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American Standard TGBWF090A93AVA Installation Manual

Natural draft, gas fired water boiler with electronic ignition and cast iron heat exchanger
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INSTALLATION GUIDE

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property and is to remain with this unit. Please
return to service information pack upon completion of work.
*GBWF090A93AVA
*GBWF130A94AVA
*GBWF173A95AVA
*GBWF215A96AVA
*May be "A" or "T"
Natural Draft, Gas Fired Water Boiler with
Electronic Ignition and Cast Iron Heat
Exchanger
© 2007 American Standard Inc. All Rights Reserved
®
C
US
18-CG01D1-4

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Summary of Contents for American Standard TGBWF090A93AVA

  • Page 1: Installation Guide

    *GBWF090A93AVA *GBWF130A94AVA *GBWF173A95AVA *GBWF215A96AVA *May be “A” or “T” Natural Draft, Gas Fired Water Boiler with Electronic Ignition and Cast Iron Heat Exchanger ® © 2007 American Standard Inc. All Rights Reserved 18-CG01D1-4...

  • Page 2: Safety Considerations

    1.0 Safety Considerations ▲ ▲ WARNING IMPORTANT: Read this entire manual before FIRE OR EXPLOSION HAZARD. beginning installation procedures. TURN OFF MAIN GAS VALVE BEFORE INSTAL- Read this manual carefully before attempting to LING, PERFORMING MAINTENANCE OR SERVI- install, operate, or perform maintenance on this CING A BOILER.
  • Page 3 ▲ ▲ The following warning complies with State of California law, Proposition 65. WARNING ▲ WARNING BURN HAZARD HAZARDOUS GASES! ALLOW BOILER TO COOL DOWN PRIOR TO EXPOSURE TO FUEL SUBSTANCES OR BY-PRODUCTS SERVICING OR PERFORMING MAINTENANCE. OF INCOMPLETE FUEL COMBUSTION IS BELIEVED BY FAILURE TO FOLLOW THIS WARNING COULD THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH RESULT IN SERIOUS INJURY, DEATH, OR PRO-...

  • Page 4: Cautions

    ▲ ▲ 1.2 CAUTIONS WARNING ▲ ▲ CAUTION If the information in this manual is not followed exactly, a fire or explosion may result causing property Do NOT install the boiler in a corrosive or contamina- damage, personal injury or loss of life. ted atmosphere.

  • Page 5: Table Of Contents

    Table of Contents 1.0 Safety Considerations ................2 1.1 Warnings .........................2 1.2 Cautions ........................4 2.0 Pre-Installation Information & Instructions ..........6 2.1 Parts Included ......................6 2.2 General Specifi cations ..................7 2.3 Codes and Regulations ..................8 2.4 Locations and Clearances ..................8 2.5 Outline Drawings ....................9 3.0 Installation Instructions ................

  • Page 6: Pre-Installation Information & Instructions

    OWNER SERVICE SUPPLY WATER PRESSURE ALERT THERMOSTAT TEMPERATURE (IGNITION LOCKOUT) SERVICE DISCONNECT SWITCH GAUGES COVER PLATE FOR FUTURE OPTIONAL ACCESSORY WATER TEMPERATURE LOCKOUT - WATER TEMP POWER SETTING °F WATER PRESSURE SERVICE REQUIRED OFF - ON DRAFTHOOD SPILL SWITCH BLANK °F INTENTIONALLY (BEHIND PANEL IN CONTROL BOX)

  • Page 7: General Specifi Cations

    2.2 General Specifi cations - Table 1 Product Specifi cations Model *GBWF090 *GBWF130 *GBWF173 *GBWF215 Ratings Input BTUH 90,000 130,000 173,000 215,000 DOE Output BTUH 76,000 111,000 145,000 180,000 Net I=B=R® Output BTUH 66,000 96,000 126,000 156,000 AFUE 83.6 83.5 83.4 83.3 Natural Gas Supply...

  • Page 8: Codes And Regulations

    ▲ ▲ 2.3 Codes & Regulations WARNING The manufacturer requires installation and services WATER SAFETY HAZARD be in compliance with all applicable codes. DO NOT USE THIS UNIT IF ANY PART HAS Codes and local utility requirements governing the BEEN UNDER WATER. IMMEDIATELY CALL installation of gas fi...

  • Page 9: Outline Drawings

    b) Minimum Clearances Table 2 Minimum Clearance Clearance for Service for Combustion NOTES: 6” 36” 1. Leave clearance on Right Side 6” See Note 1 one side of the boiler Left Side 6” See Note 1 for service access to Front 18”...

  • Page 10: Installation Instructions

    of the crate can then be lifted off of the boiler. 3.0 Installation Instructions See Figures 3 and 4. 3.1 Moving and Uncrating the Boiler If the boiler can not be moved with crate ▲ ▲ assembled, uncrate the boiler and use an WARNING appliance dolly to move the boiler to the selected location.

  • Page 11: Leveling Boiler

    3.3 Leveling the Boiler 1. Locate the leveling feet (4) shipped in a bag with Figure 5 the boiler. 2. Use discarded crating material as a safety block. Tilt the boiler toward the front and place a safety block under the rear of the boiler, locating it about 1/3 of the way toward the front of the boiler.

  • Page 12: Water Connections And Piping

    3.4 Water Connections and Piping Minimum boiler return temperature is 110°F. Systems Overview NOTE: Do not use the water system pipes to ground For good operation and long life of the boiler, the electrical appliances. piping system must be well proportioned and always complete with all those accessories that provide System Water optimum system performance, highest effi...
  • Page 13 ▲ ▲ WARNING Isolation Valves SAFETY HAZARD. It is advisable to install isolation valves between the PRESSURE RELIEF VALVE OUTLET MUST BE boiler and heating system and on the inlet and outlet ROUTED TO WITHIN 6” OF A FLOOR DRAIN OR side of all hydronic system components for service.

  • Page 14: Typical System Piping Diagrams

    3.4 Typical System Piping Diagram 18-CG01D1-4...
  • Page 15 18-CG01D1-4...
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  • Page 18: Combustion Air And Ventilation

    3.6 Combustion Air and Ventilation TABLE 4 Minimum Area in Square Feet for Unconfi ned Important: All aspects of the installation of this Space Installations boiler, including materials, methods of providing combustion air and methods of venting products of Boiler Maximum With 8 Foot Ceiling combustion to the outdoors must comply with all BTUH / Input Rating...

  • Page 19: General Venting Instructions

    3. The following types of installations will require use Figure 12 of OUT DOOR AIR for combustion, due to chemi- cal exposures: * Commercial buildings * Buildings with indoor pools * Boilers installed in commercial laundry rooms * Boilers installed in hobby or craft rooms * Boilers installed near chemical storage areas.
  • Page 20 VENT PIPING TABLE 6 ▲ ▲ Gas Vent Termination WARNING Roof Pitch Minimum Height CARBON MONOXIDE, FIRE, AND/OR SMOKE Flat to 7/12 1.0 Feet* HAZARD CARBON MONOXIDE, FIRE, OR SMOKE CAN Over 7/12 to 8/12 1.5 Feet CAUSE SERIOUS BODILY INJURY, DEATH, AND/ Over 8/12 to 9/12 2.0 Feet OR PROPERTY DAMAGE.

  • Page 21: Auto Vent Damper Instructions

    EXPLANATION OF EFFIKAL VENT DAMPER 3.8 Automatic Vent Damper Installation MODEL NUMBERS R =Redundant ▲ ▲ WARNING V = Valve G = Gas WARNING EXPLOSION HAZARD P = Plug In at Damper INSTALL THE VENT DAMPER TO SERVICE ONLY KS = Circuit Board Model THE SINGLE BOILER FOR WHICH IT IS INTEN- DED.
  • Page 22 9. A minimum clearance of 6 inches (153mm) NOTE: THE DAMPER MUST BE IN THE OPEN between the damper device and combustible con- POSITION BEFORE COMBUSTION TAKES struction must be maintained and that there be pro- PLACE. THE DAMPER MUST BE IN THE OPEN visions for access and service of the damper device.
  • Page 23 5. The motorized controller is premounted to the INSTALLING THE AUTOMATIC VENT stainless steel pipe assembly. Make sure the con- DAMPER ▲ ▲ troller is secured to the pipe assembly. The fl at rod WARNING must be engaged into the slot of the CAM. This slot ELECTRICAL SHOCK HAZARD protrudes through the base plate of the controller.
  • Page 24 ▲ ▲ WARNING FIGURE 19 FLUE GAS DO NOT USE THE EFFIKAL DAMPERS WITH FLOW DIRECTION ARROW POINTS UP HONEYWELL L8148 OR L8124 WITH MAN/ AUTO SWITCH BECAUSE THE SWITCH CAN MAKE SURE OVERRIDE THE SAFETY INTERLOCKS IN THE FOR VERTICAL MOTOR IS INSTALLATION OVER SYSTEM WIRING, CAUSING A HAZARDOUS...
  • Page 25 IMPORTANT: If either the main inlet or FIGURE 21 outlet of the gas valve is disconnected for any reason, the fl at sealing ring gasket SECURE WITH POP RIVETS located between the gas valve and the pipe OR SCREWS 3 IN EACH must be replaced with a new fl...

  • Page 26: Gas Connections

    3.9 Gas Connections Figure 22 The following warning complies with the state of California law, Proposition 65. ▲ ▲ WARNING HARAZDOUS GAS WARNING EXPOSURE TO FUEL SUBSTANCES OR BY-PRO- DUCTS OF INCOMPLETE FUEL COMBUSTION IS BELIEVED BY THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

  • Page 27: Lp Gas Conversion

    3.10 LP Conversion The boiler ships confi gured to burn Natural Gas (NG). To convert to LP use conversion kits as follows in Tables 9 and 10. Table 9 Boiler Model # LP Conversion kit Part Number *GBWF090A93AVA BAYLPK01AWBLRA *GBWF130A94AVA BAYLPK01AWBLRA *GBWF173A95AVA BAYLPK01AWBLRA...
  • Page 28 electronic control unit Honeywell gas valve Diminue Honeywell Alert Augmente RESET Key for Figure 26 Inlet pressure port Outlet pressure port Natural Gas / LP Regulator Cover “STEP” regulator - Natural Gas. Liquid Propane dial Manifold Gas Pressure Adjustment Cover Gas pressure adjustment screw Natural gas g20-G25...
  • Page 29 Disconnect pilot gas supply tube, fl ame sensor Replace the natural gas pilot orifi ce with the wire, and ground wire from the pilot and ignitor liquid propane pilot orifi ce shipped in the LP assembly. See Figures 27. conversion kit. See Figire 27. Carefully remove the screws holding the pilot Reattach the pilot gas tube, fl...

  • Page 30: High Altitude Derate

    3.11 High Altitude Derate This boiler is designed to operate up to altitudes of 2000 feet without any adjustments. At altitudes from 2000 to 4500 feet, the manifold pressure must be adjusted according to the table. Table 11 shows the maximum manifold pressures for both natural gas and propane gas at the varying altitudes.

  • Page 31: Optional Manual Reset Water Temperature Limit Installation

    Steps to remove the existing auto-reset water tempe- 3.13 Installation Instructions for rature limit switch. replacing the Factory Installed 1. Open the control panel and locate the existing Automatic-reset Water Temperature auto-reset water temperature limit. See Figures 32 and 33. Limit with the Optional Manual Reset Water Temperature Limit Accessory Figure 32...
  • Page 32 3. Remove the wires from the existing auto-reset 6. Remove the cable ties to isolate and remove the water temperature limit. See Figure 35. capillary tube of the existing auto-reset water tempe- rature limit switch. See Figure 38. Figure 35 Figure 38 4.
  • Page 33 8. Locate the capillary tube of the existing auto- 2. In a similar manner, remove the locking nut from reset water temperature limit and remove it from the the new manual reset water temperature limit. See strain relief clamp. See Figure 40. Figure 42.
  • Page 34 4. Center the reset button in the hole and secure 6. Attach the wires removed earlier from the auto- with a locking nut. Use needle nose pliers. See reset water temperature limit to the new manual Figure 44. water temperature limit. See Figure 46. Figure 44 5.
  • Page 35 8. Place the bulb of the new manual reset water 10. Tighten the strain relief cable clamp with a temperature limit along with the existing adjustable screwdriver. See Figure 50. supply water thermostat and thermometer gauge bulbs in the boiler temperature well and secure with a spring clip.

  • Page 36: Electrical Connections

    Field wiring diagrams are provided starging 3.14 Electrical Connections on page 42. ▲ WARNING NOTE: DO NOT use the gas pipes to ground electrical appliances. TO PREVENT INJURY OR DEATH DUE TO ELECTRICAL SHOCK OR CONTACT WITH Opening the front panel MOVING PARTS, LOCK UNIT DISCONNECT To open the front panel, see the sequence in Figure 51.

  • Page 37: Supply Water Thermostat (Swt) Settings Above 180°F

    Follow the steps below to reset the SWT rotation stop to 3.15 Supply Water Thermostat (SWT) allow water temperature settings up 194°F: Settings Above 180°F The adjustable SWT knob includes a factory installed rotation 1. Remove the knob from the adjustable SWT by pulling the stop that prevents supply water temperature settings below knob directly outward away from the boiler.

  • Page 38: Startup And Adjustments

    4.1 Preliminary Inspections 4.0 Start-Up and Adjustment System Start-Up and Adjustment must be carried out ▲ ▲ WARNING by qualifi ed installers. The following checks must be made at Start-Up and CARBON MONOXIDE POISONING HAZARD whenever maintenance or service is performed: FAILURE TO FOLLOW THE INSTALLATION With gas and electrical power “OFF”...
  • Page 39 Table 12 Check Supply Gas Pressure Disconnect poweer to the boiler. Final Manifold Pressure Settings Make sure all gas appliances are off, including Fuel Pressure the boiler. Verify the automatic vent damper service Natural Gas 3.5” W.C. switch is in the automatic position (see Figure LP Gas 10.6”...
  • Page 40 ▲ ▲ If the boiler does not light, refer to the Troublshooting WARNING section of the Service Facts, shipped with the boiler. SAFETY HAZARD Clock the gas meter with the boiler operating REPLACE AND/OR TIGHTEN ALL PLUGS REMO- (determine the dial rating of the meter) for one VED WHEN ADJUSTING GAS PRESSURE.

  • Page 41: Operating Information

    4.2 Operating Information ▲ WARNING Flue Spillage Switch and Flue Outlet All models are equipped with a thermostatic spill CARBON MONOXIDE POISONING HAZARD switch. In case of fl ue spillage, the device will cause Failure to follow the steps outlined below for each the circuit to open which shuts off all fl...

  • Page 42: Technical Data

    5.0 Technical Data 5.1 Electrical Diagrams 18-CG01D1-4...

  • Page 43: Schematic Diagram

    5.2 Schematic Diagrams 18-CG01D1-4...

  • Page 44: Field Wiring Diagrams

    5.3 Field Wiring Diagrams Option 1 - Factory Jumpers in Place System Configuration 1. Continuous Pump Operation 2. Burner Cycles With Supply Water Thermostat Circ Pump 120 VAC Power Setup (Field Supplied) (Field Wiring) 1. No changes needed L1 N (LV) (HV) 13 14 15 16 17 18...
  • Page 45 Option 3 - Field Installed Room System Configuration Thermostat, Orange J2 jumper 1. Pump Runs on Call from Room Thermostat OR if Water Temperature is Above Supply Water removed Thermostat setting 2. Burner Cycles with Supply Water Thermostat External Setup Limits 120 VAC Power (e.g., LWCO)
  • Page 46 Option 5 - Field Installed Room System Configuration Thermostat, Orange J2 jumper removed, 1. Pump Runs on Call from Room Thermostat OR Yellow J5 jumper removed if Water Temperature is Above Supply Water Thermostat setting External 2. Burner Cycles with Supply Water Thermostat during Call from Room Thermostat.
  • Page 47 Boiler Reset Option - Field Wiring Boiler Reset Configuration for Field Supplied Boiler Temperature NOTE: This Boiler Reset option may be Reset Controls (to Decrease Boiler Water used in combination with any of the other Temperature with Increasing Outdoor system configuration options and jumper arrangements shown in this document.
  • Page 48 Literature Order Number 18-CG01D1-3 P.I. File Number 18-CG01D1-3 Supersedes American Standard Inc. 6200 Troup Highway Stocking Location P.I. 08/02 Tyler, TX 75707 Since the manufacturer has a policy of continuous product and product data improvement, it reserves the For more information contact your local dealer (distributor) right to change design and specifi...

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