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Williamson-Thermoflo GWC-070 Manual

Gas-fired water boilers
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GWC
Model
Gas-Fired Water Boilers
Boiler Manual
• Installation
• Startup
This manual must only be used by a qualified
heating installer/service technician. BEFORE
installing, read all instructions in this manual
and all other information shipped with the boiler.
Perform steps in the order given. Failure to
comply could result in severe personal injury,
death or substantial property damage.
• Maintenance
• Parts
Part number 550-142-056/0411

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Summary of Contents for Williamson-Thermoflo GWC-070

  • Page 1 Model Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all instructions in this manual and all other information shipped with the boiler. Perform steps in the order given.

  • Page 2: How It Works

    — Boiler Manual fired water boiler How it works . . . 1 Integrated boiler control The integrated boiler control (IBC) responds to signals from the room thermostat, air LEGEND pressure switch, inlet water sensor and boiler limit circuit to operate the circulators, gas valve, igniter and blower. When a room thermostat calls for heat, the IBC starts the system circulator and blower. a Supply to system, 1” NPT The IBC runs the blower to purge the boiler flue passages, then turns on the igniter and lets it warm up. b Return from system, 1” NPT After igniter warm-up, the IBC opens the gas valve, turns the igniter off, and checks for flame. The flame must come on within 4 seconds or the IBC will shut down and try the full cycle again. c Combustion air inlet fitting — When the room thermostat is satisfied, the IBC turns off the boiler components and 3” PVC connection waits for the next heat call. The IBC indicator lights show normal sequence when the lights are on steady. When a d Flue outlet — 3” PVC connec- problem occurs, the IBC flashes combinations of lights which indicate the most likely tion...

  • Page 3: Gwc Water Boiler

    — Boiler Manual fired water boiler GWC Water Boiler Part number 550-142-056/0411...

  • Page 4: Table Of Contents

    — Boiler Manual fired water boiler Contents Gas valve adjustment — altitude How it works ....2 DIRECT VENT — Boiler room air over 5,500 feet ONLY . . . . . . . . . . . 60 openings .

  • Page 5: Please Read Before Proceeding

    — Boiler Manual fired water boiler Please read before proceeding Failure to adhere to the guidelines on this Hazard definitions page can result in severe personal injury, death or substantial property damage. The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or When servicing boiler — to important information concerning the life of the product. • To avoid electric shock, disconnect electrical supply Indicates presence of hazards that will cause severe before performing maintenance. personal injury, death or substantial property dam- • To avoid severe burns, allow boiler to cool before age.

  • Page 6: Prepare Boiler Location

    — Boiler Manual fired water boiler Prepare boiler location Installations must follow these codes: Estimated GWC input at altitude Figure 1 • Local, state, provincial, national codes, laws, regulations and ordinances. Altitude • National Fuel Gas Code, ANSI Z223.1- latest edition. % Sea level input (feet) • Standard for Controls and Safety Devices for Automatically Fired Boil- ers, ANSI/ASME CSD-1, when required. 1,000 • National Electrical Code. 2,000 • For Canada only: B149.1 or B149.2 Installation Code and CSA C22.1 3,000 Canadian Electrical Code Part 1 and any local codes.

  • Page 7: Residential Garage Installation

    Fig- is possible: ure 2, page 6, install as shown below: • When the floor can become flooded. • When the boiler mounting area is not level. • When a high-profile condensate pump is used, provide a foundation high enough that the GWC condensate connection is at least as high as the condensate pump inlet connection. Minimum foundation dimensions (inches) Figure 3 Boiler model GWC-070 30¾ GWC-105 GWC-140 37¾ GWC-175 A Area adjacent to access door must be accessible and must allow for removal of the GWC boiler * Increase height if needed to ensure for service. condensate trap outlet tee is above inlet No other appliance or air mover (exhaust fan, of condensate pump, when used.

  • Page 8: Check Orifice Plate - Replace If Necessary

    Orifice plate installation, when required Access the bottom of the blower housing as shown in Figure 5. To inspect the plate only, . It read the marking on the plate edge must read the same as the boiler size and fuel, as follows: Boiler model Natural gas marking Propane marking GWC-070 NG 3 SEC LP 3 SEC GWC-105 NG 4 SEC LP 4 SEC GWC-140 NG 5 SEC LP 5 SEC...

  • Page 9: Install Condensate Trap

    — Boiler Manual fired water boiler Prepare the boiler (continued) Install condensate trap Install condensate trap Figure 7 1. Before placing the boiler in position, install the condensate trap line, shown in Figure 7. Items shown are provided with the boiler. Attach the flue drain hose (C) to the in-line flue drain Step 1 nipple (B). Slide a screw driver or pencil through the condensate Step 2 drain nipple (G). Slide the end of the screwdriver or pencil into the open end of the flue drain hose (C). Feed the in-line flue drain (A) assembly into the flue con- nection (D), guiding the flue drain hose through the con- densate drain nipple (G) with the screwdriver or pencil. Press the in-line flue drain (A) into the flue connection Step 3 (D) and through the seal ring until it reaches the stop. Then tighten the flue connection hose clamp to secure. The flue drain hose (C) should now extend down past the end of the condensate drain nipple (G).

  • Page 10: Install High Altitude Air Pressure Switch When Required (Only Above 5,500 Feet)

    — Boiler Manual fired water boiler Prepare the boiler (continued) Install high altitude air pressure switch Air pressure switch mounting Figure 8 when required (only above 5,500 feet) 1. For installations at altitude more than 5,500 feet above sea level: a. A special high altitude air pressure switch is required. b. The gas valve outlet pressure setting must be checked, and adjusted if necessary, per the instructions on page 60.

  • Page 11: Perform Hydrostatic Pressure Test

    — Boiler Manual fired water boiler Prepare the boiler (continued) Perform hydrostatic pressure test Piping connections for hydrostatic test Figure 10 Pressure test boiler attaching water or gas piping (except as before noted below) or electrical supply. Remove jacket top panel before proceeding. Use two wrenches when tightening water piping at , using one of the wrenches to prevent the boiler boiler interior piping from turning. Failure to support the boiler...

  • Page 12: Install Water Piping

    Minimum pipe size for boiler loop piping Provide boiler loop piping no smaller than listed Figure 11 below (based on 20°F temperature rise) Boiler loop pipe size, Minimum GWC-070 or 105 1” GWC-140 or 175 1¼” Additional limit controls Following standard industry practices, if installation is to comply with...

  • Page 13: Expansion Tank

    — Boiler Manual fired water boiler Install water piping (continued) Expansion tank Relief valve installation guidelines Figure 13 Figure 14, page 14 and Figure 15, page 14 show typical installation of the expansion tank. Always locate the air separator and expansion tank as To avoid water damage or scalding shown in the suggested piping drawings, beginning with Figure 17, page 16. due to relief valve operation, as per local or state codes Ensure that the expansion tank size will handle boiler and system water volume and temperature. See tank manufacturer’s instructions and rat-...
  • Page 14 — Boiler Manual fired water boiler Install water piping (continued) Piping to single-zone system using diaphragm- or Piping closed-type expansion tank Figure 14 Figure 15 bladder-type expansion tank. Boiler connections are 1” NPT (supply from 1” tee, return to 1” recuperator flange).

  • Page 15: System Water Piping Methods

    — Boiler Manual fired water boiler Install water piping (continued) System water piping methods Simplified pipe/circulator selection 1. Install the boiler and piping using the recommended piping Most piping methods shown in this manual use layouts in this manual. primary/secondary connection to the boiler loop. 2. Size the piping and components for each circuit in the space These designs ensure proper flow through the GWC heating system using Figure 16. At the flow rates listed, the boiler, for the most efficient and reliable operation head loss in all piping will be 0.04 feet per foot of pipe.

  • Page 16: Baseboard System Piping - Circulator Zoning (Primary/Secondary)

    DO NOT exceed the limits MINIMUM Boiler loop pipe size shown in Figure 19, page 17 • GWC-070/105 1” For systems requiring higher flow or head loss, apply the GWC-140/175 1¼” suggested piping of Figure 20, page 18, NOT that of Fig- ure 18, page 17.
  • Page 17 — Boiler Manual fired water boiler Install water piping (continued) Zone valve zoning — GWC-070, GWC-105 or Figure 18 GWC-140 (DO NOT apply to GWC-175) Legend 1 Isolation valves 4 Zone valve 2 Automatic air vent (with 7 Hose bibb purge valve diaphragm-type expan- 8 Boiler pressure/tempera- sion tank), or connect to ture gauge tank fitting (closed-type expansion tank).
  • Page 18 MINIMUM Boiler loop pipe size — Provide a separate 24-volt Zoning with zone valves GWC-070/105 1” GWC-140/175 1¼” transformer to power the zone valves. Size the trans- former to handle the total rated load of all connected zone valves. Alternatively, use a zone valve zone controller. — The GWC internal system Zoning with circulators circulator cannot be removed from the boiler for use as one of the zone circulators. It must remain as shipped...
  • Page 19 See Figure 23, page 20 or Figure 24, page 20 for multi-zone systems. You may also apply the suggested piping of either Figure 23, page 20 or Figure 24, page 20 if you want automatic supply temperature regulation MINIMUM or outdoor reset temperature control. Boiler loop pipe size GWC-070/105 1” For additional information and alternatives in piping for radiant heat- GWC-140/175 1¼” ing systems, contact Williamson-Thermoflo. The system circulator must be supplied by the in- staller.
  • Page 20 — Provide a separate 24-volt Zoning with zone valves transformer to power the zone valves. Size the trans- MINIMUM former to handle the total rated load of all connected zone Boiler loop pipe size valves. Alternatively, use a zone valve zone controller. GWC-070/105 1” GWC-140/175 1¼” — The GWC internal system Zoning with circulators circulator cannot be removed from the boiler for use as one of the zone circulators. It must remain as shipped from the factory to allow proper flow control inside the boiler. You will need a circulator for each zone. Provide circulator relays or circulator zone controller.
  • Page 21 The return water temperature to the boiler must be at least 60°F. Provide and apply means to regulate the return temperature. Failure to do so can result in boiler control operation problems, causing possible significant property damage. — Each zone in the piping Zoning with zone valves MINIMUM diagrams in this section is shown with an isolation valve Boiler loop pipe size on each side. Substitute a memory-stop valve for one of GWC-070/105 1” these in each zone in order to use the memory-stop valve GWC-140/175 1¼” for balancing flow as well as isolation. Provide a separate 24-volt transformer to power the zone valves. Size the transformer to handle the total rated load of all connected zone valves. Auto return temp regulation — zone valve Figure 26 — The GWC internal system...

  • Page 22: Water Chiller Systems

    Install boiler, as shown, so chilled medium is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 27 for typical installation of balancing valve and check valve. Install the flow/check valve in the boiler supply piping, as shown in Figure 27, to prevent gravity circulation during the cooling cycle. If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other MINIMUM automatic means to prevent gravity circulation during cooling cycle. Boiler loop pipe size — GWC-070/105 1” Substitute a memory-stop Balancing, when required GWC-140/175 1¼” valve for one of the isolation valves in each zone to use the memory-stop valve for balancing flow as well as isolation. Provide a separate 24-volt — Zoning with zone valves transformer to power the zone valves. Size the trans-...

  • Page 23: Multiple Boiler Installations

    RECOMMENDED clearances instructions in this manual. 6. Provide clearance for installation of venting, air piping, gas piping, expansion tank, primary circula- tor and other accessories. Controlling multiple GWC boilers 1. Multiple GWC boilers can be controlled using any boiler control/sequencing system that provides an isolated contact for call for heat (connected to the boiler's T-T terminals). Piping multiple GWC boilers 1. See suggested piping diagrams in this manual. Contact Williamson-Thermoflo for assistance for systems not covered. 2. Always pipe the boilers on a secondary loop in a primary/secondary circuit as shown in the examples in this manual. Part number 550-142-056/0411...

  • Page 24: Multiple Boiler Water Piping

    — Boiler Manual fired water boiler Multiple boiler water piping Secondary header piping installation Maximum connected load per header: 1. Main header and secondary header pipe sizing. 2-inch header — 450 MBH a. New system — See page 15. 3-inch header — 1400 MBH b. Replacing boilers in an existing system — Without reducing 4-inch header — 2900 MBH size, connect system supply and return lines. Install tees or crosses for secondary headers as shown in Figure 30 or Fig- ure 31. Size headers to handle total connected boiler output...
  • Page 25 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Piping schematic — typical for multiple GWC boilers, using secondary headers Figure 32 Legend — Figure 32 1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable codes 2 Isolation valves (when used) 12 Isolation valve 3 Cap 13 Water flow switch (when used) 4 Secondary header (supply) — layout and size per 14 Supply water temperature control (when used) page 24...
  • Page 26 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Piping layout — typical for multiple GWC boilers, using secondary headers (2-boiler system) Figure 33 Legend — Figure 33 1 Flow/check valve (each boiler) 17 3-way diverting valve (operated by DHW aquastat — valve end 2 Isolation valves (when used) switch connects across boiler thermostat terminals) 3 Caps 18 System supply 4 Secondary header (supply) — layout and size per page 24 19 System return 5 Secondary header (return) — layout and size per page 24...
  • Page 27 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Piping layout — typical for multiple GWC boilers, with DHW storage heaters (4-boiler system) Figure 34 Flow rate Size Flow rate Size Suggested DHW 1 – 4 gpm ¾” 22 – 45 gpm 2” boiler-side pipe sizing 4 – 8 gpm 1”...
  • Page 28 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Piping layout — typical for multiple GWC boilers, using isolation exchanger Figure 35 Use isolation heat exchanger for: 1. Large volume systems with high mineral content in water. 2. Systems exposed to untreated quantities of makeup water.

  • Page 29: Venting & Air - General

    — Boiler Manual fired water boiler Venting & air — general When removing a boiler from an existing GWC boilers must be vented and common vent system supplied with combustion and ven- tilation air using piping and methods described in this manual The GWC boiler cannot be common vented with any other ap- pliance.

  • Page 30: Provide Combustion Air

    — Boiler Manual fired water boiler Venting & air — general (continued) Provide combustion air: Combustion air contamination: DIRECT VENT — The installation must provide com- Ensure that the combustion air will not contain any of the contaminants bustion air piping. In addition, ventilation openings in Figure 36 may be required.

  • Page 31: Manifolded Combustion Air Option For Direct Vent Multiple Boiler Installations

    — Boiler Manual fired water boiler Venting & air — general (continued) Manifolded combustion air Combustion air manifold option (combined air inlet, but Figure 37 option for DIRECT VENT individual vents) — must comply with Figure 41, page 35 multiple boiler installations 1. Multiple GWC boilers can use a common combus- tion air manifold.
  • Page 32 S636 compliance is required. For ULC S636 compliance, all pipe, fittings and cement must be IPEX System 636. When using IPEX kits, use only IPEX product code 196006 for 3” venting. Contact Williamson-Thermoflo for ordering information and availability of Williamson-Thermoflo venting kits. Part number 550-142-056/0411...
  • Page 33 Certified for Category IV and direct vent AL29-4C — appliance venting stainless Dura-Vent — FasNSeal™ steel Metal-Fab, Inc. — CORR/GUARD Williamson-Thermoflo bird screens (included with boiler) 3” bird screen: Williamson- W-T part number 383-500-105WT Thermoflo (two supplied with the boiler) bird screens Note 1: DO NOT use DWV, CPVC or ABS when using concentric vent termination. Use ONLY PVC schedule 40.

  • Page 34: Commonwealth Of Massachusetts Installations

    — Boiler Manual fired water boiler Commonwealth of Massachusetts installations Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below. (a) For all sidewall horizontally-vented gas-fueled equipment . The state or local gas inspector of the INSPECTION...

  • Page 35: Vent Termination Requirements

    — Boiler Manual fired water boiler Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). Figure 41 For Canadian installations, defer to the requirements of CSA B149.1 or B149.2 Installation Code. Part number 550-142-056/0411...

  • Page 36: Direct Vent - Boiler Room Air Openings

    — Boiler Manual fired water boiler DIRECT VENT — Boiler room air openings Combustion and ventilation air openings for GWC Direct Vent installations Figure 42 The GWC boiler CANNOT be in the same space with other appliances if clearances around the GWC are less than the recommended service clearances shown in Figure 2, page 6. Air openings GWC boiler GWC boiler WITH other WITHOUT other The required air opening sizes below are FREE AREA, after reduction for louver obstruction. Note the ex- appliances in room appliances in room ception below for large spaces.

  • Page 37: Direct Vent - Sidewall With Sepa- Rate Pipes

    — Boiler Manual fired water boiler DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & — Separate pipes sidewall Figure 43 INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if specified. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 39, page 32. Determine termination location 1. The air and vent terminations must be in- stalled as shown in Figure 43, page 37 and...
  • Page 38 — Boiler Manual fired water boiler DIRECT VENT — Sidewall with separate pipes (continued) Multiple separate pipes sidewall terminations For multiple boiler applications using the manifolded Figure 44 combustion air option, the vent can be terminated in an elbow as in Figure 43, page 37, or in a coupling or sidewall termination plate. The vents must be located following the restrictions in Figure 41, page 35 and Figure 38, page 31. In addition to the vent materials, this installation requires two (2) W-T sidewall termination plates and a bird screen for each air and vent termination fitting, unless using an AL29-4C vent termination fitting with integral screen. Two plates and two bird screens are supplied with the boiler. Prepare wall penetrations 1. Two W-T sidewall termination plates are included with each boiler.

  • Page 39: Concentric

    — Boiler Manual fired water boiler DIRECT VENT — Sidewall with 3” concentric Allowable vent/air pipe materials & — Concentric horizontal Figure 46 INSTALLATION SEQUENCE lengths 1. The 3” concentric termination kit must be pur- chased separately. Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified. 2. Locate the termination such that the total air piping and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 39, page 32.
  • Page 40 — Boiler Manual fired water boiler DIRECT VENT — Sidewall with 3” concentric (continued) Install termination — concentric pipes Termination location — concentric Figure 47 termination — multiple boilers — 1. Assemble the vent termination as described for concentric termi- clearance from vent of one to air intake of nations, on page 45.

  • Page 41: Direct Vent - Vertical With Sepa- Rate Pipes

    — Boiler Manual fired water boiler DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & Separate pipes vertical termination Figure 49 lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified. 1. Locate the terminations such that the total air pip- ing and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 39, page 32. Determine termination location 1. The air and vent terminations must be installed as shown in Figure 49, page 41. 2. The terminations must comply with clearances and limitations shown in Figure 41, page 35.
  • Page 42 — Boiler Manual fired water boiler DIRECT VENT — Vertical with separate pipes (continued) 3. Space the air and vent holes to provide the minimum spacings Terminations for multiple boilers Figure 50 shown in Figure 49, page 41. 4. Follow all local codes for isolation of vent pipe when passing through floors, ceilings and roofs.

  • Page 43: Direct Vent - Vertical With 3" Concentric

    — Boiler Manual fired water boiler DIRECT VENT — Vertical with 3” concentric Allowable vent/air pipe materials & — Concentric vertical Figure 51 INSTALLATION SEQUENCE lengths 1. The 3” concentric termination kit must be pur- chased separately. Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified. 2. Locate the termination such that the total air piping and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 39, page 32.
  • Page 44 — Boiler Manual fired water boiler DIRECT VENT — Vertical with 3” concentric (continued) Mount concentric termination Vertical termination — 3” PVC concentric Figure 52 — single or multiple boilers 1. Mount the termination as shown in Figure 53, page 44. 2. Support the concentric vent/air termination at the roof penetration as shown in Figure 53. • The supports/bracing used must support the termination as- sembly to prevent vertical slippage or sideways movement. • The clamps used on the outside of the termination pipe must not cut into the pipe or contain sharp edges that could cause a crack to form.

  • Page 45: Concentric Termination Assembly (Sidewall Or Vertical)

    — Boiler Manual fired water boiler Concentric termination assembly (sidewall or vertical) Assembling concentric termination 3” PVC concentric termination assembly — DO NOT Figure 54 attach the rain cap until the termination has been 1. See Figure 54, page 45 for the details of the termi- inserted through the roof or wall and all supports have nation assembly.

  • Page 46: Vent And Air Piping And Boiler Connections

    — Boiler Manual fired water boiler Vent and air piping and boiler connections DIRECT EXHAUST & DIRECT VENT Boiler vent and air connections Figure 55 Follow termination instructions 1. Read and follow all instructions for the termination type used before proceeding with this page. Installing vent and air piping 1. Work from the boiler to vent or air termination. Do not exceed the lengths given in the previous pages for either the air or vent piping. a. Provide stainless pipe to PVC adapters obtained from the stainless pipe manufacturer for con- nections at the boiler and at terminations, when...

  • Page 47: Direct Exhaust - Boiler Room Air Openings

    — Boiler Manual fired water boiler DIRECT EXHAUST — Boiler room air openings Combustion air provision Special considerations The GWC boiler can use inside air if no contaminants are present in the Tight construction boiler space. (If contaminants are likely to be present, install the boiler ANSI Z223.1 defines unusually tight construction as a direct vent appliance, using the appropriate vent instructions in this where: manual.) 1. Walls and ceilings exposed to the outside atmo- sphere have a continuous water vapor retarder with The boiler room must be fitted with combustion air openings large enough a rating of 1 perm or less with openings gasketed,...

  • Page 48: Gwc Boiler With Other Appliances In Room

    — Boiler Manual fired water boiler DIRECT EXHAUST — Boiler room air openings (cont.) MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA Figure 56 The GWC boiler CANNOT be in the same space with other appliances if If the space is smaller than clearances around the GWC are less than the recommended service clearances Figure 2, page 6, provide...

  • Page 49: Direct Exhaust - Sidewall

    — Boiler Manual fired water boiler DIRECT EXHAUST — Sidewall DO NOT sidewall vent DIRECT EX- — Direct exhaust sidewall Figure 57 INSTALLATION SEQUENCE at altitudes HAUST APPLICATIONS above 5,500 feet. Sidewall venting is only allowed for ap- DIRECT VENT plications (ducted combustion air) at altitudes above 5,500 feet. Allowable vent/air pipe materials & lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if specified.
  • Page 50 Insert a galvanized metal thimble (by installer) in the vent pipe hole as shown in Figure 58. 2. Follow all local codes for isolation of vent pipe when passing through floors or walls. Termination and fittings 1. If using a coupling or elbow for the termination, prepare the vent termination fitting (Figure 58, page 50) by inserting a bird screen, unless using an AL29-4C termination fitting with integral screen. Bird screens are not supplied with the GWC boiler. Purchase separately from Williamson-Thermoflo. See Figure 92, page 87 for part numbers. 2. You can install the vent termination using either of the con- figurations shown in Figure 57, page 49. 3. Maintain the required dimensions of the finished termination piping as shown in Figure 57, page 49. 4. Do not extend exposed vent pipe outside of the building more than shown in this document. Condensate could freeze and block vent pipe. LEGEND for Figure 58 1 Vent piping 2 Sidewall termination plates —...

  • Page 51: Direct Exhaust - Vertical

    — Boiler Manual fired water boiler DIRECT EXHAUST — Vertical Allowable vent/air pipe materials & — Direct exhaust vertical Figure 59 INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 39, page 32. Determine termination location 1. The vent terminations must be installed as shown in Figure 59, page 51.

  • Page 52: Gas Piping

    — Boiler Manual fired water boiler Gas piping Connecting gas supply piping Gas supply connection to GWC boiler gas manifold Figure 60 Do not connect gas supply to boiler or at- tempt to operate boiler unless the correct orifice plate has been verified or installed in accordance with page 8. Except where otherwise instructed in this manual, do not attempt to measure or adjust the outlet pressure setting of The gas valve is factory the gas valve.

  • Page 53: Natural Gas

    Natural gas only, with specific gravity of 0.60 following gas flow (cfh = cubic feet per hour): Based on pressure drop of 0.3” w.c. Gas pipe length Boiler model CFH natural gas (feet) Gas pipe diameter — GWC-070 ½” ¾” 1” 1¼” 1½” GWC-105 GWC-140 1050 1600...

  • Page 54: Wiring

    Installation must comply with: National Electrical Code and any other national, state, provincial or local codes or regulations. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70-latest edition. Wiring must be N.E.C. Class 1. B oiler m ust b e e lectrically grounded as required by National Electrical Code ANSI/ NFPA 70-latest edition. To replace wiring, order complete harness assemblies from Williamson-Thermoflo. If any original wiring as supplied with boiler must be replaced, and a harness is not immediately available, use only type 105°C wire or equivalent. Use this wiring only as a temporary repair. Obtain a complete harness from Williamson-Thermoflo. When using three-wire zone valves, take care to avoid mis-wiring. This can impose an ad- ditional 24 volts across the boiler control circuitry. The IBC Wiring connections will sense this problem and lockout. It will flash the POW- ER and TSTAT CIRC lights to indicate the problem. See Power wiring label on IBC for explanation of lockout conditions. To...
  • Page 55 — Boiler Manual fired water boiler Wiring (continued) Ladder wiring diagram Figure 64 Part number 550-142-056/0411...
  • Page 56 — Boiler Manual fired water boiler Wiring (continued) Schematic wiring diagram Figure 65 Part number 550-142-056/0411...

  • Page 57: Start-Up

    3. Do not fill boiler or operate with water containing chlorine in . Always Clean the system before filling excess of 200 ppm. drain and flush the system thoroughly before filling with antifreeze. Sludge, iron oxide Antifreeze deposits and other sediment in the system inhibit flow and can cause rapid breakdown 1. Use only antifreeze listed by Williamson-Thermoflo as suitable for use with GWC boilers. A list of approved antifreeze products of inhibitors. is available at www.Williamson-Thermoflo.com. Part number 550-142-056/0411...

  • Page 58: Check For Gas Leaks

    — Boiler Manual fired water boiler Start-up (continued) 2. Close the boiler or system isolation valve between the purge valve and fill connection to the system. Check for gas leaks 3. Close zone isolation valves. 4. Open quick-fill valve on cold water make-up line. Before starting the boiler, and during initial opera- tion, use a leak detector or smell near the floor and 5. Open purge valve. around the boiler for gas odorant or any unusual 6. One zone at a time, open the isolation valves. Allow odor. Remove boiler front door and smell interior water to run through the zone, pushing out the air. Run of boiler enclosure. Do not proceed with startup until no noticeable air flow is present. Close the zone if there is any indication of a gas leak. Repair any isolation valves and proceed with the next zone. Follow leak at once.

  • Page 59: Verify Gas/Air Orifice Plate

    — Boiler Manual fired water boiler Start-up (continued) 3. Inject all of the inhibitor supplied with the boiler. Allow time for 5. Once the external thermostat circuit wiring is checked the water to circulate and mix. Then check the inhibitor level. Add and corrected if necessary, reconnect the external ther- additional inhibitor if necessary. mostat circuit wires. Allow the boiler to cycle. Check/verify water chemistry Inspect/fill condensate system 1. The system may have residual substances that could affect water Inspect/check condensate lines and fittings chemistry. 1. Inspect the condensate drain line, condensate PVC fit- 2. After the system has been filled and leak tested, verify water pH tings and condensate trap. and chlorine concentrations are acceptable. 3. Verify antifreeze concentration, when used. Fill condensate trap with water 4. Follow the instructions on the Sentinel test kit to sample the system 1. Loosen the hose clamp (Figure 66, item 2) that secures water and verify inhibitor concentration.

  • Page 60: Final Checks Before Starting Boiler

    — Boiler Manual fired water boiler Start-up (continued) Final checks before starting boiler Check for igniter glow by looking into Figure 68 observation port on front of blower Review the boiler sequence of operation in Figure 71, page 63. ❏ ❏ housing Verify that the boiler and system are full of water and all system ❏ ❏ components are correctly set for operation. ❏ ❏ High altitude locations (over 5,500 feet) — verify that the high altitude pressure switch is installed per page 10. ❏...
  • Page 61 — Boiler Manual fired water boiler Start-up (continued) 5. Position and zero manometer per manufacturer’s instructions. The Tools required for gas valve outlet Figure 69 manometer must have at least 6” of tubing above the fluid level or pressure measurement fluid may be drawn into the gas valve. If manometer fluid is drawn into gas valve body, gas valve must be replaced. Fluid in valve will cause it to malfunc- tion, possibly resulting in severe personal injury, death or substantial property damage. 6. Disconnect tube from hose barb on gas valve vent tap. Connect tube end to tee hose fitting as shown in Figure 70. Then add length of hose from tee hose fitting to gas valve vent tap. 7. Connect positive side manometer hose to top of the tee hose fit- ting (Figure 70). 1 U-tube manometer with tubing - " flat head screw- 8. Connect negative side manometer hose to the barrel of the gas Manometer provides a fine scale by driver.

  • Page 62: Final Checklist

    — Boiler Manual fired water boiler Start-up (continued) Final checklist Test additional field-installed controls — If boiler has a ❏ ❏ low water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls Use the checklist following to ensure boiler is are tested. When controls are restored, boiler should operating correctly. restart. ❏ ❏ Test ignition system (integrated boiler control): Have the following been completed? f. Connect voltmeter to gas valve terminals.
  • Page 63 — Boiler Manual fired water boiler Start-up (continued) Integrated boiler control (IBC) sequence of operation — status light indications Figure 71 STEPS POWER TSTAT LIMIT PRESS FLAME Call for Timing CIRC SWITCH Heat? (After Step 8, the cycle goes back to Step 1) 1.
  • Page 64 — Boiler Manual fired water boiler Start-up (continued) Operating instructions Figure 72 Part number 550-142-056/0411...

  • Page 65: Annual Start-Up And General Maintenance Schedule

    — Boiler Manual fired water boiler Annual start-up and general maintenance schedule Service and maintenance schedules Figure 73 Service technician Owner maintenance (see following pages for instructions) (see following pages for instructions) General: • Address reported problems, page 66. • Check boiler area • Inspect boiler area, page 66. Daily • Check air openings • Inspect boiler interior, page 66.

  • Page 66: Annual Start-Up

    — Boiler Manual fired water boiler Annual start-up Inspect all piping for leaks Annual start-up only by qualified service technician Eliminate all system or boiler leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and The boiler should be inspected and started annu- ally, at the beginning of the heating season, only causing heat exchanger failure. Leaking water by a qualified service technician. In addition, the may also cause severe property damage. maintenance and care of the boiler designated in 1. Inspect all water and gas piping and verify to be leak Figure 73, page 65 and explained on the follow- free. ing pages must be performed to assure maximum boiler efficiency and reliability. Failure to service 2. Look for signs of leaking lines and correct any problems...

  • Page 67: Inspect Expansion Tank

    — Boiler Manual fired water boiler Annual start-up (continued) Inspect expansion tank Igniter observation port in blower Figure 74 1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See page 13 of this manual for suggested location of expansion tanks and air eliminators. • O pen-type — located above highest radiator or baseboard unit, usually in the attic or closet. Has a gauge glass and overflow pipe to a drain. • C losed-type — welded gas tight and located above boiler. Tank is partially filled with water, leaving an air cushion for expansion. • Make sure this type of tank is fitted with a tank fitting, such as the B & G Tank-Trol or Taco Taco-Trol. This fitting reduces gravity circulation of air-saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system.

  • Page 68: Inspect Recuperator

    — Boiler Manual fired water boiler Annual start-up (continued) Inspect recuperator Blower motor Figure 75 1. Follow the procedure on page 71 to inspect the recuperator and clean if necessary. Inspect temperature mixing system 1. Carefully check the of the as temperature system return piping it passes through the boiler jacket and on the return pipe inside just before it enters the boiler sections. You may the boiler jacket do this with a surface pyrometer or by lightly touching the piping with your fingers. To avoid potential of severe burn —...

  • Page 69: Inspect Boiler Relief Valve

    — Boiler Manual fired water boiler Annual start-up (continued) Relief valve Figure 76 Inspect boiler relief valve 1. Inspect the relief valve (Figure 76) and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read page 12 before proceeding further. Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumb- ing contractor or authorized inspection agency, to ensure that the product has not been affected by cor- rosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspec- tion must only be conducted by a plumbing con- To complete Annual Start-up, tractor or authorized inspection agency — not by perform startup and checks: the owner. Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup,...

  • Page 70: Service & Maintenance

    — Boiler Manual fired water boiler Service & maintenance Cleaning boiler heating surfaces Blower housing removal procedure Figure 77 The service procedures in this manual must only be performed by a qualified boiler service technician. Failure to com- ply could result in severe personal injury, death or substantial property damage. The boiler contains ceramic fiber and fiberglass materials. Use care when han- dling these materials per instructions on page 103 of this manual. Failure to...

  • Page 71: Inspecting And Cleaning The Recuperator

    Gas tubing to gas valve outlet c. Pressure switch hoses d. Hose from gas valve to gas/air manifold Recuperator with access panel removed Figure 79 e. Air inlet hose (GWC-070/105 top, GWC-140/175 bottom) f. Blower motor wiring harness to IBC g. Igniter harness to igniter plug h. Blower support bracket (with screw) i. Ground wire. 6. Be sure all wiring and hose connections are correct per Fig- ure 77, page 70 and are secure on the hose barb fittings.
  • Page 72 — Boiler Manual fired water boiler Service & maintenance (continued) Removing/cleaning/re-installing the recuperator Recuperator flueway drain holes Figure 80 Disconnect the vent pipe from the recuperator 1. The vent pipe must be disconnected (at the in-line flue drain, item A in Figure 7, page 9). 2. If the vent piping can be moved enough, loosen the flue pipe clamp on the in-line flue drain. Then lift the flue pipe up and move aside slightly. 3. If the vent piping cannot be moved, then cut the flue pipe carefully so a coupling can be inserted later, or remove a section of vent pipe if using stainless vent pipe. Isolate boiler and drain partially 1. Remove the jacket top panel and front panel.

  • Page 73: Troubleshooting

    — Boiler Manual fired water boiler Troubleshooting VERIFY PROPER OPERATION AFTER Connecting a manometer to check Figure 81 SERVICING. air pressure switch. DO NOT use this arrangement to check gas valve Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and danger- ous operation.

  • Page 74: Igniter

    — Boiler Manual fired water boiler Troubleshooting (continued) Igniter Igniter Figure 82 Wait several minutes until igniter cools down before at- tempting replacement. Failure to do so will cause severe personal injury. 1. Disconnect igniter (Figure 82) from igniter wiring harness and remove igniter before removing from blower assembly. 2. Replace igniter gasket if original gasket is frayed or damaged OR if room-temperature resistance across igniter is not between 40 and 95 ohms. 3. Igniter is fragile — handle with care. Do not touch igniter surface Gas valve Figure 83 with bare hands. Body oils can cause failure of the carbide. Gas Valve The gas valve (Figure 83) operates with a negative pres- sure at the outlet — approximately –0.2” w.c. — DO NOT set gas pressure higher than this.

  • Page 75: Ibc (Integrated Boiler Control)

    — Boiler Manual fired water boiler Troubleshooting (continued) c. Immediately disconnect the return temperature sensor plug from Return temperature sensor resistance Figure 87 the IBC. d. Measure the resistance of the sensor. Write down the result. Temperature Resistance Temperature Resistance e. Let the sensor cool to room temperature and measure the resistance °F Ohms °F Ohms again. Write down the result. 15300 2480 f. Compare the sensor resistances at both temperatures to the closest temperatures in Figure 87. 11900 1680 g. If the measured values are within 10% of the values listed, the sen- 9310 1160 sor is good. If not, replace the sensor. See Replacement parts for the part number.
  • Page 76 — Boiler Manual fired water boiler Troubleshooting (continued) IBC harness plug receptacle and indicator light locations Figure 89 Part number 550-142-056/0411...

  • Page 77: Makeup Water

    — Boiler Manual fired water boiler Troubleshooting (continued) Common causes and possible corrections, part 1 Figure 90 Symptom Common Causes Possible Corrections Rapid cycling — boiler Thermostat installed where drafts Locate thermostat on inner wall away from turns on and off frequently or heat affect reading heat sources or cool drafts.
  • Page 78 — Boiler Manual fired water boiler Troubleshooting (continued) Common causes and possible corrections, part 2 Figure 91 Symptom Common Causes Possible Corrections Popping or percolating Mineral deposits in sections due Call qualified service technician to de- noise heard in boiler to constant use of makeup water lime boiler, if necessary.
  • Page 79 • Using voltmeter, check across pins of receptacle. Is POWER light flashing now? Does voltmeter indicate 24 VAC? Have system checked by a Replace IBC. Boiler should now operate Replace transformer. licensed electrician. normally. Retest. Retest. If problem persists, call your local Williamson-Thermoflo sales representative. Part number 550-142-056/0411...
  • Page 80 — Boiler Manual fired water boiler Troubleshooting (continued) TSTAT CIRC & POWER lights flashing CHART 2 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Is return water temperature sensor clamped •...
  • Page 81 — Boiler Manual fired water boiler Troubleshooting (continued) LIMIT & POWER lights flashing CHART 3 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 82 — Boiler Manual fired water boiler Troubleshooting (continued) PRESS SWITCH & POWER lights flashing CHART 4 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 83 — Boiler Manual fired water boiler Troubleshooting (continued) FLAME & POWER lights flashing CHART 5 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Are manual main shutoff valve and gas valve turned on? •...
  • Page 84 — Boiler Manual fired water boiler Troubleshooting (continued) TSTAT CIRC light flashing and POWER light on steady CHART 6 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 85 — Boiler Manual fired water boiler Troubleshooting (continued) LIMIT light flashing and POWER light on steady CHART 7 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 86 — Boiler Manual fired water boiler Troubleshooting (continued) Insufficient heat or no heat to system (POWER light on steady) CHART 8 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. •...

  • Page 87: Replacement Parts

    — Boiler Manual fired water boiler Replacement parts Miscellaneous parts Figure 92 Description Model Williamson- Thermoflo part number Vent termination plate for 3" AL29-4C or 3" PVC pipes (plate includes knockouts to 452-100-163WT provide larger holes needed for PVC) Vent Termination Bird Screen 3" PVC (1 pc) 383-500-105WT Termination bag assembly (includes two 2-hole sidewall termination plates and two 542-200-314WT...
  • Page 88 Replacement parts (continued) Section assembly Figure 93 Item Description Model Williamson-Thermoflo number part number Block assembly, includes: 322-200-304 Front section, intermediate section, back section, square 322-200-305 cut seals — 2”, silicone sealant, tie rods, tie rod nuts, tie rod...
  • Page 89 — Boiler Manual fired water boiler Replacement parts (continued) Section assembly Figure 94 Part number 550-142-056/0411...
  • Page 90 — Boiler Manual fired water boiler Replacement parts (continued) Jacket assembly Figure 95 Item Description Model Williamson-Thermoflo number part number Jacket panel, top 070 and 105 382-200-700 140 and 175 382-200-701 Jacket panel, front 382-200-702 Jacket panel, left side, front...
  • Page 91 — Boiler Manual fired water boiler Replacement parts (continued) Jacket assembly Figure 96 Part number 550-142-056/0411...
  • Page 92 Replacement parts (continued) Blower assembly Figure 97 Item Description Model Williamson-Thermoflo number part number Burner replacement kit, includes burner, blower flange gasket, igniter, 382-200-320 WT igniter screws, igniter washers, igniter gasket 382-200-325 WT 382-200-330 WT 382-200-335 WT...
  • Page 93 — Boiler Manual fired water boiler Replacement parts (continued) Blower assembly Figure 98 Part number 550-142-056/0411...
  • Page 94 — Boiler Manual fired water boiler Replacement parts (continued) Trim assembly Figure 99 Item Description Williamson- number Thermoflo part number System circulator, Taco 007 511-405-113WT Bypass circulator, Taco 007 511-405-113WT Circulator gasket, Taco 110-339 590-317-543WT Manifold, casting/circulator kit, includes water manifold, circulator gasket (Taco 382-200-720WT 110-339) (2), square cut seal (manifold to casting) Return manifold, recuperator/circulator kit, includes water manifold, circulator...
  • Page 95 — Boiler Manual fired water boiler Replacement parts (continued) Trim assembly Figure 100 Part number 550-142-056/0411...
  • Page 96 — Boiler Manual fired water boiler Replacement parts (continued) Interior panel Figure 101 Item Description Williamson-Thermoflo number part number Interior panel see Figure 95, page 90, item 8 Integrated boiler control assembly, includes IBC and screws 382-200-448WT Transformer 511-842-370WT Air pressure switch...
  • Page 97 — Boiler Manual fired water boiler Replacement parts (continued) Interior panel Figure 102 Part number 550-142-056/0411...

  • Page 98: Dimensions And Ratings

    — Boiler Manual fired water boiler Dimensions and ratings Dimension drawing (see Figure 104, page 99 for dimensional table) Figure 103 Item Description number 1” NPT Supply 1” NPT Return Combination pressure-temperature gauge, 2 ½” short shank ¾” NPT Relief valve outlet Plug dome, 2”...
  • Page 99 (inches NPT (inches NPT (inches) (inches NPT (amperes) (gallons) (pounds) male) female) female) GWC-070 30¾ ½ GWC-105 30¾ ½ GWC-140 37¾ ½ GWC-175 37¾ ½ Note 1: Gas piping from meter to boiler to be sized per local utility requirements.
  • Page 100 19.4 11.7 17.4 23.3 1050 28.9 13.6 20.3 27.2 1225 1127 33.7 15.5 23.2 1120 1040 31.1 1400 1288 38.5 1120 Note 1 Based on standard test procedures outlined by DOE for individual boilers. Net I=B=R ratings are based on piping and pickup allowance of 1.15. Note 2 Consult Williamson-Thermoflo for other allowances. All GWC installations require a separate vent pipe and termination for each boiler. . Install and Vent piping cannot be manifolded terminate vents as described in vent/air installation instructions in this manual. Note 3 Combustion air piping can be individually piped or manifolded. See Figure 37, page 31, for manifolded air piping. Part number 550-142-056/0411...
  • Page 101 Figure 107 Water flow rate per boiler Vent/air pipe size — Provide a separate vent Boiler for each boiler Model GPM @ 20°F rise GPM @ 40°F rise Note 1 GWC-070 3” GWC-105 3” GWC-140 13.0 3” GWC-175 16.1 3”...

  • Page 102: Notes

    — Boiler Manual fired water boiler NOTES Part number 550-142-056/0411...

  • Page 103: Handling Ceramic Fiber And Fiberglass Materials

    — Boiler Manual fired water boiler Handling ceramic fiber and fiberglass materials HANDLING CERAMIC FIBER REMOVAL OR INSTALLATION MATERIALS OF FIBERGLASS WOOL Ceramic fibers can be converted to cristobalite This product contains fiberglass jacket insula- in very high temperature applications. The tion and ceramic fiber materials in combus- International Agency for Research on Cancer tion chamber lining or base panels in gas fired (IARC) has concluded, “Crystalline silica products. Airborne fibers from these materials inhaled in the form of quartz or cristobalite...

  • Page 104: Installation And Service Certificate

    — Boiler Manual fired water boiler Installation and service certificate Boiler model __________________ Series __________ CP number ___________ Date installed _______________  Installation instructions have been followed. Measured Btuh input ____________  Check-out sequence has been performed.  Above information is certified to be correct.  Information received and left with owner/maintenance person. Installer ________________________ ________________________________ ______________________________ (company) (address) (phone) _______________________________ (installer’s signature) 8201 W. Calumet Rd. Milwaukee, WI 53223 Part number 550-142-056/0411...

This manual is also suitable for:

Gwc-105Gwc-140Gwc-175

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