Lennox GWM-050IE Installation Instructions Manual

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 affixed
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 qualified 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 Certified 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. C [03/2014]

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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 affixed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance could result in death or serious injury.
  • Page 2 VERIFY CONTENTS RECEIVED Description Illustration Item Fully Assembled Boiler Metal Wall Bracket Lag Bolt, 3/8" x 3" Hex (4 ea) *Safety Relief Valve 3/4" Tee 3/4" Nipple 3/4" x 1/4" Elbow Air Vent **Temperature Pressure Gauge Bushing 3/4" x 1/4" 3/4"...
  • Page 3: Safety Relief Valve

    DIMENSIONS DIMENSIONS FIGURE 1-1 Dimensions Safety Relief Valve Vent Connector Connection Combustion Air (¾ NPT) Wall Hanging Bracket Table 1 : Physical Data Models 050/075/100 150/200 Width (A) 20" (508mm) 23" (584mm) Height (B) 30" (762mm) 40" (1041mm) 16.0" Depth (C) 14"...
  • Page 4: Table Of Contents

    TABLE OF CONTENTS 1 - Introduction ..........................5 2 - Important Safety Information ....................6 3 - Component Listing ........................7 4 - Locating Boiler ......................... 11 5 - Hydronic Piping ........................13 5.2 Special Conditions ......................... 13 5.3 Safety Relief Valve and Air Vent.................... 5.4 Trim Piping ...........................
  • Page 5: 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 liquefied petroleum gases (LP/propane). 1.2 The unit MUST NOT: • Directly heat potable water. Indirect heating is acceptable. •...
  • Page 6: 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 qualified agency. requirements: See glossary for additional information. • United States WARNING •...
  • Page 7: Component Listing

    3 - COMPONENT LISTING Component Listing - Refer to diagrams on Gas (Control) Valve Delivers proper quantity of fuel following pages. to Combustion Air Blower. See section 7. Supply Water Temperature Sensor and High Limit User Interface Displays information regarding boiler Switch condition.
  • Page 8 3 - COMPONENT LISTING FIGURE 3-1 Boiler Components (Viewed from Back of Boiler) NOTE: AIR VENT See Section 5-3 For Safety Relief Valve SAFETY RELIEF VALVE Piping Instructions VENT CONNECTOR COMBUSTION AIR INLET WALL MOUNT SUPPORT BRACKET FIGURE 3-2 Upper and Lower Jacket Latch (Viewed from front of boiler) Lift Jacket up, Upper and Lower...
  • Page 9 3 - COMPONENT LISTING FIGURE 3- Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover NOTE: See Section 5 (28) AIR VENT For Piping (23) SAFETY RELIEF VALVE Instructions (25) VENT CONNECTOR (21) SUPPLY WATER (2) COMBUSTION TEMPERATURE SENSOR AIR INLET...
  • Page 10: Locating Boiler

    4 - LOCATING BOILER FIGURE 4-1 Clearance to Combustible Materials 4.1 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 11 4 - LOCATING BOILER FIGURE 4-2 Wall Mount Bracket Engaged with Pre-pipe supply and return water connections Bracket on Boiler with factory fittings before wall mounting. Center brackets. Avoid 4.3 Wall Mounting overhang on sides of Mount boiler on wall using wall mounting bracket included wall mount bracket.
  • Page 12: Hydronic Piping

    5 - HYDRONIC PIPING 5.1 General WARNING • Install piping in accordance with authority having jurisdiction. • Poison hazard. Ethylene glycol is toxic. Do not NOTICE use ethylene glycol. Use two (2) wrenches when tightening and fitting • Never use automotive or standard glycol antifreeze, to pipe boiler's threaded fittings.
  • Page 13: Trim Piping

    5 - HYDRONIC PIPING • Install discharge piping from safety relief valve. See WARNING figure 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 14 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 WALL MOUNTED ONLY System System Supply Return Pipe to...
  • Page 15 5 - HYDRONIC PIPING FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves Pump CH/System Heat exchanger Pump ball valve open (as shipped) 3/8"/10mm Open End Wrench may be required to turn valve FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps Pump Heat exchanger ball valve open...
  • Page 16 5 - HYDRONIC PIPING FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping With Closed External Primary Loop Heating Load Heating Load 12"(305mm) Maximum separation Heating Load 12"(305mm) Maximum separation Existing closely spaced tees in primary system loop Limit length CH/System Pump 5' (1.6m) Heating system with existing...
  • Page 17 5 - HYDRONIC PIPING FIGURE 5-8A Multiple Boiler Two Pipe Zoned System With Zone Valves - (See Multiple Boiler Guide) Pump CH/System Pump 12"/305mm Maximum Separation Size common piping System per maximum heat Temperature capacity of entire Sensor system Limit length to 5' (1.6m) All internal...
  • Page 18 5 - HYDRONIC PIPING FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping with Closed External Primary Loop Heating Load Heating Load 12"/305mm Maximum Separation 12"/305mm Existing closely spaced tees Heating Load Maximum in primary system loop Separation CH/System Pump System Size common piping Temperature per maximum heat Sensor...
  • Page 19 5 - HYDRONIC PIPING 5-8C Multiple Boilers Using Primary/Secondary Pumping with Open External Primary Loop 12"/305mm Maximum Separation Existing closely spaced tees 12"/305mm in primary system loop Maximum Separation CH/System Pump System Size common piping Temperature per maximum heat Sensor capacity of entire system Limit...
  • Page 20: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING 6.1 General • Any improper operation of common venting system 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 21: Vent Pipe Installation

    6 - COMBUSTION AIR AND VENT PIPING 6.4 Vent Pipe Installation • Canadian installations only. All venting material, primer and glue must be listed to ULC S636. • Minimum and maximum combustion air and vent pipe lengths listed in Table 5. Pipe length counted from •...
  • Page 22: Venting Configurations

    6 - COMBUSTION AIR AND VENT PIPING 6.6 Venting Configurations NOTICE Various venting configurations can be applied to this boiler. Use of vent covers may cause freezing. If using For guidance see Venting Configuration Table 7 and vent covers overall vent length must be considered. corresponding figures.
  • Page 23 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 Two Pipe Roof Vent 3" (80mm)  3" (80mm) Minimum horizontal Minimum separation between combustion air intake and vent of same appliance. 12" (305mm) 15" (381mm)  8" (203mm) Minimum vertical Minimum Maximum Roof Line...
  • Page 24 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 Side Wall Concentric Terminal FIGURE 6-5 Side Wall Concentric Terminal Multiple Appliances Roof 1"(2.54cm) Overhang 1" (25mm) Maximum 1" (25.4mm) Maximum Maximum 12" (305mm) Minimum * See Note ) Minimum 36"(0.9m Below Vent Maintain 12"...
  • Page 25 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-7 Concentric Roof Terminal Vent Maintain 12"(305mm) US  Glue inner vent pipe to prevent (18"(457mm) Canada) recirculation. clearance above highest anticipated snow level 24"  Maintain 12" (305mm) US Combustion Air (610mm) above roof (18"(457mm) Canada) minimum clearance above highest...
  • Page 26 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-10 Flue on Sidewall, Combustion Air on Roof NOTICE Maintain 12"(305mm) US (18"(457mm) Canada) Configurations of single pipe vent with flue on the clearance above highest sidewall, requires a tee as the vent terminal. See Combustion anticipated snow level 24"...
  • Page 27: Side Venting Terminal Requirements

    6 - COMBUSTION AIR AND VENT PIPING 6.7 Side Venting Terminal Requirements of • USA - National Fuel Gas Code, ANSI 223.1/NFPA 54. • Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1 Venting terminal from doors and windows See figure 6-12 Venting terminal from forced air inlet of other appliances See figure 6-13...
  • Page 28 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-15 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’ (1.2m), Meters, Canada - 6' (1.9m) horizontally from, Regulators,...
  • Page 29: Multiple Boiler Venting Installation

    6 - COMBUSTION AIR AND VENT PIPING 6.8 Multiple Boiler Venting Installation Table 8 - Minimum Diameter for Individual Boiler in Common Venting System • Multiple boiler application boiler can vent individually or use common vent pipes. Minimum Model • If boilers vent individually follow guidelines as Diameter described in figures 6-1 through 6-7.
  • Page 30: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING 6.9 Condensate Piping FIGURE 6-18 Condensate Drain • 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 31: Gas Supply Piping

    7 - GAS SUPPLY PIPING FIGURE 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. •...
  • Page 32 7 - GAS SUPPLY PIPING FIGURE 7-2 Manual Main Gas Shutoff Valve Outside DANGER Boiler Jacket Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Failure to comply will result in death or serious injury.
  • Page 33: 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 34 8 - ELECTRICAL CONNECTIONS FIGURE Isolation Relays for CH System Pump • Outdoor Sensor, if used. and DHW Pump A. Provided with boiler. B. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor. C. Maximum wire length is 100 ft (30m) for 22 ga. wire, or 150 ft (45m) for 18 ga.
  • Page 35: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Fill Boiler With Water And Purge Air NOTICE NOTICE IMPORTANT: Condensate trap must be manually filled with water at initial start up. To maintain boiler efficiency and prevent boiling inside the heat exchanger, flush entire heating FIGURE 9-1 Condensate Drain Assembly system until clean.
  • Page 36 9 - START UP PROCEDURE 9 -2 User Interface 9 -2 User Interface 9.3 Program Boiler Control Description - Manual Lockout Reset - Enter/Exit user menu - Go to previous screen - Select a menu item - Confirm new parameter value - Scroll up to next menu item - Increase value - Scroll down to next menu item...
  • Page 37 9 - START UP PROCEDURE 9.4 Boiler Start-up and Operational Test 9.5 Check Combustion Verify air is purged from hydronic piping Natural Gas System test pumps - verify each pump is Measure input. English units* operational • Turn off gas to all other appliances. Verify gas piping •...
  • Page 38 9 - START UP PROCEDURE Verify Burner, Proper Operation Min. Max. Inspect burner flame through Sight Glass. See Natural Gas <200ppm figure 11-1 & 11-2. Propane 10.0 11.0 <200ppm Operate boiler through several heating cycles, including domestic hot water, if used. Verify proper operation.
  • Page 39: Perform Csd-1 Compliance Test

    9 - START UP PROCEDURE 9.6 Perform CSD-1 Compliance Test (see WARNING paragraph 2.4 page 6) Asphyxiation hazard. Carbon monoxide is odorless, Verify operation of boiler safety control operation with tasteless, clear colorless gas, which is highly toxic. regard to no flow conditions as follows: Verify cap is firmly placed on combustion analyzer Turn off boiler using boiler service switch.
  • Page 40: Complete Start Up Procedure

    9 - START UP PROCEDURE 9.7 Complete Start Up Procedure 9-8 Control Module J7 Connector Reset control parameters to operating settings if adjusted to allow startup and operation test. Follow instructions TO TURN OFF GAS TO APPLIANCE (page 42) if boiler is not being placed into immediate operation.
  • Page 41: 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 • Do not try to light any appliance. exactly, a fire or explosion may result causing •...
  • Page 42: 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 flammable vapors and liquids. at service switch. Close manual gas valve to turn •...
  • Page 43 11 - GENERAL MAINTENANCE AND CLEANING 11.3 Annual Inspection and Cleaning of Boiler Figure 11-3 Condensate Trap - 050,075,100,150,200 Components • Obtain Burner Inspection Kit. Follow kit instructions to prepare for examination and cleaning. • Burner and heat exchanger inspection and cleaning. •...
  • Page 44: Ratings And Capacities

    12 - RATINGS AND CAPACITIES TABLE 12-1: SEA LEVEL RATINGS NATURAL AND PROPANE GASES Net AHRI Rating, Boiler Input Rate (MBH) Heating Capacity Size Water (MBH) (1)(3) AFUE (1)(2) (MBH) Maximum Minimum 95.0 95.0 95.0 95.0 94.0 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
  • Page 45 13 - TROUBLE SHOOTING...
  • Page 46: Trouble Shooting

    13 - TROUBLE SHOOTING Go to Page For Screen Display Explanation Troubleshooting Control has blocking error for more than 20 Go to Page 48 hours in a row. Three unsuccessful ignition attempts in a row Go to Page 49 Open gas valve power circuit. May involve high temperature switch, gas valve, or gas Go to Page 48 valve relay in control module.
  • Page 47 13 - TROUBLE SHOOTING Go to Page For Screen Display Explanation Troubleshooting Low water cutoff sees no water. Go to Page 54 Flue temperature sensor sees temperature Go to Page 55 higher than 200°F. E 39 B l o c k i n g E r r o r F l u e G a s E r r o r Return water temperature sensor sees Go to Page 56...
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  • Page 62: Wiring Diagram

    14 - WIRING DIAGRAM 14.1 Connection Diagram - 050/075/100 MBH...
  • Page 63: Wiring Diagram

    14 - WIRING DIAGRAM 14.2 Schematic Diagram of Ladder Form - 050/075/100 MBH LADDER DIAGRAM GROUND ARGUS CONTROL J13-2 FLAME SENSOR BURNER J16-1 IGNITION LWCO J16-4 J9-1 J16-5 DC+/L J9-2 J16-8 J9-6 DATA/PWM J9-7 J16-6 HALL 120VAC J9-5 J16-7 J9-4 DC-/N J16-3 J9-3...
  • Page 64: Wiring Diagram

    14 - WIRING DIAGRAM 14.3 Connection Diagram - 150/200 MBH EXTERNAL PUMP RELAY - LIMIT OF 1 AMP PER PUMP SEE SECTION 8...
  • Page 65 14 - WIRING DIAGRAM 14.4 Schematic Diagram of Ladder Form - 150/200 MBH LADDER DIAGRAM GROUND ARGUS CONTROL J13-2 FLAME SENSOR BURNER J16-1 IGNITION LWCO J16-4 J9-1 J16-5 DC+/L J9-2 J16-8 J9-6 DATA/PWM J9-7 J16-6 HALL 120VAC J9-5 J16-7 J9-4 DC-/N J16-3 J9-3...
  • Page 66: Glossary

    15 - GLOSSARY • ANSI - American National Standards Institute, • GAS PIPE SIZES - Table 14 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 67 15 - GLOSSARY • QUALIFIED AGENCY - Any individual, firm, 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 68: Appendix A - Control Module

    APPENDIX A - CONTROL MODULE 1.1 Introduction Operation with LCD character display module Boiler is equipped with programmable electronic control and user interface module. 1.2 Operation • Display: 4 x 20 character LCD screen to show boiler status. • Function Keys Description - Manual Lockout Reset - Enter/Exit user menu...
  • Page 69: 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 70 APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation After 2 seconds If flame 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 71: User Menu

    APPENDIX A - CONTROL MODULE 1.5 User Menu Explanation User Interface Display Boiler operates in standby mode until demand for Central Heat (CH) or Domestic Hot Water (DHW) is detected. User Menu (Press Menu botton on user interface to access User Menu) User Menu structure includes: •...
  • Page 72 APPENDIX A - CONTROL MODULE Explanation User Interface Display Adjust CH set point to hydronic system design while in Operating in CH Mode = 0 (CH with Thermostat) or 3 (Permanent Demand). In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2 (CH with Full Outdoor Reset).
  • Page 73 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. Installer 'Menu' can be accessed by first pressing and holding the 'Enter' key continue to hold and at the same time press and hold the 'Menu’...
  • Page 74 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 Following control features are implemented to ensure safe and reliable operation of Combustion System:...
  • Page 75 APPENDIX A - CONTROL MODULE Explanation User Interface Display Boiler stores information regarding total CH and DHW run time in hours. Data stored in non-volatile memory and retained in event of power failure. Boiler logs last 16 blocking errors and 16 lockout errors in non-volatile memory.
  • Page 76 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 77 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 firing rate to maintain CH set point and match system heat load.
  • Page 78 APPENDIX A - CONTROL MODULE Explanation User Interface Display If outdoor temperature is greater than Warm Weather Shutdown Temperature, demand for CH blocked and pumps stopped. Allowed Range: 35°F to 100°F (2°C to 38°C) Default Setting: 70°F (21°C) Boiler capable of operating in Outdoor Reset Mode when included Outdoor Sensor is connected and proper CH Mode selected.
  • Page 79 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’). 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:...
  • Page 80 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 Maximum Priority Time has elapsed.
  • Page 81 NOTES...
  • Page 82 NOTES...
  • Page 83 NOTES...
  • Page 84 • This boiler is not used for any space heating • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. PRODUCT LITERATURE Lennox Industries Inc. Dallas, Texas...

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

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