Page 1 Model Series 2 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 erieS 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, boiler water temperature sensor and boiler limit circuit to operate the circulators, gas valve, igniter and blower.
Page 3: Gwc Water Boiler
— Boiler Manual erieS fired water boiler GWC Series 2 Water Boiler Part number 550-142-786/0712...
Page 4: Table Of Contents
— Boiler Manual erieS fired water boiler Contents How it works ....2 DIRECT VENT — Sidewall with 3” Department of Energy Compliance . 63 concentric ... . . 39 IBC (Sequence of operations).
Page 5: Please Read Before Proceeding
— Boiler Manual erieS 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 —...
Page 6: Prepare Boiler Location
— Boiler Manual erieS fired water boiler Prepare boiler location Installations must follow these codes: Figure 1 Estimated GWC input at altitude • Local, state, provincial, national codes, laws, regulations and ordinances. Altitude % Sea level input • National Fuel Gas Code, ANSI Z223.1- latest edition. (feet) •...
Page 7: Residential Garage Installation
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. Figure 3 Minimum foundation dimensions (inches) Boiler model GWC-070 30¾ GWC-105 GWC-140 37¾ GWC-175...
Page 8: Check Orifice Plate - Replace If Necessary
To inspect the plate only, . It 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...
Page 9: Install Condensate Trap
— Boiler Manual erieS fired water boiler Prepare the boiler (continued) Install condensate trap Figure 7 Install condensate trap 1. Before placing the boiler in position, install the condensate trap line, shown in Figure 7. Items shown are provided with the boiler. Step 1 Attach the flue drain hose (C) to the in-line flue drain nipple (B).
Page 10: Install High Altitude Air Pressure Switch When Required (Only Above 5,500 Feet)
— Boiler Manual erieS fired water boiler Prepare the boiler (continued) Install high altitude air pressure switch Figure 8 Air pressure switch mounting when required (only above 5,500 feet) 1. For installations at altitude more than 5,500 feet above sea level: a.
Page 11: Perform Hydrostatic Pressure Test
— Boiler Manual erieS fired water boiler Prepare the boiler (continued) Perform hydrostatic pressure test Figure 10 Piping connections for hydrostatic test before Pressure test boiler attaching water or gas piping (except as noted below) or electrical supply. Remove jacket top panel before proceeding.
Page 12: Install Water Piping
Minimum pipe size for boiler loop piping Figure 11 Provide boiler loop piping no smaller than listed 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 erieS fired water boiler Install water piping (continued) Expansion tank Figure 13 Relief valve installation guidelines Figure 14, page 14 and Figure 15, page 14 show typical installation of the To avoid water damage or scalding expansion tank. Always locate the air separator and expansion tank as shown in the suggested piping drawings, beginning with Figure 17, page 16.
Page 14 — Boiler Manual erieS fired water boiler Install water piping (continued) Figure 14 Figure 15 Piping to single-zone system using diaphragm- or Piping closed-type expansion tank 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 erieS fired water boiler Install water piping (continued) Simplified pipe/circulator selection System water piping methods 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.
Page 16: Baseboard System Piping - Circulator Zoning (Primary/Secondary)
18, page 17. MINIMUM Boiler loop pipe size Balancing, when required — Substitute a memory-stop GWC-070/105 1” valve for one of the isolation valves in each zone to use GWC-140/175 1¼” the memory-stop valve for balancing flow as well as isolation.
Page 17 — Boiler Manual erieS fired water boiler Install water piping (continued) Figure 18 Zone valve zoning — GWC-070, GWC-105 or GWC-140 (DO NOT apply to GWC-175) Legend 4 Zone valve 1 Isolation valves 2 Automatic air vent (with 7 Hose bibb purge valve...
Page 18: Radiator System Piping
Boiler loop pipe size Zoning with zone valves Provide a separate 24-volt — transformer to power the zone valves. Size the trans- GWC-070/105 1” GWC-140/175 1¼” former to handle the total rated load of all connected zone valves. Alternatively, use a zone valve zone controller.
Page 19: Single-Zone Radiant Heating Or Heat Pump
MINIMUM Boiler loop pipe size For additional information and alternatives in piping for radiant heat- GWC-070/105 1” ing systems, contact Williamson-Thermoflo. GWC-140/175 1¼” The system circulator must be supplied by the in- staller. Adjust balancing valves...
Page 20: Multi-Zone Radiant Heating System
MINIMUM Alternatively, use a zone valve zone controller. Boiler loop pipe size Do not use R & C connections for zone valve. GWC-070/105 1” GWC-140/175 1¼” Zoning with circulators —...
Page 21: Piping Snow Melt Systems Or Combination Snow Melt/Space Heating Systems
MINIMUM on each side. Substitute a memory-stop valve for one of Boiler loop pipe size these in each zone in order to use the memory-stop valve GWC-070/105 1” for balancing flow as well as isolation. GWC-140/175 1¼”...
Page 22: Water Chiller Systems
MINIMUM Boiler loop pipe size Balancing, when required — Substitute a memory-stop GWC-070/105 1” valve for one of the isolation valves in each zone to use GWC-140/175 1¼” the memory-stop valve for balancing flow as well as isolation.
Page 23: Multiple Boiler Installations
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.
Page 24: Multiple Boiler Water Piping
— Boiler Manual erieS 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 —...
Page 25 — Boiler Manual erieS fired water boiler Multiple boiler water piping (continued) Figure 32 Piping schematic — typical for multiple GWC boilers, using secondary headers 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...
Page 26 — Boiler Manual erieS fired water boiler Multiple boiler water piping (continued) Figure 33 Piping layout — typical for multiple GWC boilers, using secondary headers (2-boiler system) 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...
Page 27 — Boiler Manual erieS fired water boiler Multiple boiler water piping (continued) Figure 34 Piping layout — typical for multiple GWC boilers, with DHW storage heaters (4-boiler system) Flow rate Size Flow rate Size Suggested DHW 1 – 4 gpm ¾”...
Page 28 — Boiler Manual erieS fired water boiler Multiple boiler water piping (continued) Figure 35 Piping layout — typical for multiple GWC boilers, using isolation exchanger Use isolation heat exchanger for: 1. Large volume systems with high mineral content in water. 2.
Page 29: Venting & Air - General
— Boiler Manual erieS 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- Every boiler must have its own vent pliance.
Page 30: Provide Combustion Air
— Boiler Manual erieS 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 bustion air piping. In addition, ventilation openings not contain any of the contaminants may be required.
Page 31: Manifolded Combustion Air Option For Direct Vent Multiple Boiler Installations
— Boiler Manual erieS fired water boiler Venting & air — general (continued) Manifolded combustion air Figure 37 Combustion air manifold option (combined air inlet, but option for DIRECT VENT individual vents) — must comply with Figure 41, page 35 multiple boiler installations 1.
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 550-142-786/0712...
Page 33 Certified for Category IV and direct vent — stainless appliance venting Dura-Vent — FasNSeal™ steel Metal-Fab, Inc. — CORR/GUARD Williamson-Thermoflo bird screens (included with boiler) Williamson- 3” bird screen: Thermoflo W-T part number 383-500-105WT (two supplied with the boiler) bird screens Note 1: DO NOT use DWV, CPVC or ABS when using concentric vent termination.
Page 34: Commonwealth Of Massachusetts Installations
— Boiler Manual erieS 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 INSPECTION .
Page 35: Vent Termination Requirements
— Boiler Manual erieS fired water boiler Vent termination requirements Figure 41 The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). For Canadian installations, defer to the requirements of CSA B149.1 or B149.2 Installation Code. Part number 550-142-786/0712...
Page 36: Direct Vent - Boiler Room Air Openings
— Boiler Manual erieS fired water boiler DIRECT VENT — Boiler room air openings Figure 42 Combustion and ventilation air openings for GWC Direct Vent installations 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.
Page 37: Direct Vent - Sidewall With Sepa- Rate Pipes
— Boiler Manual erieS fired water boiler DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & Figure 43 — Separate pipes sidewall INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if specified.
Page 38: Prepare Wall Penetrations
— Boiler Manual erieS fired water boiler DIRECT VENT — Sidewall with separate pipes (continued) Figure 44 Multiple separate pipes sidewall terminations For multiple boiler applications using the manifolded 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.
Page 39: Direct Vent - Sidewall With 3" Concentric
— Boiler Manual erieS fired water boiler DIRECT VENT — Sidewall with 3” concentric Allowable vent/air pipe materials & Figure 46 — Concentric horizontal 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.
Page 40 — Boiler Manual erieS fired water boiler DIRECT VENT — Sidewall with 3” concentric (continued) Install termination — concentric pipes Figure 47 Termination location — concentric 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 erieS fired water boiler DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & Figure 49 Separate pipes vertical termination lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified.
Page 42 — Boiler Manual erieS fired water boiler DIRECT VENT — Vertical with separate pipes (continued) 3. Space the air and vent holes to provide the minimum spacings Figure 50 Terminations for multiple boilers 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 erieS fired water boiler DIRECT VENT — Vertical with 3” concentric Allowable vent/air pipe materials & Figure 51 — Concentric vertical INSTALLATION SEQUENCE lengths 1. The 3.00” concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 40, page 33.
Page 44 — Boiler Manual erieS fired water boiler DIRECT VENT — Vertical with 3” concentric (continued) Mount concentric termination Figure 52 Vertical termination — 3” PVC concentric — single or multiple boilers 1. Mount the termination as shown in Figure 53, page 44. 2.
Page 45: Concentric Termination Assembly (Sidewall Or Vertical)
— Boiler Manual erieS fired water boiler Concentric termination assembly (sidewall or vertical) Assembling concentric termination Figure 54 3” PVC concentric termination assembly — DO NOT 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 erieS fired water boiler Vent and air piping and boiler connections DIRECT EXHAUST & DIRECT VENT Figure 55 Boiler vent and air connections 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.
Page 47: Direct Exhaust - Boiler Room Air Openings
— Boiler Manual erieS 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:...
Page 48: Gwc Boiler
— Boiler Manual erieS fired water boiler DIRECT EXHAUST — Boiler room air openings (cont.) Figure 56 MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA 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 erieS fired water boiler DIRECT EXHAUST — Sidewall DO NOT sidewall vent DIRECT EX- Figure 57 — Direct exhaust sidewall INSTALLATION SEQUENCE HAUST APPLICATIONS at altitudes above 5,500 feet. Sidewall venting is DIRECT VENT only allowed for plications (ducted combustion air) at altitudes above 5,500 feet.
Page 50 AL29-4C termination fitting with integral screen. Bird screens are not supplied with the GWC boiler. Purchase separately from Williamson-Thermoflo. See Figure 93, page 88 for part numbers. 2. You can install the vent termination using either of the con- figurations shown in Figure 57, page 49.
Page 51: Direct Exhaust - Vertical
— Boiler Manual erieS fired water boiler DIRECT EXHAUST — Vertical Allowable vent/air pipe materials & Figure 59 — Direct exhaust vertical INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified.
Page 52: Gas Piping
— Boiler Manual erieS fired water boiler Gas piping Connecting gas supply piping Figure 60 Gas supply connection to GWC boiler gas manifold 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.
Page 53: Natural Gas
To replace wiring, order complete harness assem- • minimum 3.5” w.c. blies from Williamson-Thermoflo. If any original wiring as supplied with boiler must be replaced, Install 100% lockup gas pressure regulator in sup- and a harness is not immediately available, use only ply line if inlet pressure exceeds 14”...
Page 54: Field Wiring
— Boiler Manual erieS fired water boiler Wiring (continued) Figure 62 Field wiring connections — service switch and thermostat (or end switch) provided by installer Carbon monoxide detector Direct Exhaust units, a carbon monoxide de- Connect the DHW aquastat as shown in wiring above. The tector is required in the boiler room.
Page 55 — Boiler Manual erieS fired water boiler Wiring (continued) Figure 64 Ladder wiring diagram Part number 550-142-786/0712...
Page 56 — Boiler Manual erieS fired water boiler Wiring (continued) Figure 65 Schematic wiring diagram Part number 550-142-786/0712...
Page 57: Start-Up
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.
Page 58: Fill And Test Water System
— Boiler Manual erieS fired water boiler Start-up (continued) 2. See Replacement parts at the end of this manual for Williamson- b. Pressure will rise when boiler is turned on and sys- tem water temperature increases. Operating pressure Thermoflo part numbers to obtain antifreeze through a William- must never exceed 5 PSIG less than the boiler relief son-Thermoflo distributor.
Page 59: Check For Gas Leaks
— Boiler Manual erieS fired water boiler Start-up (continued) 5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external ther- Check for gas leaks mostat circuit wires. Allow the boiler to cycle. Before starting the boiler, and during initial opera- Inspect/fill condensate system tion, use a leak detector or smell near the floor and around the boiler for gas odorant or any unusual...
Page 60: Final Checks Before Starting Boiler
— Boiler Manual erieS fired water boiler Start-up (continued) Final checks before starting boiler IMPORTANT Review the boiler sequence of operation in Figure 71, page 64. ❏ ❏ Verify that the boiler and system are full of water and all system ❏...
Page 61: Gas Valve Adjustment - Altitude
— Boiler Manual erieS fired water boiler Start-up (continued) 3. Using common bit screwdriver, remove outlet pressure tap Figure 68 Check for igniter glow by looking into plug from gas valve and save plug (Figure 70). observation port on front of blower housing 4.
Page 62: Final Checklist
— Boiler Manual erieS fired water boiler Start-up (continued) Final checklist Figure 69 Tools required for gas valve outlet pressure measurement Use the checklist following to ensure boiler is operating correctly. Have the following been completed? ❏ ❏ Is proper orifice plate installed? Refer to page 8 to check size and fuel type.
Page 63: Department Of Energy Compliance
— Boiler Manual erieS fired water boiler Start-up (continued) 6 seconds and then return to 0 VDC. Control will attempt ❏ ❏ Cycle boiler with thermostat — Raise to highest setting and ignition two more times, increasing igniter time to 30 verify boiler goes through normal start-up cycle.
Page 64: Ibc (Sequence Of Operations)
— Boiler Manual erieS fired water boiler Start-up (continued) Figure 71 Integrated boiler control (IBC) sequence of operation — status light indications STEPS Call for POWER TSTAT LIMIT PRESS FLAME Timing CIRC SWITCH Heat? (After Step 8, the cycle goes back to Step 1) 1.
Page 65: Operating Instrustions
— Boiler Manual erieS fired water boiler Start-up (continued) Figure 72 Operating instructions Part number 550-142-786/0712...
Page 66: Annual Start-Up And General Maintenance Schedule
— Boiler Manual erieS fired water boiler Annual start-up and general maintenance schedule Figure 73 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see following pages for instructions) General: • Address reported problems, page 67. •...
Page 67: Annual Start-Up
— Boiler Manual erieS 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- causing heat exchanger failure.
Page 68: Inspect Expansion Tank
— Boiler Manual erieS fired water boiler Annual start-up (continued) Inspect expansion tank Figure 74 Igniter observation port in blower 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.
Page 69: Inspect Temperature Mixing System
— Boiler Manual erieS fired water boiler Annual start-up (continued) Inspect temperature mixing system Figure 75 Blower motor temperature system return piping 1. Carefully check the of the return pipe inside it passes through the boiler jacket and on the the boiler jacket just before it enters the boiler sections.
Page 70: Inspect Boiler Relief Valve
— Boiler Manual erieS fired water boiler Annual start-up (continued) Figure 76 Relief valve 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.
Page 71: Service & Maintenance
— Boiler Manual erieS fired water boiler Service & maintenance Cleaning boiler heating surfaces Figure 77 Blower housing removal procedure 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.
Page 72: Inspecting And Cleaning The Recuperator
— Boiler Manual erieS fired water boiler Service & maintenance (continued) To clean the burner Figure 78 Recuperator access and cleaning The burner may contain ceramic fiber particles. Use care when handling these materials per instructions on page 106 of this manual. Failure to comply could result in severe personal injury.
Page 73 — Boiler Manual erieS fired water boiler Service & maintenance (continued) Make sure the recuperator access cover and the Figure 79 Recuperator flueway drain holes condensate trap are re-installed securely. Failure to comply with the above could result in severe personal injury, death or substantial property damage.
Page 74: Troubleshooting
— Boiler Manual erieS fired water boiler Troubleshooting VERIFY PROPER OPERATION AFTER Figure 80 Connecting a manometer to check SERVICING. air pressure switch. DO NOT use this arrangement to check gas valve Label all wires prior to disconnection when servicing controls.
Page 75: Igniter
— Boiler Manual erieS fired water boiler Troubleshooting (continued) Igniter Figure 81 Igniter Wait several minutes until igniter cools down before at- tempting replacement. Failure to do so will cause severe personal injury. 1. Disconnect igniter (Figure 81) from igniter wiring harness and remove igniter before removing from blower assembly.
Page 76: Return Temperature Sensor
— Boiler Manual erieS fired water boiler Troubleshooting (continued) Return temperature sensor Supply temperature sensor 1. See Figure 85. See Figure 87 . Figure 85 Return temperature sensor 2. The boiler temperature sensor is a resistance-type device. 3. The Figure 88 below shows the correct value for the sensor at various temperatures.
Page 77: Ibc (Integrated Boiler Control)
— Boiler Manual erieS fired water boiler Troubleshooting (continued) Control indicator lights — Figure 89 GWC Integrated Boiler Control (IBC) HARD LOCKOUT Summary (Flashing LED’s) MAY remove 120VAC power for more than 2 seconds to clear lockout OR ignition control will automatically restart sequence of operation after 1 hour waiting period after fault condition is cleared.
Page 78 — Boiler Manual erieS fired water boiler Troubleshooting (continued) Figure 90 IBC harness plug receptacle and indicator light locations Part number 550-142-786/0712...
Page 79 — Boiler Manual erieS fired water boiler Troubleshooting (continued) Figure 91 Common causes and possible corrections, part 1 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 80 — Boiler Manual erieS fired water boiler Troubleshooting (continued) Figure 92 Common causes and possible corrections, part 2 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 81 • Using voltmeter, check across pins of receptacle. 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 550-142-786/0712...
Page 82 — Boiler Manual erieS 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 83 — Boiler Manual erieS fired water boiler Troubleshooting (continued) PRESS SWITCH & 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 84 — Boiler Manual erieS fired water boiler Troubleshooting (continued) FLAME & 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. Are manual main shutoff valve and gas valve turned on? •...
Page 85 — Boiler Manual erieS fired water boiler Troubleshooting (continued) TSTAT/CIRC light flashing and POWER light on steady 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. •...
Page 86 — Boiler Manual erieS fired water boiler Troubleshooting (continued) LIMIT 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 87 — Boiler Manual erieS fired water boiler Troubleshooting (continued) Insufficient heat or no heat to system (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 88: Replacement Parts
— Boiler Manual erieS fired water boiler Replacement parts Figure 93 Miscellaneous parts 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"...
Page 89 Replacement parts (continued) Figure 94 Section assembly 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 90 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 95 Section assembly Part number 550-142-786/0712...
Page 91 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 96 Jacket assembly Item Description Model Williamson-Thermoflo number part number Jacket panel, top 070 and 105 382-200-735 140 and 175 382-200-736 Jacket panel, front 382-200-702 Jacket panel, left side, front...
Page 92 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 97 Jacket assembly Part number 550-142-786/0712...
Page 93 Replacement parts (continued) Figure 98 Blower assembly 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 94 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 99 Blower assembly Part number 550-142-786/0712...
Page 95 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 100 Trim assembly 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 96 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 101 Trim assembly Part number 550-142-786/0712...
Page 97 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 102 Interior panel Item Description Williamson-Thermoflo number part number Interior panel see Figure 96, page 91, item 8 Integrated boiler control assembly, includes IBC and screws 381-330-017WT Transformer 381-356-578WT...
Page 98 — Boiler Manual erieS fired water boiler Replacement parts (continued) Figure 103 Interior panel Part number 550-142-786/0712...
Page 99: Dimensions And Ratings
— Boiler Manual erieS fired water boiler Dimensions and ratings Figure 104 Dimension drawing (see Figure 105, page 100 for dimensional table) 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 100 (inches NPT (inches NPT (inches) (inches NPT (pounds) (amperes) (gallons) 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 101 Based on standard test procedures outlined by DOE for individual boilers. Net AHRI ratings are based on piping and pickup allowance of 1.15. Note 2 Consult Williamson-Thermoflo for other allowances. Vent piping cannot be manifolded All GWC installations require a separate vent pipe and termination for each boiler.
Page 102 Engineering data — see page 100 for additional technical information 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 103 — Boiler Manual erieS fired water boiler NOTES Part number 550-142-786/0712...
Page 104: Notes
— Boiler Manual erieS fired water boiler NOTES Part number 550-142-786/0712...
Page 105 — Boiler Manual erieS fired water boiler NOTES Part number 550-142-786/0712...
Page 106: Handling Ceramic Fiber And Fiberglass Materials
— Boiler Manual erieS 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...
Page 107: Installation And Service Certificate
— Boiler Manual erieS 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.
Page 108 — Boiler Manual erieS fired water boiler 8201 W. Calumet Rd. Milwaukee, WI 53223 Part number 550-142-786/0712...

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Gwc-105 Gwc-140 Gwc-175

Williamson-Thermoflo GWC-070 Manual

How It Works

GWC Water Boiler

Please Read before Proceeding

Prepare Boiler Location

Install Water Piping

Multiple Boiler Installations

Multiple Boiler Water Piping

Venting & Air - General

Commonwealth of Massachusetts Installations

Vent Termination Requirements

DIRECT VENT - Boiler Room Air Openings

Openings . . . . . . . . . . . . . . 36 Gas Valve Adjustment - Altitude

DIRECT VENT - Sidewall with Sepa- Rate Pipes

DIRECT VENT - Sidewall with 3" Concentric

DIRECT VENT - Vertical with Sepa- Rate Pipes

DIRECT VENT - Vertical with 3”

DIRECT VENT - Vertical with 3" Concentric

Concentric Termination Assembly (Sidewall or Vertical)

Vent and Air Piping and Boiler Connections

Openings . . . . . . . . . . . . . .

DIRECT EXHAUST - Boiler Room Air Openings

DIRECT EXHAUST - Sidewall

DIRECT EXHAUST - Vertical

Gas Piping

Wiring

Start-Up

Adjust Boiler Control Settings

Department of Energy Compliance

Annual Start-Up and General Maintenance Schedule

Nance Schedule . . . . . . . . . . 66

Annual Start-Up

Service & Maintenance

Troubleshooting

Replacement Parts

Dimensions and Ratings

Notes

Handling Ceramic Fiber and Fiberglass Materials

Installation and Service Certificate

Quick Links

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Summary of Contents for Williamson-Thermoflo GWC-070

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Table of Contents