CH/System Limit length Pump 5'/1.6 m Heat exchanger ball valves closed 3/8"/10mm Open End Wrench 5-7B SINGLE BOILER USING PRIMARY/SECONDAY PUMPING 12"/305mm Max.
  • Page 16 5 - HYDRONIC PIPING 5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide) Pump System Pump 12"/305mm Max. apart System Size common piping Temperature according to Sensor maximum heat capacity of entire system Up to 16 boilers All heat exchanger ball valves closed 3/8"/10mm Open End Wrench...

  • Page 17: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING • Any improper operation of common venting system 6.1 General should be corrected so installation conforms with National This boiler requires a dedicated direct vent system. Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas Install combustion air and vent piping in accordance and Propane Installation Code, CAN/CSA B149.1.

  • Page 18: Pipe Installation

    6 - COMBUSTION AIR AND VENT PIPING 6.4 Pipe Installation 6.5 Termination • Minimum and maximum combustion air and vent pipe • Terminate combustion air and vent pipes with fi ttings or lengths listed in Table (4). Pipe length counted from concentric vent kit.
  • Page 19 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 3" (8 cm) Maximum  3" (8 cm) Maximum horizontal separation between combustion air intake and vent of same appliance. 12" (30 cm) 15" (38 cm)  8" (21 cm) Minimum vertical Minimum Maximum Roof Line...
  • Page 20 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 FIGURE 6-5 1" (2.54cm) 1" (2.54cm) Roof overhang Maximum Maximum 1"(2.54cm) Maximum 12" (30cm) Minimum * See Note 36"(0.9m) Minimum Below Maintain 12" Maintain 12"(30cm) clearance above Vent Vent clearance above highest highest anticipated Combustion anticipated snow level or...
  • Page 21 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-6  Glue inner vent pipe to prevent Vent recirculation. Maintain 12"(30cm)  Maintain 12" (30 cm) US ((18"(46 clearance above highest cm) Canada)) minimum clearance anticipated snow level above highest anticipated snow 24"...
  • Page 22 6 - COMBUSTION AIR AND VENT PIPING Combustion air and vent termination Doors & must be 12" (300 mm) from or below Windows doors, windows or gravity inlet. Termination must Vent gas may condense, forming be 12" (30.5 cm) moisture, may be corrosive. Protect Condensate from or below doors, building materials at vent from exhaust...
  • Page 23 6 - COMBUSTION AIR AND VENT PIPING Keep vent termination 3’ minimum Vegetation, (0.9m) away from vegetation. Position Plants & termination where vent vapors will not Shrubs damage plants/shrubs or air conditioning equipment. Termination Vent termination US only - 4’ (1.2 m), Meters, Canada - 6' (1.83m) horizontally from, Regulators,...

  • Page 24: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 Condensate Drain 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. •...

  • Page 25: Gas Supply Piping

    7 - GAS SUPPLY PIPING 7-1 Gas Connection CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone.
  • Page 26 7 - GAS SUPPLY PIPING 7-2 Manual Main Gas Shutoff Valve Outside Boiler DANGER Jacket Fire Hazard. Do not use matches, candles, open fl ames, or other methods providing ignition source. Failure to comply will result in death or serious injury.

  • Page 27: Electrical Connections

    8 - ELECTRICAL CONNECTIONS 8.1 General WARNING Electrically bond boiler to ground in accordance with Electrical shock hazard. Turn OFF electrical power requirements of authority having jurisdiction. Refer to: supply at service panel before making electrical • USA- National Electrical Code, ANSI/NFPA 70. connections.
  • Page 28 8 - ELECTRICAL CONNECTIONS • Argus Link (Multiple boiler applications only) 8-2 EXTERNAL CONNECTIONS • Outdoor Sensor, if used. (Do not apply voltage to external terminals.) A. Provided with boiler. B. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor.

  • Page 29: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Fill boiler with water and purge air NOTICE • Fill boiler with potable water. IMPORTANT: Condensate trap must be manually • Fill boiler and system piping with water (or antifreeze- fi lled with water at initial start up. water solution, if used).
  • Page 30 9 - START UP PROCEDURE 9 -2 User Interface -2 User Interface 9.3 Program Boiler Control Description - Manual Lockout Reset - Enter/Exit user menu - Go to previous screen - Select a menu item - Confi rm new parameter value - Scroll up to next menu item - Increase value - Scroll down to next menu item...
  • Page 31 9 - START UP PROCEDURE 9.4 Boiler Start-up and Operational Test Compare measured input to table. Adjust input rate if needed using fi gure 9-3 below. Verify air is purged from hydronic piping Size Minimum Maximum System test pumps - verify each pump is operational Verify gas piping •...

  • Page 32: Csd-1 Compliance Test

    9 - START UP PROCEDURE Operate boiler through several heating cycles, WARNING including domestic hot water, if used. Verify proper Asphyxiation hazard. Carbon monoxide is odorless, operation. tasteless, clear colorless gas, which is highly toxic. Verify cap is fi rmly placed on combustion analyzer 9.6 Perform CSD-1 Compliance Test (see port to prevent CO emission.
  • Page 33 9 - START UP PROCEDURE 9-6 Control Module J7 Connector Follow instructions TO TURN OFF GAS TO APPLIANCE if boiler is not being placed into immediate operation. Enter installer information on Warranty Registration Card. Gather all instructions, manuals, wiring diagrams, warranty registration card and other supporting information.

  • Page 34: Operating Instructions

    10 - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WARNING WHAT TO DO IF YOU SMELL GAS If you do not follow these instructions exact- • Do not try to light any appliance. ly, a fi re or explosion may result causing prop- •...

  • Page 35: General Maintenance And Cleaning

    11 - GENERAL MAINTENANCE AND CLEANING 11.1 Beginning of Each Heating Season DANGER • Check boiler area is free from combustible materials, Before servicing, turn off electrical power to boiler gasoline, and other fl ammable vapors and liquids. at service switch. Close manual gas valve to turn •...
  • Page 36 11 - GENERAL MAINTENANCE AND CLEANING Figure 11-2 Condensate Trap 11.2 Annual Shut Down Procedure • Follow instructions “To Turn Off Gas To Appliance” unless boiler is also used to supply domestic hot water. See section 10. • Drain system completely if system does not have antifreeze when heating system is to remain out of service during freezing weather.
  • Page 37 11 - GENERAL MAINTENANCE AND CLEANING • Remove ¼-20 hex fl ange nuts securing condensate collector to heat exchanger using 7/16" deep well socket. See fi gure 11-2. • Remove condensate collector assembly from heat exchanger and fl ue pipe. •...

  • Page 38: Ratings And Capacities

    12 - RATINGS AND CAPACITIES TABLE 12-1: SEA LEVEL RATINGS NATURAL AND PROPANE GASES Boiler Input Rate (MBH) Heating Capacity Net AHRI Rating, Size AFUE (MBH) Water (MBH) (1)(2) (1)(3) Maximum Minimum 96.0 96.0 96.0 96.0 96.0 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Effi...

  • Page 39: Troubleshooting

    13 - TROUBLE SHOOTING GO TO NEXT PAGE...

  • Page 40: Trouble Shooting

    13 - TROUBLE SHOOTING Go to Page 45 Go to Page 41 Go to Page 46 Go to Page 42 Go to Page 41 Go to Page 47 Replace Control Replace Control Module Module Go to Page 47 Go to Page 43 Replace Control Go to Page 48 Module...
  • Page 41 13 - TROUBLE SHOOTING...
  • Page 42 13 - TROUBLE SHOOTING...
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  • Page 53: Wiring Diagram

    14 - WIRING DIAGRAM 14.1 Connection Diagram...
  • Page 54 14 - WIRING DIAGRAM 14.2 Schematic Diagram of Ladder Form...

  • Page 55: Glossary

    15 - GLOSSARY • ANSI - American National Standards Institute, Inc. oversees creation and maintenance of voluntary consensus standards, including ANSI Z21.13/CSA 4.9: NATURAL GAS Gas-Fired Low Pressure Steam and Hot Water Boilers. Pipe Capacity - BTU Per Hour Input Includes Fittings Length of Pipe - Ft.
  • Page 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. •...

  • Page 57: Appendix A - Control Module

    APPENDIX A - CONTROL MODULE 1.1 Introduction Operation with LCD character display module Operation with LCD character display module Boiler is equipped with programmable electronic control and user interface module. 1.2 Operation • Display: 4x20 character LCD screen to show boiler status.

  • Page 58: Sequence Of Operation

    APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation Boiler operates in standby mode until S t a n d b y : N o D e m a n d demand for Central Heat (CH) or Heat Domestic Hot Water (DHW) is detected.
  • Page 59 APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation After 2 seconds If fl ame detected before Gas Valve opens during ignition boiler will lockout. Lockout Flame Error A21 Detected? Please refer to troubleshooting guide. Note: 5 Ignition trials,...

  • Page 60: Theory Of Operation

    APPENDIX A - CONTROL MODULE...
  • Page 61 APPENDIX A - CONTROL MODULE...
  • Page 62 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu 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...
  • Page 63 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu 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 S T A T U S ▲...
  • Page 64 APPENDIX A - CONTROL MODULE...
  • Page 65 APPENDIX A - CONTROL MODULE Explanation User Interface Display Two pump modes are available: Pump Mode = 0 ‘CH or CH&DHW’ • In this mode either the CH or DHW pump terminal is energized depending on the type of demand (CH or DHW). •...
  • Page 66 APPENDIX A - CONTROL MODULE Explanation User Interface Display 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.
  • Page 67 APPENDIX A - CONTROL MODULE Explanation User Interface Display S E T T I N G S ▲ If outdoor temperature is greater than Warm Weather W a r m W e a t h e r Shutdown Temperature, demand for CH blocked and pumps S h u t d o w n T e m p stopped.
  • Page 68 APPENDIX A - CONTROL MODULE Explanation User Interface Display Outdoor reset boost function increases CH set point by increment (‘Temp’) if CH demand continues beyond pre-set time limit (‘Time’). S E T T I N G S ▲ CH set point will continue to increase until set point reaches B o o s t F u n c t i o n 195°F / 91°C...
  • Page 69 APPENDIX A - CONTROL MODULE Explanation User Interface Display Maximum time boiler operates in DHW mode limited by DHW Maximum Priority Time Setting. Priority timer starts when both CH and DHW demand is present. Boiler will switch from DHW back to CH operation after D H W S E T T I N G S ▲...
  • Page 70 NOTES...
  • Page 72 PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...

This manual is also suitable for:

Gwm-075ieGwm-100ieGwm-150ieGwm-200ie

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