Lennox GWM-050IE Installation Instructions Manual Download Page 15

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FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves

FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps

Heat exchanger

ball valve open

(as shipped)

Heat exchanger

ball valve open

(as shipped)

DHW

Pump

CH/System

Pump

DHW

Pump

Zone

Pump

5 - HYDRONIC PIPING

3/8"/10mm Open

End Wrench may

be required to

turn valve

3/8"/10mm Open

End Wrench may

be required to

turn valve

Summary of Contents for GWM-050IE

Page 1: ...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 S...

Page 2: ...for packaging holes on back of boiler Plastic Plug 2 ea 18 Used for packaging holes on back of boiler Outdoor Sensor 19 Used for measuring outside temperature Critical Installation Instruction 20 11...

Page 3: ...23 584mm Height B 30 762mm 40 1041mm Depth C 14 356mm 16 0 406mm Bracket D 28 711mm 40 1016mm Height E 31 787mm 42 1092mm Water Connections Size F 1 1 4 NPT 1 1 4 NPT Location G 2 51mm 2 51mm Locatio...

Page 4: ...7 Side Venting Terminal Requirements 28 6 8 Multiple Boiler Venting Installation 30 6 9 Condensate Piping 31 7 Gas Supply Piping 32 8 Electrical Connections 34 8 3 Line Voltage Connections 34 8 4 Exte...

Page 5: ...d 150 psig 1 03 MPa maximum allowable working 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...

Page 6: ...ensed plumber or gas fitter NOTICE Used to address practices not related to personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury WARNIN...

Page 7: ...Gas Shutoff Valve Fuel supply isolation during servicing See section 7 19 Combustion Air Blower Delivers proper quantity of combustion air receives fuel from gas valve mixes air and fuel sending mixt...

Page 8: ...3 For Safety Relief Valve Piping Instructions COMBUSTION AIR INLET SAFETY RELIEF VALVE AIR VENT FIGURE 3 2 Upper and Lower Jacket Latch Viewed from front of boiler Lift Jacket up engage jacket with ch...

Page 9: ...XCHANGER 29 BOILER CONTROL MODULE Fuse and Holder 5 IGNITER 6 FLAME SENSOR 7 SIGHT GLASS 32 FLUE AIR MIXTURE PRESSURE TEST PORT 16 CONDENSATE DRAIN 7 SIGHT GLASS 7 SIGHT GLASS 33 COMBUSTION 33 COMBUST...

Page 10: ...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 c...

Page 11: ...on hazard Mount boiler vertically or slightly tilted backward to insure proper function of low water cutoff Failure to follow these instructions could result in death or serious injury When mounting b...

Page 12: ...rigerated air circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Boiler ra...

Page 13: ...for general guidance Additional considerations Boiler control is designed for single central heating pump Installer responsible for integration of multiple central heating pumps Boiler control allows...

Page 14: ...e to condensate drain Table 3 System Piping Configurations Single Boiler Two Pipe Zoned System With Zone Valves figure 5 5 With Zone Pumps figure 5 6 Primary Secondary Pumping Closed External Primary...

Page 15: ...Two Pipe Zoned System With Zone Pumps Heat exchanger ball valve open as shipped Heat exchanger ball valve open as shipped DHW Pump CH System Pump DHW Pump Zone Pump 5 HYDRONIC PIPING 3 8 10mm Open End...

Page 16: ...primary loop Internal primary loop ball valves closed FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With Open External Primary Loop CH System Pump 12 305mm Maximum separation Existing clos...

Page 17: ...ING Up to 16 boilers DHW Pump See Multiple Boiler Guide CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system All internal...

Page 18: ...d Existing closely spaced tees in primary system loop 12 305mm Maximum Separation Up to 16 boilers CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum h...

Page 19: ...y system loop 12 305mm Maximum Separation CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system Heat exchanger ball valve o...

Page 20: ...Adjust thermostat so appliances will operate continuously Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use flame of match or candle smoke from cigarette cig...

Page 21: ...nents must NOT be interchanged with other vent systems or unlisted pipe fittings Canadian installations only All venting material primer and glue must be listed to ULC S636 Canadian installations only...

Page 22: ...1 Concentric figure 6 7 Side Wall Single Pipe figure 6 8 Inside Air Single Pipe figure 6 9 Side Wall Roof Single Pipe figure 6 10 Side Wall Two Pipe figures 6 2 6 3 Concentric figures 6 4 6 5 6 6 Ins...

Page 23: ...bustion air intake and vent of different appliances 15 381mm Maximum horizontal length of vent Minimum vent intake between different appliances 12 305mm Maximum allowable total vertical vent length wi...

Page 24: ...be field installed to prevent movement of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 or 3 51 or 77 mm Diameter PVC intake combustion air Combustion Air 2 51mm Diamet...

Page 25: ...ve roof FIGURE 6 8 Flue on Roof Air Intake on Side Wall FIGURE 6 9 Flue on Roof Combustion Air Grade Snow Ice Terminate vent system bottom minimum 12 300 mm above highest anticipated snow level Avoid...

Page 26: ...w Line 6 COMBUSTION AIR AND VENT PIPING NOTICE Configurations of single pipe vent with flue on the sidewall requires a tee as the vent terminal See figures 6 10 and 6 11 Maintain 12 305mm US 18 457mm...

Page 27: ...may condense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas Termination must be 12 305mm from or below doors windows or gravity inlet 12 305mm Minimum Te...

Page 28: ...rn leaves snow or recirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkwa...

Page 29: ...to prevent flue gas back flow External terminals follow same rule as single boiler venting as described in Section 6 6 and 6 7 FIGURE 6 17 Mulitple Boilers With Common Venting Pipe Model Minimum Diam...

Page 30: ...ondensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by author...

Page 31: ...gas valve Install manual main shutoff valve outside of jacket See figure 7 2 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler Table 10 Gas Supply Pressure CAUT...

Page 32: ...corrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods that can provide ignition source Correct le...

Page 33: ...ct pump to line voltage terminal strip CH PUMP L N G Domestic Hot Water Pump if used A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figure 8 3 and Table 11 B...

Page 34: ...interchangeable to DHW T T terminals Wires are interchangeable Central Heating Thermostat A Use thermostat or boiler system control with dry contacts related 0 5 amps 120 VAC Boiler control does not...

Page 35: ...ntil boiler resets Do not open gas shutoff valve until all air is purged from system 9 2 Fill Condensate Trap with Water Disconnect spring tension clip from condensate hose barb See figure 9 1 Disconn...

Page 36: ...104 195 F 40 91 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Enabled Enable Disabled Pump Mode 0 0 4 Service Reminder Status On ON OFF Service R...

Page 37: ...lows adequately and is disposed properly 8 Check control module operation 9 Check field sourced limits low water cutoffs etc per manufacturer s instructions 9 5 Check Combustion Natural Gas 1 Measure...

Page 38: ...CO2 is low increase gas flow following figure 9 3 If CO2 is high decrease gas flow following figure 9 3 FIGURE 9 3 Gas Valve Models 050 075 100 150 200 MBH To increase gas flow turn throttle left or...

Page 39: ...drops below limit boiler will automatically refire then Lockout A 06 requiring manual reset of control module Press Reset button on User Interface OR C Shut off burner E39 Flue Temperature Sensor Thi...

Page 40: ...2 Follow instructions TO TURN OFF GAS TO APPLIANCE page 42 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all instructions...

Page 41: ...ped with an ignition device which automatically lights the burner Do not try to light burner by hand Remove upper jacket panel Turn gas shutoff valve clockwise to closed position Handle should be perp...

Page 42: ...kages or obstructions air vent check venturi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in place return temperature sensor clip must be sec...

Page 43: ...Clean burner using air hose directed into top of burner opening to dislodge any debris in burner ports Inspect burner for foreign matter in flame ports or inside burner Remove foreign matter by blowi...

Page 44: ...piping and pickup requirements such as intermittent system operation extensive piping systems etc 12 RATINGS AND CAPACITIES 12 1 Ratings and Capacities Constructed and hydrostatically tested for maxi...

Page 45: ...45 13 TROUBLE SHOOTING...

Page 46: ...Control Module High Temperature opens during normal operation Go to Page 52 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas...

Page 47: ...61 Hz Go to Page 57 Boiler power supply ground wire is not grounded Go to Page 58 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replac...

Page 48: ...nnected to both Gas Valve and J13 connector on Control Module NO YES Disconnect J13 connector on Control Module Measure resistance across third blue wire and fourth brown wire terminals Is resistance...

Page 49: ...49 13 TROUBLE SHOOTING...

Page 50: ...water flow in system piping Flush system if water is dirty Is boiler supply pipe above heat exchanger hot Wait for boiler to cool down YES NO Replace Broken Switch Unplug molex connector on supply tem...

Page 51: ...51 13 TROUBLE SHOOTING...

Page 52: ...Control Module J13 Continuity from J13 5 to Switch 1 Continuity from J13 6 to Switch 3 continuity of the two purple wires Disconnect harness from High Temperature Supply Switch and Control Module J13...

Page 53: ...TURN OFF GAS TO APPLIANCE Replace Gas Valve Turn off manual gas shutoff valve Follow instructions TO TURN OFF GAS TO APPLIANCE Replace Gas Valve Follow Operating Instructions to initiate boiler operat...

Page 54: ...m Piping remove any remaining air in system Repair System Piping remove any remaining air in system Connect harness to Transformer Disconnect harness from Low Water Cutoff Is 24 vac at terminals 1 2 B...

Page 55: ...blem if any purging all air out of the system Replace Flue Gas Sensor Replace Control Module Use thermal couple to measure flue gas temperature through sampling port Is the measured temperature and fl...

Page 56: ...O Is Heat Exchanger Pump properly oriented Pump arrow pointing down YES NO Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 to 33 000 oh...

Page 57: ...supply rated at 60 Hz 2 Replace Control Module YES YES NO NO Replace circuit breaker 13 TROUBLE SHOOTING Fix the connection These error messages are displayed when the control board detects fault in...

Page 58: ...F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Supply Water Sensor Resistance Chart Disconnect field wiring Is continuity between field wiring neutral...

Page 59: ...re Return Temperature Sensor resistance with digital meter Estimate Sensor temperature Do temperature and resistance fall within ranges shown in chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 15...

Page 60: ...SHOOTING Supply Water Temperature Sensor Resistance Chart Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Does temperature fall within ranges s...

Page 61: ...Sensor Replace Control Module Disconnect wire harness from Vent Temperature Sensor Measure Sensor resistance Does resistance match estimated flue temperature NO YES _ P _ _ _ Blocking Error E 6 5 Flu...

Page 62: ...62 14 WIRING DIAGRAM 14 1 Connection Diagram 050 075 100 MBH...

Page 63: ...C L DATA PWM HALL GND DC N GROUND FLAME SENSOR IGNITION LWCO CH THERMOSTAT USER INTERFACE DISPLAY ARGUS LINK MULTI BOILER OPTIONAL ARGUS LINK POWER ON OFF SUPPLY SENSOR RETURN SENSOR DHW THERMOSTAT FL...

Page 64: ...64 14 WIRING DIAGRAM 14 3 Connection Diagram 150 200 MBH EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8...

Page 65: ...L DATA PWM HALL GND DC N GROUND FLAME SENSOR IGNITION LWCO CH THERMOSTAT USER INTERFACE DISPLAY ARGUS LINK MULTI BOILER OPTIONAL ARGUS LINK POWER ON OFF SUPPLY SENSOR RETURN SENSOR DHW THERMOSTAT FLUE...

Page 66: ...production of heat or heat and light Complete combustion of fuel is possible only in presence of adequate supply of Oxygen COMBUSTIBLE MATERIAL Materials made of or surfaced with wood compressed paper...

Page 67: ...E Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner i...

Page 68: ...Increase value Scroll down to next menu item Decrease value Key Boiler Status Indicator F Flame Detected P Central Heating System pump On B Combustion Air Blower On S Safety Relay Check G Gas Valve O...

Page 69: ...demand CH call is illustrated Control Module compares supply temperature to set point Boiler proceeds to ignition if supply temperature is less than set point Combustion Air Blower speed modulates to...

Page 70: ...g rate according to heating demand When Boiler detects demand met will enter post purge mode then standby mode If simultaneous demand for Central Heat and DHW boiler will enter DHW Priority Mode Prior...

Page 71: ...as part of multiple boiler installation submenu used to view runtime parameters See Multiple Boiler Manual This line is not shown if boiler is not in cascade system Boiler Status Supply Temperature se...

Page 72: ...to OD Reset Setpoint and cannot be changed Controller calculates set point based on outdoor temperature Note For explanation of available CH heating modes refer to CH Mode section located in CH Settin...

Page 73: ...function DHW Settings Modifies Domestic hot Water control settings such as DHW priority time Cascade Settings Refer to Multiple Boiler Manual System Test Tool aids setup of boiler installation or dia...

Page 74: ...ition If at end of safety period no flame detected control will go to post purge removing unburned gas Re ignition attempt started following same cycle Number of re ignition attempts limited to 3 afte...

Page 75: ...ler Configuration Address Selection screen used to set boiler position in multiple boiler cascade installation Refer to Multiple Boiler Installation Manual Default setting of 0 indicates boiler is ope...

Page 76: ...ct this pump to the CH System Pump electrical terminal block See page 56 for diagram The DHW pump terminal does not function This is typical of a hydronic system design which utilizes zone valves for...

Page 77: ...and Warm Weather Shutdown temperature Boiler will permanently attempt to satisfy CH demand when CH demand is available CH thermostat input is ignored CH set point calculated as function of outdoor tem...

Page 78: ...upply temperature follows thick black line in graph below based on outdoor temperature Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor detected CH set point e...

Page 79: ...100 Default Setting 100 DHW Settings Two DHW modes are available DHW Mode 0 No DHW DHW Mode is disabled The DHW thermostat input is ignored and the DHW pump is not used DHW Mode 2 DHW Store with Ther...

Page 80: ...demand being present System Test has priority over any system demand while test mode activated System test mode automatically ends after 30 minutes boiler resumes normal operation The following modes...

Page 81: ...81 22 NOTES...

Page 82: ...82 22 NOTES...

Page 83: ...83 22 NOTES...

Page 84: ...energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that red...

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