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
installing. 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 transportation
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 18.
GWA
Gas-Fired Water Boilers
Boiler Manual
Contents
1 Prepare boiler location ........................................................ 2
2 Prepare boiler ..................................................................... 6
3 Install water piping ............................................................ 10
4 Install gas piping ............................................................... 13
5 Field wiring ....................................................................... 14
6 Start-up ............................................................................ 15
7 Checkout procedure ......................................................... 18
8 Sequence of operation - standing pilot boilers ................. 19
9 Lighting instructions - GWA standing pilot boilers ........... 20
10 Service and maintenance ................................................. 22
11 Troubleshooting ................................................................ 27
12 Replacement parts ........................................................... 29
13 Dimensions ...................................................................... 34
14 Ratings ............................................................................. 35
Hazard definitions
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.
• 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
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 670 01 1001 00
Page
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Table of Contents
Related Manuals for ICP GWA 052
Summary of Contents for ICP GWA 052
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Page 1: Table Of Contents
Gas-Fired Water Boilers Boiler Manual Contents Page 1 Prepare boiler location ............2 2 Prepare boiler ..............6 3 Install water piping ............10 4 Install gas piping ............... 13 5 Field wiring ............... 14 6 Start-up ................15 7 Checkout procedure ............18 8 Sequence of operation —... -
Page 2: Prepare Boiler Location
GW A 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 substantial property damage. Installations must follow these codes: •... -
Page 3: Residential Garage Installation
GW A Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Clearances Service clearances Small space installations 1. Provide minimum clearances for cleaning and servicing the 1. When the boiler is located in a closet or small space, provide boiler and for access to controls and components as listed in clearances no less than those shown in Figure 1. -
Page 4: Vent System
GW A Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Vent system Failure to follow all instructions can result in flue gas Equipment”, of National Fuel Gas Code, ANSI Z223.1–latest spillage and carbon monoxide emissions, causing edition and applicable building codes. Canadian installations severe personal injury or death. -
Page 5: Air Openings
GW A Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air contamination Air openings Please review the following information on potential combustion air Combustion air and ventilation openings must comply with Section contamination problems. 5.3, “Air for Combustion and Ventilation”, of National Fuel Gas Code ANSI Z223.1–latest edition, or applicable local building codes. -
Page 6: Prepare Boiler
GW A Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air openings continued Exhaust fans and air movers Motorized air dampers The appliance space must never be under a negative pressure. If the air openings are fitted with motorized dampers, electrically Always provide air openings sized not only to the dimensions interlock the damper to: required for the firing rate of all appliances, but also to handle the air... - Page 7 GW A Gas-Fired Water Boilers – Boiler Manual 2 Prepare boiler continued Pressure test Perform hydrostatic pressure test Fill and pressure test Pressure test boiler before attaching water or gas piping or electrical 1. Open the shutoff valves you installed on supply and return supply (except as noted below).
- Page 8 GW A 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 or Draft hood installation vent with same size vent connector. 1.
- Page 9 GW A 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 Williamson-Thermoflo warranty.
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Page 10: Install Water Piping
GW A Gas-Fired Water Boilers – Boiler Manual 3 Install water piping General Near-boiler piping continued If installation is to comply with ASME or Canadian requirements, Table 4 Water pipe size (based on 20 °F rise) an additional high temperature limit is needed. Install control in supply Boiler model From piping between boiler and isolation valve. - Page 11 GW A 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 diaphragm-type or bladder-type expansion...
- Page 12 GW A 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.
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Page 13: Install Gas Piping
GW A Gas-Fired Water Boilers – Boiler Manual 4 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 rated a. -
Page 14: Field Wiring
GW A Gas-Fired Water Boilers – Boiler Manual 5 Field wiring Thermostat For your safety, turn off electrical power supply at service entrance panel before making any electrical 1. Connect thermostat as shown on wiring diagram on boiler. connections to avoid possible electric shock hazard. 2. -
Page 15: Start-Up
GW A Gas-Fired Water Boilers – Boiler Manual 6 Start-up Fill the system with water Preparation 1. Close manual and automatic air vents and boiler drain cock. Check for gas leaks 2. Fill to correct system pressure. Correct pressure will vary with each application. - Page 16 GW A Gas-Fired Water Boilers – Boiler Manual 6 Start-up continued Operate boiler Check system and boiler DO NOT proceed with boiler operation unless boiler and system have been filled with water and all Eliminate all system leaks. Continual fresh makeup instructions and procedures of previous manual water will reduce boiler life.
- Page 17 GW A Gas-Fired Water Boilers – Boiler Manual 6 Start-up continued Verify operation Check burner flames — Main burner Check the pilot ignition system used for the boiler. The boiler model suffix will contain an “S” for standing Proper main burner flame (see Figure 13): pilot or an “I”...
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Page 18: Checkout Procedure
GW A Gas-Fired Water Boilers – Boiler Manual 7 Checkout procedure Boiler and heat distribution units filled with water? gas valve. Manometer should confirm there is no gas flow. Pilot will relight, flame sensing element will sense Automatic air vent, if used, open one full turn? pilot flame and main burners reignite. -
Page 19: Sequence Of Operation - Standing Pilot Boilers
GW A Gas-Fired Water Boilers – Boiler Manual Part Number 670 01 1001 00... -
Page 20: Lighting Instructions - Gwa Standing Pilot Boilers
GW A Gas-Fired Water Boilers – Boiler Manual 9 Lighting Instructions — GWA standing pilot boilers Honeywell VR8200/VR8300 gas valve FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. - Page 21 GW A Gas-Fired Water Boilers – Boiler Manual 9 Lighting Instructions — GWA standing pilot boilers Robertshaw 7200 gas valve FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
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Page 22: Service And Maintenance
GW A Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance Table 6 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: Daily • Check boiler area •... -
Page 23: Handling Ceramic Fiber And Fiberglass Materials
GW A Gas-Fired Water Boilers – Boiler Manual 10 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 24 GW A Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance continued The boiler should be inspected and started annually, Inspect ..at the beginning of the heating season, only by a qualified service technician.
- Page 25 GW A Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance continued Service..Check/test..Oiled-bearing circulators Air vents and air elimination 1.
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Page 26: Review With Owner
GW A Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance continued 2. After following the preceding warning directions, if the relief valve Check/test..continued weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not Diaphragm- or bladder-type —... -
Page 27: Troubleshooting
GW A Gas-Fired Water Boilers – Boiler Manual 11 Troubleshooting In event of vent damper failure: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and Effikal vent damper dangerous operation. Never jumper (bypass) rollout thermal fuse element If troubleshooting chart recommends replacing actuator and actuator or any other device except for momentary testing as is not immediately available, damper blade can be fixed in an open... - Page 28 GW A Gas-Fired Water Boilers – Boiler Manual 11 Troubleshooting continued Chart 1 — Standing pilot — Boiler will not fire Before proceeding, follow "Troubleshooting sequence" on page 27. If problem persists, then: Is damper harness securely plugged in at both ends? Secure connections.
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Page 29: Replacement Parts
GW A Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts Figure 16 Section assembly, flue collector, draft hood and vent damper Item Description International Item Description International number Comfort number Comfort Products Products part number part number not shown Replacement GWA052 321114501WT High limit, 30°... - Page 30 GW A Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts continued Figure 17 Base assembly, manifold, orifices and burners It em D esc ript ion Int ernat ional number C omfort Produc t s part number Base assembly kit GWA052 &...
- Page 31 GW A Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts continued Figure 18 Jacket assembly Item Description International Item Description International number Comfort number Comfort Products Products part number part number Junction box, 4 x 4 Jacket GWA052 & GWA070 431223433WT panel, top GWA105...
- Page 32 GW A Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts continued Figure 19 Trim assembly Item Description Manufacturer Manufacturer’s International Comfort number part number Products part number Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Conbraco 10-407-10 511546920WT Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾"...
- Page 33 GW A Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts continued Figure 20 Gas control assembly It em D esc ript ion Manuf ac t urer Manuf ac t urer’s Int ernat ional number part number C omfort Produc t s part number St anding pilot —...
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Page 34: Dimensions
GW A Gas-Fired Water Boilers – Boiler Manual 13 Dimensions Figure 21 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return Gas connection “A” “D” “W” “H” model tapping tapping & manifold size Vent Vent Jacket Damper number (inches NPT) (inches NPT) (Note 3) location... -
Page 35: Ratings
GW A Gas-Fired Water Boilers – Boiler Manual 14 Ratings Boiler 0–2,000 feet altitude 2,000–4,500 feet altitude Boiler Chimney model (Canada) I=B=R water Seasonal number ratings content efficiency breeching (Btuh) (gallons) (% A.F .U.E) size Input DOE Heating Capacity Input Output (Btuh) (Output) (Btuh) - Page 36 GW A Gas-Fired Water Boilers – Boiler Manual Part Number 670 01 1001 00...
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