American Standard GRWF130A94A0A Installation Manual
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American Standard GRWF130A94A0A Installation Manual

American Standard GRWF130A94A0A Installation Manual

Direct vent gas fired with cast iron heat exchanger
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INSTALLATION GUIDE

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property and is to remain with this unit. Please
return to service information pack upon completion of work.
*GRWF130A94A0A
*May be "A" or "T"
Direct Vent Gas Fired Water Boiler
with Cast Iron Heat Exchanger
© 2007 American Standard Inc. All Rights Reserved
®
C
US
18-CG02D1-4

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Summary of Contents for American Standard GRWF130A94A0A

  • Page 1: Installation Guide

    IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work. *GRWF130A94A0A *May be “A” or “T” Direct Vent Gas Fired Water Boiler with Cast Iron Heat Exchanger ® © 2007 American Standard Inc. All Rights Reserved 18-CG02D1-4...

  • Page 2: Safety Considerations

    ▲ ▲ 1.0 Safety Considerations WARNING IMPORTANT: Read this entire manual before FIRE OR EXPLOSION HAZARD. beginning installation procedures. TURN OFF MAIN GAS VALVE BEFORE INSTAL- Read this manual carefully before attempting to LING, PERFORMING MAINTENANCE OR SERVI- install, operate, or perform maintenance on this CING A BOILER.
  • Page 3 ▲ ▲ ▲ WARNING WARNING CARBON MONOXIDE POISONING HAZARD SAFETY HAZARD Failure to follow the steps outlined below for each DO NOT BYPASS SAFETY CONTROLS appliance connected to the venting system being placed into operation could result in carbon monoxide FAILURE TO FOLLOW THIS WARNING COULD poisoning or death.

  • Page 4: Cautions

    ▲ ▲ 1.2 CAUTIONS WARNING ▲ ▲ CAUTION If the information in this manual is not followed exactly, a fire or explosion may result causing property Do NOT install the boiler in a corrosive or contaminated damage, personal injury or loss of life. atmosphere.

  • Page 5: Table Of Contents

    Table of Contents 1.0 Safety considerations ................. 2 1.1 Warnings .........................2 1.2 Cautions ........................4 1.3 Notes ........................4 2.0 Pre-Installation Information & Instructions ..........6 2.1 Parts Included ......................6 2.2 General Specifi cations ..................7 2.3 Codes and Regulations ..................8 2.4 Locations and Clearances ..................8 2.5 Outline Drawings ....................9 3.0 Installation Instructions ................

  • Page 6: Pre-Installation Information & Instructions

    19.68 Figure 1 23.62 1. Blank Cover Plate* 10. Thermo-well 2. Pressure-Temperature gauge 11. Fan 3. Unused space for Optional Manual Limit 12. Boiler Drain Reset Switch 13. Pilot light unit 4. Service light 14. Main Burner 5. Supply water thermostat 15.

  • Page 7: General Specifi Cations

    2.2 General Specifi cations - Table 1 Product Specifi cations Model *GRWF130 Ratings Input BTUH 130,000 DOE Output BTUH 110,000 Net (I=B=R®) Output BTUH 96,000 AFUE 84.3 Natural Gas Supply Pilot gas orifi ce Qty X ID 1 x 0.40mm Main gas orifi...

  • Page 8: Codes And Regulations

    ▲ 2.3 Codes & Regulations WARNING The manufacturer assumes no responsibility for equipment installed in violation of any code or regu- SAFETY HAZARD lation. THESE BOILERS ARE NOT APPROVED OR INTENDED FOR INSTALLATION IN MANUFAC- Codes and local utility requirements governing the TURED (MOBILE) HOUSING, TRAILERS, OR installation of gas fi...

  • Page 9: Outline Drawings

    b) Minimum Clearances Table 2 Minimum Clearances Recommended Clearances for Combustion for Service 6” 36” Right Side 6” 24” Left Side 6” 6” Front 18” 30” Back 6” 6” 2.5 Outline Drawings Dimensions and Connections - Figure 2 Front view Rear view Side view 4.72...

  • Page 10: Installation Instructions

    1. Move crated boiler as close as possible to the loca- 3.0 Installation Instructions tion to be installed. Uncrate the boiler using 3.1 Uncrating Boiler a saw to cut the four bottom corner posts even with the top of the pallet. The top of the crate ▲...

  • Page 11: Setting Boiler

    3.2 Setting Boiler 3.3 Leveling the Boiler 1. Locate the leveling feet (4) shipped in a bag with Verify the fl oor structure where the boiler will the boiler. be set can support the weight of the boiler. 2. Tilt the boiler toward the front and place a safety Locate the boiler so all components are pro- block under the rear of the boiler beyond the front tected from water damage during operation.

  • Page 12: Water Connections And Piping Systems

    The return water temperature to the boiler must 3.4 Water Connections and Piping Systems be above 110° F. The temperature drop between the ▲ ▲ delivery manifold should not exceed 68° F. WARNING CONTAMINATION HAZARD. Before installation, carefully fl ush the system with AIR IN BOILER PIPING SYSTEM LEADS TO water to remove residues or impurities that could OXYGEN CONTAMINATING THE SYSTEM.
  • Page 13 ▲ ▲ Characteristics of system water WARNING In the presence of water harder than 14 grains per gallon, SAFETY HAZARD. we recommend the use of suitably conditioned water PRESSURE RELIEF VALVE OUTLET MUST BE in order to avoid possible scaling in the boiler, caused ROUTED TO WITHIN 6”...
  • Page 14 I. Typical System Piping Diagrams 18-CG02D1-4...
  • Page 15 18-CG02D1-4...
  • Page 16 18-CG02D1-4...
  • Page 17 18-CG02D1-4...

  • Page 18: Combustion Air And Ventilation

    ume of all spaces meets the criteria for an unconfi ned 3.5 Combustion Air and Ventilation space. The total input of all gas utilization equipment installed in the combined space shall be considered Important: All aspects of the installation of this boiler, in making this determination.
  • Page 19 3. The following types of installations will require use of Figure 12 OUT DOOR AIR for combustion, due to chemical expo- sures: * Commercial buildings * Buildings with indoor pools * Boilers installed in commercial laundry rooms * Boilers installed in hobby or craft rooms * Boilers installed near chemical storage areas.

  • Page 20: General Venting Instructions

    3.6 GENERAL VENTING INSTRUCTIONS Table 6A Category III Boiler - Approved Venting Systems Vent VENT PIPING Material Equivalent Length System ▲ 3" 90° Elbow, Z-Vent Model SVE, WARNING 3 Equivalent Feet, Each Series III or Equal Flue FIRE AND CARBON MONOXIDE HAZARD 3"...
  • Page 21 i) A boiler shall not be con- TABLE 7 nected to a chimney or Gas Vent Termination fl ue serving a separate Roof Pitch Minimum Height appliance designed to Flat to 7/12 1.0 Feet* burn solid fuel. Flue gas vent pipe Over 7/12 to 8/12 1.5 Feet restrictor orifi...

  • Page 22: Gas Supply Connections

    ▲ ▲ WARNING Figure 15 HAZARDOUS GAS WARNING EXPOSURE TO FUEL SUBSTANCES OR BY-PRO- DUCTS OF INCOMPLETE FUEL COMBUSTION IS (FACTORY BELIEVED BY THE STATE OF CALIFORNIA TO SUPPLIED) CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. ▲ WARNING FIRE OR EXPLOSION HAZARD FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY, DEATH, OR PRO- PERTY DAMAGE.

  • Page 23: Lp Gas Conversion

    Figure 18 Boiler Model # LP Conversion kit Part Number Open the control panel and remove two screws *GRWF130A94A0A BAYLPK01AWBLRA that are through attachment clips. See Figure *May be “A” or “T” The boiler ships confi gured to burn Natural Gas Remove the burner box cover by removing four (NG).
  • Page 24 IMPORTANT: If either the main inlet or outlet of the gas valve is disconnected for any reason, the fl at sealing ring gasket located between the gas valve and the pipe must be replaced with a new fl at sealing ring gasket to ensure a leak-proof seal.
  • Page 25 electronic control unit Honeywell gas valve Honeywell Diminue Alert RESET Augmente Key for Figure 22 Upstream pressure port Downstream pressure port Natural Gas / LP Regulator Cover Ignition “STEP” regulator Manifold Gas Pressure Adjustment Cover Gas pressure adjustment screw Natural gas g20-G25 Remove the hood and position the arrow pointer as shown in...
  • Page 26 Disconnect pilot gas supply tube, fl ame sensor Reattach the pilot gas supply tube, fl ame sensor wire, and ground wire from the pilot and ignitor wire, ignitor wire, and ground wire to the pilot assembly. See Figures 23, 24 and 25. and ignitor assembly.

  • Page 27: High Altitude Derate

    154,000 126,000 10.6 *GBWF215A96AVA 215,000 176,100 191,400 156,800 10.6 *GRWF130A94A0A 130,000 107,400 115,700 95,600 10.6 NOTES: 1. * May be “A” or “T” 2. No orifi ce change is required up to 4500 Feet. 3.10 Lighting Instructions TO SHUT OFF BOILER For complete shutdown: Close the manual valve loca- ▲...

  • Page 28: Electrical Connections

    3.11 Electrical Connections The layout of the terminals for various ▲ connections is provided in the wiring diagrams WARNING and schematic on pages 38 and 39. NOTE: Do NOT use the gas pipes to ground electrical ELECTRICAL HAZARD appliances. TO PREVENT INJURY OR DEATH DUE TO Opening the front panel ELECTRICAL SHOCK OR CONTACE WITH MOVING PARTS, LOCK UNIT DISCONNECT...

  • Page 29: Optional Manual Reset Water Temperature Limit Installation

    Steps to remove the existing auto-reset water tempe- 3.12 Installation Instructions for repla- rature limit switch. cing the Factory Installed Automatic- 1. Open the control panel and locate the existing reset Water Temperature Limit with the auto-reset water temperature limit. See Figures 31 Optional Manual Reset Water Tempera- and 32.
  • Page 30 6. Locate the capillary tube of the existing auto- 3. Remove the wires from the existing auto-reset reset water temperature limit and remove it from the water temperature limit. See Figure 34. strain relief clamp. See Figure 37. Figure 34 Figure 37 4.
  • Page 31 8. Remove the cable ties to isolate and remove the 2. In a similar manner, remove the locking nut from capillary tube of the existing auto-reset water tempe- the new manual reset water temperature limit. See rature limit switch. See Figure 39. Figure 41.
  • Page 32 4. Center the reset button in the hole and secure 6. Attach the wires removed earlier from the auto- with a locking nut. Use needle nose pliers. See reset water temperature limit to the new manual Figure 43. water temperature limit. See Figure 45. Figure 43 5.
  • Page 33 8. Place the bulb of the new manual reset water 10. Tighten the strain relief cable clamp with a temperature limit along with the existing adjustable screwdriver. See Figure 49. supply water thermostat and thermometer gauge bulbs in the boiler temperature well and secure with a spring clip.

  • Page 34: Supply Water Thermostat (Swt) Settings Above 180°F

    3.13 Supply Water Thermostat (SWT) Follow the steps below to reset the SWT rotation stop to allow water temperature settings up 194°F: Settings Above 180°F The adjustable SWT knob includes a factory installed rotation 1. Remove the knob from the adjustable SWT by pulling the stop that prevents supply water temperature settings below knob directly outward away from the boiler.

  • Page 35: Startup And Adjustments

    Open the manual On/Off valve located in the 4.0 Start-Up and Adjustment supply gas line. ▲ ▲ Reconnect power to boiler and cycle on. Set WARNING the room thermostat for continuous heating CARBON MONOXIDE POISONING HAZARD operation as required. The boiler must be ope- FAILURE TO FOLLOW THE INSTALLATION rating to check the supply gas pressure.
  • Page 36 Verify the boiler On/Off switch is On. Turn Table 11 the boiler supply water thermostat knob to the desired setting. See Figure 1. The boiler will Manifold Pressure Settings begin to function automatically. Fuel Pressure If the boiler does not light, refer to the Troublshooting section of the Service Facts, shipped with the boiler.

  • Page 37: Operating Information

    Energize gas valve by setting thermostat ▲ CAUTION above room temperature. If, after correctly carrying out the lighting procedure, f) Adjust manifold gas pressure, as the burners do not light and the red pushbutton light on needed, to achieve desired input capacity. the control panel comes on, wait about 15 seconds and To accomplish this, turn the adjustment then press the pushbutton to reset.
  • Page 38 IMPORTANT: To check for proper operation of the Control and Safety Switch Adjustment Water Temperature Limit switch (WTL), shut off the power to the boiler and TEMPORARILY bypass the Limit Switch Check Out supply water thermostat (SWT) with a TEMPORARY The limit switch is a safety device designed to shut JUMPER.

  • Page 39: Technical Data

    5.0 Technical Data 5.1 Electrical Diagrams 18-CG02D1-4...

  • Page 40: Schematic Diagram

    5.2 Schematic Diagram 18-CG02D1-4...

  • Page 41: Field Wiring Diagrams

    5.3 Field Wiring Diagrams Option 1 - Factory Jumpers in Place System Configuration 1. Continuous Pump Operation 2. Burner Cycles With Supply Water Thermostat Circ Pump 120 VAC Power Setup (Field Supplied) (Field Wiring) 1. No changes needed L1 N (LV) (HV) 13 14 15 16 17 18...
  • Page 42 Option 3 - Field Installed Room System Configuration Thermostat, Orange J2 jumper 1. Pump Runs on Call from Room Thermostat OR if Water Temperature is Above Supply Water removed Thermostat setting 2. Burner Cycles with Supply Water Thermostat External Setup Limits (e.g., LWCO) 120 VAC Power...
  • Page 43 Option 5 - Field Installed Room System Configuration Thermostat, Orange J2 jumper removed, 1. Pump Runs on Call from Room Thermostat OR Yellow J5 jumper removed if Water Temperature is Above Supply Water Thermostat setting External 2. Burner Cycles with Supply Water Thermostat during Call from Room Thermostat.
  • Page 44 Boiler Reset Option - Field Wiring Boiler Reset Configuration for Field Supplied Boiler Temperature NOTE: This Boiler Reset option may be Reset Controls (to Decrease Boiler Water used in combination with any of the other Temperature with Increasing Outdoor system configuration options and jumper arrangements shown in this document.

  • Page 45: Appendices

    6.0 Appendices 6.1 Appendix A - Venting Supplement (For Illustration and Reference) See page 20, section 3.6 for General Venting Instructions Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 46 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 47 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 48 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 49 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 50 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 51 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...
  • Page 52 Printed with permission from Z-Flex, US, Inc. 18-CG02D1-4...

  • Page 53: Appendix B - Vent Terminations

    6.2 Appendix B - Vent Terminations The vent terminal of a direct-vent appliance with an input THROUGH THE WALL VENT TERMINATIONS (excerp- of 10,000 Btu/hr (3 kW) or less shall be located at least 6 ted from NFPA - National Fuel Gas Code - See illustration in.
  • Page 54 ® Literature Order Number 18-CG02D1-3 P.I. File Number 18-CG02D1-3 American Standard Inc. Supersedes 6200 Troup Highway Stocking Location P.I. 08/02 Tyler, TX 75707 For more information contact Since the manufacturer has a policy of continuous product and product data improvement, it reserves the your local dealer (distributor) right to change design and specifi...

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