Table of Contents
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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 in-
stalling. Read page 2 first. Follow all instructions
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 21.
G W I
Gas-Fired Water Boilers
Boiler Manual
Contents
1 Prepare boiler location ....................................................... 2
2 Prepare boiler ..................................................................... 6
3 Vent installation .................................................................. 7
4 Install water piping ............................................................ 13
5 Install gas piping ............................................................... 16
6 Field wiring ....................................................................... 17
7 Start-up ............................................................................ 18
8 Checkout procedure ......................................................... 20
9 Department of Energy Compliance .................................. 21
9a Sequence of operation ..................................................... 22
10 Operating instructions ...................................................... 26
11 Service and maintenance ................................................. 27
12 Troubleshooting ................................................................ 31
13 Replacement parts ........................................................... 41
14 Dimensions ....................................................................... 46
15 Ratings ............................................................................. 47
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
Series 2
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 550-142-785/0812
Page
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Table of Contents
Related Manuals for Williamson Series 2
Summary of Contents for Williamson Series 2
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Page 1: Table Of Contents
G W I Series 2 Gas-Fired Water Boilers Boiler Manual Contents Page 1 Prepare boiler location ............2 2 Prepare boiler ..............6 3 Vent installation ..............7 4 Install water piping ............13 5 Install gas piping ............... 16 6 Field wiring ............... -
Page 2: Series
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual Read this first! 1 Prepare boiler location Failure to adhere to the guidelines below can Codes & checklist result in severe personal injury, death or sub- stantial property damage. Installations must follow these codes: The boiler contains ceramic fiber and fiber- •... -
Page 3: Residential Garage Installations
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Clearances Service clearances Residential garage installations 1. Provide minimum clearances for cleaning and servicing the Take the following special precautions when installing the boiler in boiler and for access to controls and components as listed in a residential garage, per ANSI Z223.1, paragraph 5.1.9:... -
Page 4: Vent System
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Vent system Failure to follow all instructions can result in flue gas Chimney draft vent requirements spillage and carbon monoxide emissions, causing 1. Venting must be installed according to Part 7, Venting of severe personal injury or death. -
Page 5: Air Openings
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air contamination Air openings Please review the following information on potential combustion Combustion air and ventilation openings must comply with Sec- tion 5.3, “Air for Combustion and Ventilation”, of National Fuel air contamination problems. -
Page 6: Prepare Boiler
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air openings continued Exhaust fans and air movers Motorized air dampers If the air openings are fitted with motorized dampers, electrically The appliance space must never be under a negative pressure. -
Page 7: Vent Installation
3 Vent installation GWI venting options The GWI boiler can be vented using one of the following methods: b. Double-wall metal vent (B-vent) or chimney with liner approved by the National Fuel Gas Code, ANSI Z223.1–latest edition, Use only the vent materials and methods outlined or in Canada B149.1 or B149.2 Installation Code. - Page 8 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 3 Vent installation continued Chimney draft venting Inspect existing chimney before installing boiler. 1. Use doublewall metal vent (B-vent) or chimney with liner as Failure to clean or replace perforate pipe or lining required by the National Fuel Gas Code, ANSI Z223.1–latest...
- Page 9 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 3 Vent installation continued Direct exhaust venting 1. Select a vent pipe manufacturer from separate GWI Vent Obtain vent system components Component Supplement and obtain all vent components 1. The following special gas vent systems comply with UL-1738 needed, based on boiler location and venting method.
- Page 10 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 3 Vent installation continued Direct exhaust venting continued Vent termination location Figure 4 Maintain minimum clearances from public walkways and building air openings Follow instructions on this page when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.
- Page 11 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 3 Vent installation continued Direct exhaust venting continued • Elbow and termination coupling with screen (not available Installing direct exhaust vent and termination for StaR-34). 1. Do not mix types or manufacturers of vent materials.
- Page 12 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 3 Vent installation continued Direct exhaust venting continued Using any termination other than one of those shown Figure 8 Sidewall vent termination options and could cause nuisance outages and loss of heat, installation requirements resulting in substantial property damage.
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Page 13: Install Water Piping
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 4 Install water piping 4 Install water piping Table 6 Water pipe size (based on 20 °F rise) General Boiler From If installation is to comply with ASME or Canadian requirements,... - Page 14 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 4 Install water piping continued Use Figure 9 or Figure 10 only for systems designed Figure 9 Diaphragm- or bladder-type expansion tank: for return water at least 130 °F. For systems with...
- Page 15 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 4 Install water piping continued Near-boiler piping continued Figure 12 System bypass piping in boiler loop with Figure 13 Boiler bypass piping — use only for high separate system circulator, using primary/ water content systems —...
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Page 16: Install Gas Piping
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 5 Install gas piping Failure to apply pipe dope as described in this Connecting gas supply piping to boiler manual can result in severe personal injury, death or substantial property damage. -
Page 17: Field Wiring
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 6 Field wiring For your safety, turn off electrical power supply at page 24 and 25, for anticipator setting. For other devices, see service entrance panel before making any electrical manufacturer’s specifications. Wiring diagram on boiler gives connections to avoid possible electric shock hazard. -
Page 18: Start-Up
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 7 Start-up Preparation 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. - Page 19 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 7 Start-up continued Operate boiler THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST DO NOT proceed with boiler operation unless boiler ONE OF THE FOLLOWING CONDITIONS IS TRUE: and system have been filled with water and all in- structions and procedures of previous manual sec- •...
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Page 20: Checkout Procedure
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 7 Start-up 8 Checkout procedure continued Boiler and heat distribution units filled with water? ❏ Verify operation ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? Check burner flame —... -
Page 21: Department Of Energy Compliance
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 8 Checkout procedure continued ❏ rating label. Set room thermostat to desired room temperature. ❏ Check manifold gas pressure by connecting manometer to ❏ Fill in “Installation and service certificate” below? downstream test tapping on main gas valve. -
Page 22: Sequence Of Operation
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 9a Sequence of operation Follow all procedures given in this manual and “Operating Instructions” when operating the boiler. Failure to do so could result in severe personal injury, death or substantial property damage. - Page 23 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 9a Sequence of operation Figure 18 Control module sequence of operation — status light indications Part Number 550-142-785/0812...
- Page 24 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 9a Sequence of operation continued Figure 19 Schematic wiring diagram Part Number 550-142-785/0812...
- Page 25 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 9a Sequence of operation continued Figure 20 Ladder wiring diagram Part Number 550-142-785/0812...
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Page 26: Operating Instructions
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 10 Operating instructions FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result caus- ing property damage, personal injury or loss of life. -
Page 27: Service And Maintenance
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance Table 8 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 •... - Page 28 GWI Series 2 Gas-Fired Water Boilers – 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 48 of this manual. Failure to comply could result in severe personal injury.
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Page 29: Temperature Sensor
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance continued ❏ Service ❏ Check/test Inducer motor 2. The cap must be unscrewed one turn to allow air to escape. 1. With boiler power OFF, place a few drops of S.A.E. 20 motor 3. -
Page 30: Review With Owner
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance continued ❏ Check/test ❏ Review with owner 1. Review the User’s Information Manual with the owner. Boiler relief valve 2. Emphasize the need to perform the maintenance schedule 1. -
Page 31: Troubleshooting
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting Label all wires prior to disconnection when servic- Figure 21 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 32 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting – components (continued) Temperature sensor INDICATOR LIGHT CONDITION POWER 1. The boiler temperature sensor is a resistance-type device. Flashes once per second 120 VAC connection to 2. The Chart below shows the correct value for the sensor at boiler reversed.
- Page 33 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting – components (continued) Figure 23 Control module connections Part Number 550-142-785/0812...
- Page 34 GWI Series 2 Gas-Fired Water Boilers – 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 35 GWI Series 2 Gas-Fired Water Boilers – 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 36 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting continued CHART 3 — PURGE & 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 37 GWI Series 2 Gas-Fired Water Boilers – 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 38 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting continued CHART 5 — PURGE 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 39 GWI Series 2 Gas-Fired Water Boilers – 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 40 GWI Series 2 Gas-Fired Water Boilers – 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.
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Page 41: Replacement Parts
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts Figure 24 Section assembly, flue collector, draft hood and vent damper Item number Description Part number GWI-047 & GWI-063 not shown Replacement section assembly 321-114-345WT GWI-095 321-114-346WT GWI-127... - Page 42 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 25 Base assembly, manifold, orifices and burners Item Description Part number number Base assembly kit GWI-047 & GWI-063 381-354-800WT (includes base panels items GWI-095 381-354-801WT GWI-127...
- Page 43 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 26 Jacket assembly Item Description Part number Part number Item Description Part number number number Junction box, 2 x 4 GWI-047 & GWI-063 Jacket 431-223-439WT (Available at local supply house)
- Page 44 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 27 Trim assembly Item Description Manufacturer Manufacturer’s Part number number part number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet Conbraco 10-407-05 511-546-920WT M330 Watts Pressure relief valve, ASME, 30 PSIG, ¾”...
- Page 45 GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 28 Gas control assembly Item Boiler model Manufacturer’s Part description Manufacturer Part number number number part number Ignition Control United Technologies 11135-611 381330099WT Honeywell VR8204A-2001 Gas valve, ½” x ½”, Natural gas...
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Page 46: Dimensions
GWI Series 2 Gas-Fired Water Boilers – Boiler Manual 14 Dimensions Figure 29 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return “W” model tapping tapping connection size manifold size Jacket number width (inches NPT) (inches NPT) (Note 3) -
Page 47: Ratings
GWI boilers are CSA design certified for installation on combustible flooring. GWI boilers are ASME rated for 50 psig working pressure. -
Page 48: Handling Ceramic Fiber And Fiberglass Materials
GWI Series 2 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. Ceramic 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...
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