Table of Contents
Advertisement
Quick Links
Hazards that will cause severe personal injury,
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
INSTALLER - Read all instructions before
installing. Read page 2 first. Follow all instruc-
tions in proper order to prevent personal injury or
death.
• Consider piping and installation when determining
boiler location.
• Any claims for damage or shortage in shipment
must be filed immediately against the transporta-
tion company by the consignee.
This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
When calling or writing about the boiler- Please have: • boiler model number from the boiler rating label and
• CP number from the boiler jacket. You may list the CP number in the space provided on the "Installation and service
certificate" found on page 16.
GWS - 090 E
Gas-Fired Water Boiler
Boiler Manual
Contents
1 Prepare boiler location ....................................................... 2
2 Prepare boiler ..................................................................... 8
3 Install water piping .............................................................. 9
4 Venting and combustion air .............................................. 12
5 Gas piping ........................................................................ 12
6 Field wiring ....................................................................... 13
7 Start-up ............................................................................ 14
8 Checkout procedure ......................................................... 16
9 Sequence of operation ..................................................... 17
10 Operating instructions ...................................................... 19
11 Service and maintenance ................................................. 20
12 Troubleshooting ................................................................ 25
13 Replacement parts ........................................................... 33
14 Dimensions ....................................................................... 38
15 Ratings ............................................................................. 39
Hazard definitions
• This manual is for use only by your qualified
• Please see the User's Information Manual for your
• Have the boiler serviced by a qualified service
Hazards that will or can cause minor personal
injury or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
USER - Please read the following. Failure to
comply could result in severe personal injury,
death or substantial property damage.
heating installer/service technician.
reference.
technician, at least annually.
Part Number 550-110-737/1108
Page
Advertisement
Table of Contents
Related Manuals for Williamson-Thermoflo GWS-090E
Summary of Contents for Williamson-Thermoflo GWS-090E
-
Page 1: Table Of Contents
GWS - 090 E Gas-Fired Water Boiler Boiler Manual Contents Page 1 Prepare boiler location ............2 2 Prepare boiler ..............8 3 Install water piping .............. 9 4 Venting and combustion air ..........12 5 Gas piping ................ 12 6 Field wiring ............... -
Page 2: Read This First
3. Do not block flow of combustion or ventilation air to Certification boiler. The GWS-090E boiler gas manifold and controls met 4. Should overheating occur or gas supply fail to shut off, do safe lighting and other performance criteria when not turn off or disconnect electrical supply to circulator. -
Page 3: Residential Garage Installations
Minimum service clearances Flooring and foundation Flooring The GWS-090E boiler is approved for installation on combustible flooring, but must never be installed on carpeting. Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage. -
Page 4: Vent System
When removing boiler from existing common vent item, designed only for GWS and GWS-90E, available from each system: vendor. Do not attempt to connect the vent to a GWS-090E boiler At the time of removal of an existing boiler, the following steps with any other means. - Page 5 GWS-090E Gas-Fired Water Boiler – Boiler Manual 1 Prepare boiler location continued Air contamination Table 3 Corrosive contaminants and likely locations Please review the following information on potential combustion air contamination problems. See Table 3 for products and areas which may cause contami- nated combustion air.
-
Page 6: Air Openings
GWS-090E Gas-Fired Water Boiler – Boiler Manual 1 Prepare boiler location continued Air openings Using outside air — direct venting Special considerations Combustion air can be ducted directly from outside to the GWS- Tight construction 090E boiler air intake fitting.This method is defined as direct vent ANSI Z223.1 defines unusually tight construction where:... - Page 7 GWS-090E Gas-Fired Water Boiler – Boiler Manual 1 Prepare boiler location continued Figure 2 Provide minimum air openings for GWS-090E boiler installations based on following: Part Number 550-110-737/1108...
-
Page 8: Prepare Boiler
Prepare boiler for test than 45 psi is reached on the pressure/temperature gauge. 1. Remove the shipping nipple (from GWS-090E supply tapping) 6. Test at no more than 45 psi for no more than 10 minutes. and remove the boiler relief valve. Temporarily plug the relief Do not leave boiler unattended. -
Page 9: Install Water Piping
GWS-090E Gas-Fired Water Boiler – Boiler Manual 3 Install water piping General Near-boiler piping continued If installation is to comply with ASME or Canadian requirements, Table 5 Water pipe size (based on 20 °F rise) an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. - Page 10 GWS-090E Gas-Fired Water Boiler – Boiler Manual 3 Install water piping continued Use Figure 3 or Figure 4 only for systems designed Figure 3 Diaphragm- or bladder-type expansion tank: for return water at least 130 °F. For systems with Piping to single-zone system using...
- Page 11 GWS-090E Gas-Fired Water Boiler – Boiler Manual 3 Install water piping continued Near-boiler piping continued Figure 6 System bypass piping in boiler loop with Figure 7 Boiler bypass piping — use only for high separate system circulator, using primary/ water content systems — DO NOT use for...
-
Page 12: Venting And Combustion Air
GWS-090E Gas-Fired Water Boiler – Boiler Manual 4 Venting and combustion air The GWS-090E boiler must be direct vented only Install vent piping and air piping (if used) per appropriate instruc- tions in the GWS Venting Manual, included in boiler envelope (combustion air ducted to boiler) and supplied with assembly. -
Page 13: Field Wiring
Field wiring connections — service switch and thermostat (or end switch) provided by installer The GWS-090E control module is polarity-sensitive. The hot and neutral wires must be connected to the correct leads. A flashing POWER light usually indicates reversed polarity of 120 VAC lead wires. -
Page 14: Start-Up
GWS-090E Gas-Fired Water Boiler – Boiler Manual 7 Start-up Check for gas leaks Fill the system with water Before starting the boiler, and during initial opera- 1. Close manual and automatic air vents and boiler drain cock. tion, smell near the floor and around the boiler for 2. - Page 15 1. Yellow-orange streaks may appear (caused by dust). (The iron, and causing section failure. GWS-090E will operate at low fire for the first 60 seconds.) If you discover evidence of any gas leak, shut down Improper main burner flame: the boiler at once.
-
Page 16: Checkout Procedure
GWS-090E Gas-Fired Water Boiler – Boiler Manual 8 Checkout procedure Set limit control(s) to system temperature requirements. Adjust ❏ ❏ Boiler and heat distribution units filled with water? balancing valves and controls to provide design temperature Automatic air vent, if used, open one full turn? ❏... -
Page 17: Sequence Of Operation
10. Return the thermostat to normal setting. 4. The GWS-090E timer relay delays high fire for the first 60 11. Set thermostat heat anticipator setting per wiring diagram, seconds of main flame. - Page 18 GWS-090E Gas-Fired Water Boiler – Boiler Manual Part Number 550-110-737/1108...
-
Page 19: Operating Instructions
GWS-090E Gas-Fired Water Boiler – Boiler Manual 10 Operating instructions Part Number 550-110-737/1108... -
Page 20: Service And Maintenance
GWS-090E Gas-Fired Water Boiler – Boiler Manual 11 Service and maintenance Table 6 Service and maintenance schedules (service technician and user) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) ❏ Daily Check boiler area ❏... -
Page 21: Handling Ceramic Fiber And Fiberglass Materials
GWS-090E Gas-Fired Water Boiler – Boiler Manual 11 Service and maintenance continued Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. - Page 22 GWS-090E Gas-Fired Water Boiler – Boiler Manual 11 Service and maintenance continued The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury.
- Page 23 1. Inspect and test the boiler limit control. Verify operation by turn- ing control set point below boiler temperature. Boiler should 1. The circulator shipped with the GWS-090E boiler is water- cycle off. Return dial to original setting. lubricated. No oiling is required.
-
Page 24: Review With Owner
GWS-090E Gas-Fired Water Boiler – Boiler Manual 11 Service and maintenance continued ❏ Check/test ..❏ Cleaning boiler heating surfaces continued The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials Boiler relief valve per instructions on page 21 of this manual. -
Page 25: Troubleshooting
GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting Label all wires prior to disconnection when servic- Figure 14 Checking pressure switch ing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in “Troubleshooting”... - Page 26 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 1 — Troubleshooting POWER light status — Usually indicates reversed 120 VAC polarity if POWER light flashes by itself — 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 27 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — 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 28 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — 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 29 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — 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 30 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 5 — PRESS SWITCH light flashing and POWER light on steady — Usually indicates pressure switch opened during run cycle — — May also be caused by wind gusts in excess of 31 mph for non-direct vent sidewall-vented boilers —...
- Page 31 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 6 — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame 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 32 GWS-090E Gas-Fired Water Boiler – Boiler Manual 12 Troubleshooting continued CHART 7 — Insufficient heat or no heat to system (POWER light on steady) 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 33: Replacement Parts
GWS-090E Gas-Fired Water Boiler – Boiler Manual 13 Replacement parts Figure 15 Section assembly, flue collector, draft hood and vent damper The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury. - Page 34 GWS-090E Gas-Fired Water Boiler – Boiler Manual 13 Replacement parts continued Figure 16 Base assembly, manifold, orifices and burners The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury.
- Page 35 GWS-090E Gas-Fired Water Boiler – Boiler Manual 13 Replacement parts continued Figure 17 Jacket assembly The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury.
- Page 36 GWS-090E Gas-Fired Water Boiler – Boiler Manual 13 Replacement parts continued Figure 18 Trim assembly Item Description Manufacturer Manufacturer’s Part number number part number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet Conbraco 10-407-10 511-546-920WT M330 Watts Pressure relief valve, ASME, 30 PSIG, ¾” female inlet...
- Page 37 Tubing, air pressure switch, 0.12 I.D. silicone not shown red, to collector hood Lydall 590-317-650WT white, to transition 590-317-651WT * The ABB timer relay TS12190 is designed for 90-second delay, but operates for 60 seconds in the GWS-090E boiler. Part Number 550-110-737/1108...
-
Page 38: Dimensions
GWS-090E Gas-Fired Water Boiler – Boiler Manual 14 Dimensions Figure 20 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return “A” “W” model tapping tapping connection size manifold size Air inlet Jacket number (inches NPT) (inches NPT) Note 3... -
Page 39: Ratings
The GWS-090E boiler may be direct-vented (using 3” diameter air piping) as specified in the GWS Vent Manual. 5. As an Energy Star Partner, W-T has determined that the GWS-090E meets the Energy Star guidelines for energy efficiency. 6. The boiler must be equipped with specially-sized orifices for high altitude ap- plications. -
Page 40: Commonwealth Of Massachusetts
GWS-090E Gas-Fired Water Boiler – Boiler Manual Addendum Instruction for the Commonwealth of Massachusetts This addendum must only be used by a one-half (1/2) inch in size, “GAS VENT DIRECTLY BE- LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” qualified heating installer/service technician.