1. Manuals
  2. Brands
  3. Williamson-Thermoflo Manuals
  4. Boiler
  5. GWA 3 Series
  6. Manual

Williamson-Thermoflo GWA 3 Series Manual

Gas-fired water boilers
Hide thumbs Also See for GWA 3 Series:
Table of Contents

Advertisement

Quick Links

Contents
1 Prepare boiler location ...........................................3
2 Prepare boiler ..........................................................7
3 Install water piping ...............................................10
4 Water piping — multiple zones ............................13
5 Install gas piping ...................................................20
6 Field wiring ............................................................21
7 Start-up .................................................................22
8 Checkout procedure .............................................25
9 Department of Energy – Compliance ...................26
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
instructions in proper order to prevent
personal injury or death.
• Consider piping and installation when determin-
ing boiler location.
• Any claims for damage or shortage in shipment
must be filed immediately against the transpor-
tation 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
• Consumer Protection (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 25.
GWA
Gas-Fired Water Boilers
Boiler Manual
Page
Contents .......................................................... Page
10 Sequence of operation .........................................26
11 Operating instructions ..........................................30
12 Service and maintenance .....................................32
13 Troubleshooting ....................................................36
14 Replacement parts ...............................................45
15 Dimensions ...........................................................50
16 Ratings ..................................................................51

Hazard definitions

• This manual is for use only by your qualified
• Please see the User's Information Manual for
• Have the boiler serviced by a qualified service
Series 3
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.
your reference.
technician, at least annually.
Part Number 550-142-320/0720

Advertisement

Table of Contents
loading

Related Manuals for Williamson-Thermoflo GWA 3 Series

Summary of Contents for Williamson-Thermoflo GWA 3 Series

  • Page 1 Series 3 Gas-Fired Water Boilers Boiler Manual Contents Page Contents ............Page 1 Prepare boiler location ...........3 10 Sequence of operation .........26 2 Prepare boiler ............7 11 Operating instructions ..........30 3 Install water piping ..........10 12 Service and maintenance ........32 4 Water piping —...
  • Page 2 Therefore, and any gas control that has been under water. Williamson-Thermoflo equipment contaminated with salt- Boiler water — water or polluted water will no longer be covered under warranty and should be replaced.
  • Page 3 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location Codes & checklist Clearances Installations must follow these codes: Service clearances • Local, state, provincial, and national codes, laws, regula- 1. Provide minimum clearances for cleaning and servicing the tions and ordinances.
  • Page 4 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Clearances Vent system continued Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, Small space installations causing severe personal injury or death. 1.
  • Page 5 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Vent system Air contamination continued Chimney or vent requirements Please review the following information on potential combus- tion air contamination problems. 1. Venting must be installed according to Part 7, “Venting of See Table 2 for products and areas which may cause contami- Equipment”, of National Fuel Gas Code, ANSI Z223.1 –...
  • Page 6 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air openings Exhaust fans and air movers Combustion air and ventilation openings must comply with Section 5.3, “Air for Combustion and Ventilation”, of National The appliance space must never be under a negative pressure. Fuel Gas Code ANSI Z223.1 –...
  • Page 7 (Note 1) use in the system piping. 4. Remove plug from relief valve tapping. See Section 3, Note 1: For elevations above 2,000 feet, contact your page 10, to replace relief valve. Williamson-Thermoflo sales office for details. Part Number 550-142-320/0720...
  • Page 8 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 2 Prepare boiler continued Draft hood & spill switch Install vent piping 1. Connect from draft hood or vent damper outlet to chimney Draft hood installation or vent with same size vent connector. 1.
  • Page 9 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 2 Prepare boiler continued Vent damper continued Damper installation Do not modify draft hood or vent damper, or make another connection between draft hood and vent damper or boiler except as noted below. This will void CSA certification and will not be covered by warranty.
  • Page 10 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 3 Install water piping General Near-boiler piping continued If installation is to comply with ASME requirements, an additional • Failure to comply with the above guidelines could result in failure of the relief valve to oper- high temperature limit is needed.
  • Page 11 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 3 Install water piping continued Near-boiler piping continued Use Figure 5 or Figure 6 only for systems designed Figure 5 Diaphragm- or bladder-type expansion tank: for return water at least 130 °F. For systems with low Piping to single-zone system using return water temperature possible, such as converted diaphragm-type or bladder-type expansion...
  • Page 12 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 3 Install water piping continued Near-boiler piping continued Figure 8 System bypass piping in boiler loop with Figure 9 Boiler bypass piping — use only for high separate system circulator, using primary/ water content systems —DO NOT use for secondary piping.
  • Page 13 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 4 Water piping — multiple zones Piping multiple zones Piping for radiant heating systems or converted gravity systems Follow instructions on pages 11 and 12 to install near-boiler or single-zone piping. (Also refer to Piping for radiant heating Converted gravity (or steam) systems systems or converted gravity systems, below, if applicable.) Whenever possible, use the primary/secondary piping...
  • Page 14 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 4 Water piping — multiple zones continued Figure 10 Figure 11 Zoning with circulators — return water 130°F or Zoning with zone valves — return water 130°F higher. or higher. Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank).
  • Page 15 Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature. Contact your Williamson-Thermoflo representative for suggested piping and control methods.
  • Page 16 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 4 Water piping — multiple zones continued Water piping — low temperature systems continued Figure 12 Primary/secondary piping Figure 13 Primary/secondary piping Zoning with circulators Zoning with zone valves 10 Automatic air vent (with diaphragm-type expansion tank), 1 Boiler isolation (balancing) valves or connect to tank fitting (closed-type expansion tank).
  • Page 17 Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature. Contact your Williamson-Thermoflo representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 18 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 4 Water piping — multiple zones continued Water piping — low temperature systems continued Figure 14 Boiler-bypass piping Figure 15 Boiler-bypass piping Zoning with circulators (Alternative to Zoning with zone valves (Alternative to primary/ primary/secondary piping Figures 12 and 13) secondary piping Figures 12 and 13) 1 Boiler isolation (balancing) valves...
  • Page 19 DO NOT provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature. Contact your Williamson-Thermoflo representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 20 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 5 Install gas piping Connecting gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and see Figure 10 to pipe gas to boiler. 1. See Table 5 for pipe length and diameter. Base on a.
  • Page 21 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 6 Field wiring For your safety, turn off electrical power supply amps. For other devices, see manufacturer’s specifications. at service entrance panel before making any Wiring diagram on boiler gives setting for control module electrical connections to avoid possible electric and gas valve.
  • Page 22 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 7 Start-up Fill the system with water Preparation 1. Close manual and automatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure will vary Check for gas leaks with each application.
  • Page 23 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 7 Start-up continued Operate boiler DO NOT proceed with boiler operation unless boiler and system have been filled with water and all instructions and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage.
  • Page 24 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 7 Start-up continued Verify operation 1. Check system piping for leaks. If found, shut down boiler Figure 19 Typical pilot burner flame and repair immediately. 2. Vent air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.
  • Page 25 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 8 Checkout procedure o Set Boiler Temp adjustment knob to system temperature Boiler and heat distribution units filled with water? requirements. Adjust balancing valves and controls to Automatic air vent, if used, open one full turn? provide design temperature to system.
  • Page 26 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 9 Department of Energy – Compliance This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water temperature changes.
  • Page 27 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 10 Sequence of operation – spark-ignited pilot boilers Propane Gas Lockout manual reset – ONLY after boiler c. In the event the limit control shuts down the boiler — The control module closes the main gas valve, area has been cleared of any accumulated LP gas: but keeps the circulator operating and the vent •...
  • Page 28 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 10 Sequence of operation – spark-ignited pilot boilers Figure 22 Schematic wiring diagram — Spark-ignited pilot system Part Number 550-142-320/0720...
  • Page 29 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 10 Sequence of operation – spark-ignited pilot boilers Figure 23 Schematic wiring diagram — Spark-ignited pilot system Part Number 550-142-320/0720...
  • Page 30 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 11 Operating instructions Gas valve — Honeywell VR8204 or VR8304 — White-Rodgers 36C or 36E FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 31 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 11 Operating instructions Gas valve — Robertshaw 7200 Part Number 550-142-320/0720...
  • Page 32 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 12 Service and maintenance Table 7 Service and maintenance schedules (service technician and owner) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) Inspect: o Daily •...
  • Page 33 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 12 Service and maintenance continued The boiler should be inspected and started Inspect ..annually, at the beginning of the heating season, only by a qualified service technician.
  • Page 34 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 12 Service and maintenance continued Service..Check/test..Oiled-bearing circulators Air vents and air elimination 1.
  • Page 35 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 12 Service and maintenance continued 2. After following the preceding warning directions, if the relief Check/test..valve weeps or will not seat properly, replace the relief valve. continued Ensure that the reason for relief valve weeping is the valve Diaphragm- or bladder-type —...
  • Page 36 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting In event of vent damper failure: Label all wires prior to disconnection when servicing controls. Wiring errors can cause Effikal or Field Controls vent damper improper and dangerous operation. If troubleshooting chart recommends replacing actuator and Never jumper (bypass) rollout thermal fuse actuator is not immediately available, damper blade can be fixed...
  • Page 37 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers Temperature sensor Figure 26 GWA Ignition control module 1. The boiler temperature sensor is a resistance-type device. 2. See Figure 25 below shows the correct value for the sensor at various temperatures.
  • Page 38 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers Figure 27 Control module connections Part Number 550-142-320/0720...
  • Page 39 • Using voltmeter, check across left and right pins of receptacle. Does voltmeter indicate 24 VAC? Have system checked by a licensed electrician. If problem persists, call your Replace control module. Replace transformer. Boiler should now operate local Williamson-Thermoflo normally. Retest. Retest. sales representative. Part Number 550-142-320/0720...
  • Page 40 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers CHART 2 –– Spark-ignited pilot –– 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 41 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers CHART 3 –– Spark-ignited pilot –– DAMPER light flashing –– If POWER light is flashing: Usually indicates vent damper failed to prove open within 45 seconds –– ––...
  • Page 42 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers CHART 4 –– Spark-ignited pilot –– 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 43 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers CHART 5 –– Spark-ignited pilot –– 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 44 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 13 Troubleshooting – spark-ignited pilot boilers CHART 6 –– Spark-ignited pilot –– Insufficient heat or no heat (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 45 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 14 Replacement parts Figure 28 Section assembly, flue collector, draft hood and vent damper Item Description Part number Item Description Part number number number Temperature sensor 381-356-577WT GWA-038 Replacement 321-114-360WT shown section GWA-067 321-114-361WT...
  • Page 46 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 14 Replacement parts continued Figure 29 Base assembly, manifold, orifices and burners Item Description Part number number Base assembly kit GWA-038 381-354-355WT GWA-067 381-354-356WT GWA-100 381-354-357WT GWA-133 381-354-358WT GWA-166 381-354-359WT GWA-200 381-354-360WT GWA-233 381-354-361WT...
  • Page 47 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 14 Replacement parts continued Figure 30 Jacket assembly Item Description Part number Part number Item Description Part number number number Junction box, 2 x 4 Jacket GWA-038 & GWA-067 431-223-433WT panel, GWA-100 431-223-434WT (Available at local supply house)
  • Page 48 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 14 Replacement parts continued Figure 31 Trim assembly Description Part number Item number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet 511-546-920WT Pressure relief valve, ASME, 30 PSIG, ¾” female inlet 511-546-924WT (Fittings shown are factory-installed on boiler.) Combination pressure-temperature gauge, with 2½...
  • Page 49 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 14 Replacement parts continued Figure 32 Controls Item Description Boiler model Part number number Natural gas components 511-044-381WT Gas valve, ½” x ½” GWA-038 through GWA-166 ¾ ¾ 511-044-382WT Gas valve, ”...
  • Page 50 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 15 Dimensions Figure 33 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return Gas connection “A” “D” “W” “H” model & manifold size Vent Vent Jacket Damper tappings tappings number location diameter width...
  • Page 51 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 16 Ratings AHRI Certified Ratings Seasonal 2,000-4,500 efficiency Chimney 0-2,000 feet altitude feet altitude Boiler Boiler Input Output Input Output water model Heating breeching N - L (Btuh) (Btuh) (Btuh) (Btuh) number Capacity Ratings...
  • Page 52 GWA Series 3 Gas-Fired Water Boilers – Boiler Manual 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. Ce- ramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”: o Avoid breathing dust and contact with skin and eyes.

This manual is also suitable for:

Gwa-038Gwa-067Gwa-100Gwa-133Gwa-166Gwa-200 ... Show all

Table of Contents