Table of Contents
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GL
Model
Indirect-Fired Water Heaters
Product Manual
• Installation
• Startup
User —
Read important user safety information
found on page 3, page 24 and page 25. Installation
and service should only be performed by a qualified
service technician. Retain this manual for future
reference.
This manual must only be used by a qualified heating
installer/service technician. BEFORE installing, read
all instructions in this manual and all other informa-
tion shipped with the water heater. Perform steps in
the order given. Failure to comply could result in
severe personal injury, death or substantial property
damage.
• Maintenance
• Parts
®
Part number GL-E224-ADOC 0413
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Summary of Contents for Williamson-Thermoflo GL
- Page 1 BEFORE installing, read all instructions in this manual and all other informa- tion shipped with the water heater. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. Part number GL-E224-ADOC 0413...
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Page 2: Table Of Contents
Wiring options ......20 Use domestic priority ..... . . 20 Part number GL-E224-ADOC 0413... -
Page 3: Please Read Before Proceeding
— less than 6 grains/gal. operation guidelines for Williamson- • pH — above 6 and less than 8. Thermoflo Model GL indirect water • chlorides — less than 200 ppm. heaters. The installer is responsible for Boiler water restrictions... -
Page 4: Pre-Installation
• in Canada — B149.1 or B149.2 Installation Code. 2. GL water heaters are exempt from ASME Section VIII, Division 1 Code construction per Interpre- tation VIII-1-86-136. Check with local codes for applicability. 3. Where recommendations in this manual differ from local or national codes, local or national codes take precedence. -
Page 5: Domestic Water Piping Requirements
Direct water flow away from any person. Protection must be taken against excessive tem- perature and pressure! — Installation of a tem- perature & pressure (T&P) relief valve (provided with water heater) and a thermostatic mixing valve (provided by installer) is required. Part number GL-E224-ADOC 0413... -
Page 6: Domestic Water Piping
100 feet. See page 8 for details. Figure 3 Piping connection sizes Connections (inches NPT) Model Boiler water Recirculation in/out in/out tapping ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ Part number GL-E224-ADOC 0413... - Page 7 • The anode is specially made for this water heater. Use valve. A thermal expansion tank is also required. only the anode available from Williamson-Thermoflo, as listed in Replacement parts. This symbol, where used in this manual, indicates the item is required by Massachusetts code.
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Page 8: Recirculation
2. See Figure 6, page 10 for the piping required to the water strainer as shown in Figure 5, page 9. heater. b. Check local codes for specific installation require- ments. — Continued on page 10 — Part number GL-E224-ADOC 0413... - Page 9 Fixture flow rate (GPM) - Piping length (feet) - Copper pipe ½” ¾” Steel pipe ½” ¾” CPVC pipe ½” ¾” NOTE: Select branch size and length for less than 31 seconds delay. Figure 5 Recirculation components Part number GL-E224-ADOC 0413...
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Page 10: Components
Recirculated water through cold port, hot water through hot port. 4. Aquastat reaches temperature — Circulator is off. There is no flow through #3, #4, #5 or #6. 5. Circulator too small — Mixing valve performance erratic. Part number GL-E224-ADOC 0413... -
Page 11: Boiler-Side Piping
Do NoT apply the drawings in 2. See boiler manual for spe- this manual. Refer only to the cific details on installing 1” 1¼” * boiler manual. the boiler. 1” Requires 1¼”x1” reducers at water heater Part number GL-E224-ADOC 0413... - Page 12 Do NoT apply the drawings in 2. See boiler manual for spe- this manual. Refer only to the cific details on installing 1” 1¼” * boiler manual. the boiler. 1” Requires 1¼”x1” reducers at water heater Part number GL-E224-ADOC 0413...
- Page 13 Do NoT apply the drawings in 2. See boiler manual for spe- this manual. Refer only to the cific details on installing 1” 1¼” * boiler manual. the boiler. 1” Requires 1¼”x1” reducers at water heater Part number GL-E224-ADOC 0413...
- Page 14 Do NoT apply the drawings in 2. See boiler manual for spe- this manual. Refer only to the cific details on installing 1” 1¼” * boiler manual. the boiler. 1” Requires 1¼”x1” reducers at water heater Part number GL-E224-ADOC 0413...
- Page 15 The installer is responsible for proper sizing / selection of all hardware shown on this diagram. 2. See boiler manual for spe- cific details on installing the boiler. Part number GL-E224-ADOC 0413...
- Page 16 T-T terminals. 3. Install automatic mixing valve at either the system hot water connection or at each water heater. 4. See page 8 through page 10 for additional recircula- tion information and pip- ing details. Part number GL-E224-ADOC 0413...
- Page 17 / selection of all hardware shown on this diagram. 2. See boiler manual for spe- GWC boilers cific details on installing Do NoT apply the drawings in this manual. Refer only to the boiler manual. the boiler. Part number GL-E224-ADOC 0413...
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Page 18: Connecting To A Low-Pressure Steam Boiler
1. Follow the procedure given in Figure 16, page 19 to fill the water that the strainer is restricting circulator heater piping. flow, causing cavitation. 2. Follow the boiler manual instructions to fill the steam boiler. Part number GL-E224-ADOC 0413... -
Page 19: Filling The Piping
Step 12 Continue checking under varying drain. Let water run until all air has the boiler. been removed from the line. Close DHW demand conditions to ensure valve 4. Then close valve 3. system will operate as required. Part number GL-E224-ADOC 0413... -
Page 20: Boiler-Side Wiring And Controls
Field wiring terminal block Wiring options 1. This manual shows wiring only for use of circulator zone controllers or zone valve zone controllers. 2. Other wiring methods may be acceptable and are left to the installer. Part number GL-E224-ADOC 0413... -
Page 21: Wiring - Zoning With Circulators
/ selection of all hardware shown on this diagram. 2. Follow component manu- facturer’s instructions for installation of all items shown. 3. See boiler manual for spe- cific details on installing the boiler. Part number GL-E224-ADOC 0413... -
Page 22: Wiring - Zoning With Zone Valves
/ selection of all hardware shown on this diagram. 2. Follow component manu- facturer’s instructions for installation of all items shown. 3. See boiler manual for spe- cific details on installing the boiler. Part number GL-E224-ADOC 0413... -
Page 23: Water Heater Filling And Start-Up
Higher flow rates could result in an input above the rating of the ❏ ❏ Start boiler according to the Boiler Manual. T&P valve. Models GL-32, 42 and 52 — do not exceed 12 GPM. • Verify that the boiler and water heater are operating ❏ ❏... -
Page 24: Water Heater Temperature Adjustment
Direct water flow away from any person. Protection must be taken against excessive tem- perature and pressure! — Installation of a tem- perature & pressure (T&P) relief valve (provided with water heater) and a thermostatic mixing valve (provided by installer) is required. Part number GL-E224-ADOC 0413... -
Page 25: Water Heater Maintenance
Check valves, pipes and fittings for leaks. Read page 3 and verify that all requirements are met by the ❏ ❏ Check function of all controls and valves (see con- installation. trol manufacturer’s instructions). Review homeowner’s maintenance responsibilities ❏ ❏ Part number GL-E224-ADOC 0413... -
Page 26: Inspect Anode And Water Heater Interior
If boiler water does not contain sufficient antifreeze, inspection plate. Align the gasket carefully. DO NOT over-tighten then the boiler water and the domestic water must the bolts. This could damage the gasket or distort the plate. be drained. Part number GL-E224-ADOC 0413... -
Page 27: Troubleshooting
Know the boiler manufacturer and model number. ❏ ❏ ❏ ❏ Have the boiler manual and wiring and piping schematics readily available. ❏ ❏ Get the latest revisions from www.Williamson-Thermoflo.com. Review all manuals before leaving for the jobsite. ❏ ❏ Part number GL-E224-ADOC 0413... -
Page 28: Hot Water
Check for leaks from sources other Loose piping connections? Top of tank or than the water heater. insulation wet Water smells like “rotten eggs.” Discolored water from the hot Water quality water faucet. Milky water. problems Part number GL-E224-ADOC 0413... - Page 29 • Is the boiler piping to the water heater properly sized to allow the required flow rate for maximum BTU transfer? The temperature differential of the boiler supply and return water should be 20°F to 30°F. Part number GL-E224-ADOC 0413...
- Page 30 During a call for heat by the water heater, does the boiler circulator begin pumping, does the zone valve open, does the boiler fire? Check every component in the system to ensure they are properly functioning. Part number GL-E224-ADOC 0413...
- Page 31 A dirty boiler system can cause deposits to form on the water heater coil. This insulates the coil, reducing the heat transfer. • Clean the boiler system per the boiler manufacturer’s instructions. • Install a strainer in the boiler piping on older installations or for systems likely to carry sediment. Part number GL-E224-ADOC 0413...
- Page 32 Installing a thermostatic mixing valve will provide uniform delivery temperature with minimal regard to water usage. 3 Install a recirculation loop. • Installing a properly-sized recirculation loop not only provide prompt delivery of hot water, but it will provide circulation and mixing of the water within the tank. Part number GL-E224-ADOC 0413...
- Page 33 3 Faulty boiler relief valve? • Is the boiler pressure relief valve functioning properly? Dirt and water deposits can accumulate under the valve seat. 4 Faulty boiler fill valve? • Is the valve filling to the correct pressure? Part number GL-E224-ADOC 0413...
- Page 34 If the boiler operating temperature is too high, stacking can occur in the water heater raising the domestic water tempera- ture close to the boiler operating temperature. — Reduce the boiler operating temperature to 180°F. Also follow page 32 suggestions if the problem persists. Part number GL-E224-ADOC 0413...
- Page 35 • If water is leaking from around one of the tank connections, a weld may have been broken. Contact your Williamson-Thermoflo supplier to determine how to handle the problem. Top of tank or insulation wet 1 Check for leaks from sources other than the water heater •...
- Page 36 “Operating restrictions,” page 3. Failure to inspect the anode regularly and replace if necessary could result in damage to the water heater, causing possible severe personal injury, death or substantial property damage. Part number GL-E224-ADOC 0413...
- Page 37 When air and gases are forced out of the heated water, the problem may be evident in one or both of the following conditions: • Gases, in the form of small bubbles, may make the water appear milky from the tap, but clear after several minutes when those bubbles will separate. Part number GL-E224-ADOC 0413...
- Page 38 Fl ( fluorides) added in treatment in large cities • Elevated levels of iron, manganese, and sulfur. • If the pH is high or low, this has a major effect on the metal tanks, piping and heat transfer surfaces. Part number GL-E224-ADOC 0413...
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Page 39: Replacement Parts
Inspection plate replacement kit 633500045WT Inspection hatch cover replacement 633500047WT ¾” 633500064WT Fitting grommet 1” 633500037WT Anode cover 633500048WT 633500059WT 633500060WT Jacket replacement kit 633500061WT 633500062WT 633500063WT Mixing valve kit, 1" 633500012WT Part number GL-E224-ADOC 0413... -
Page 40: Ahri Ratings
180°F boiler water entering | 58°F to 135°F domestic water Model Minimum Minimum First Hour Continuous Heat Source First Draw Standby Heat Output Heat Source Rating Draw Rating Friction Loss Rating Loss Rate Flow Rate Degrees F Btu/hr Feet w.c. per hour Part number GL-E224-ADOC 0413... -
Page 41: Ratings With 200°F Boiler Supply Water
4.2 ft wc 6.6 ft wc 8 GPM 8 GPM 8 GPM 14 GPM 14 GPM minimum minimum minimum minimum minimum 1.6 ft wc 1.6 ft wc 2.9 ft wc 4.2 ft wc 6.6 ft wc Part number GL-E224-ADOC 0413... -
Page 42: Ratings With 190°F Boiler Supply Water
4.2 ft wc 6.6 ft wc 8 GPM 8 GPM 8 GPM 14 GPM 14 GPM minimum minimum minimum minimum minimum 1.6 ft wc 1.6 ft wc 2.9 ft wc 4.2 ft wc 6.6 ft wc Part number GL-E224-ADOC 0413... -
Page 43: Ratings With 180°F Boiler Supply Water
4.2 ft wc 6.6 ft wc 8 GPM 8 GPM 8 GPM 14 GPM 14 GPM minimum minimum minimum minimum minimum 1.6 ft wc 1.6 ft wc 2.9 ft wc 4.2 ft wc 6.6 ft wc Part number GL-E224-ADOC 0413... -
Page 44: Dimensions
Model GL — Product Manual indirect fired water heaters Dimensions Figure 25 Dimensions and ratings — Model GL indirect-fired water heaters Boiler water inlet (see table for size) Boiler water outlet (see table for size) Cold domestic water inlet (see table for size)
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