Table Of Contents - Williamson-Thermoflo GWC-070 Manual

GWC -
gas fired water boiler
Contents
How it works . . . . . . . . . . . . . . 2
GWC Water Boiler . . . . . . . . . . 3
Please read before proceeding . . . 5
Prepare boiler location . . . . . . . 6
Installations must follow these codes: . . . 6
High altitude installations. . . . . . . . . . 6
Residential garage installation . . . . . . . 7
Check orifice plate - replace if necessary . 8
Install condensate trap. . . . . . . . . . . . 9
Install high altitude air pressure switch when
required (only above 5,500 feet) . . . . . 10
Rotate the boiler into position . . . . . . 10
Perform hydrostatic pressure test . . . . . 11
Install water piping . . . . . . . . 12
General piping information. . . . . . . . 12
Install relief valve . . . . . . . . . . . . . 12
Expansion tank. . . . . . . . . . . . . . . 13
System water piping methods. . . . . . . 15
Circulators . . . . . . . . . . . . . . . . . 15
Simplified pipe/circulator selection . . . 15
Baseboard system piping -
CIRCULATOR zoning (primary/secondary)
16
Baseboard system piping -
ZONE VALVE zoning (direct connection) 16
Radiator system piping . . . . . . . . . . 18
Single-zone radiant heating or heat pump 19
Adjust balancing valves . . . . . . . . . . 19
Multi-zone radiant heating system . . . . 20
Piping snow melt systems or combination
snow melt/space heating systems . . . . . 21
Water chiller systems . . . . . . . . . . . 22
Multiple boiler installations . . . . 23
Placing multiple boilers . . . . . . . . . . 23
Controlling multiple GWC boilers . . . . 23
Piping multiple GWC boilers . . . . . . . 23
Multiple boiler water piping . . . . 24
Secondary header piping installation. . . 24
Venting & air - general . . . . . . 29
When removing a boiler from an existing
common vent system . . . . . . . . . . . 29
Existing vent test procedure. . . . . . . . 29
Provide combustion air: . . . . . . . . . . 30
Vent and air termination options. . . . . 30
DIRECT VENT installations . . . . . . . 30
DIRECT EXHAUST installations. . . . . 30
Combustion air contamination: . . . . . 30
Manifolded combustion air option for
DIRECT VENT multiple boiler installations
31
Air manifold sizing . . . . . . . . . . . . 31
Commonwealth of Massachusetts
installations . . . . . . . . . . . . 34
Vent termination requirements . . 35
4
- Boiler Manual
DIRECT VENT - Boiler room air
openings . . . . . . . . . . . . . . 36
DIRECT VENT - Sidewall with sepa-
rate pipes. . . . . . . . . . . . . . 37
DIRECT VENT - Sidewall with 3"
concentric . . . . . . . . . . . . . 39
DIRECT VENT - Vertical with sepa-
rate pipes. . . . . . . . . . . . . . 41
DIRECT VENT - Vertical with 3"
concentric . . . . . . . . . . . . . 43
Concentric termination assembly
(sidewall or vertical) . . . . . . . . 45
Vent and air piping and boiler con-
nections . . . . . . . . . . . . . . 46
DIRECT EXHAUST & DIRECT VENT . 46
Follow termination instructions . . . . . 46
Installing vent and air piping . . . . . . . 46
DIRECT EXHAUST ONLY . . . . . . . . 46
DIRECT EXHAUST - Boiler room air
openings . . . . . . . . . . . . . . 47
Combustion air provision. . . . . . . . . 47
Sizing combustion air openings . . . . . 47
Special considerations . . . . . . . . . . . 47
GWC boiler
WITHOUT other
appliances in room. . . . . . . . . . . . . 48
Air openings . . . . . . . . . . . . . . . . 48
GWC boiler
WITH other
appliances in room. . . . . . . . . . . . . 48
DIRECT EXHAUST - Sidewall . . 49
DIRECT EXHAUST - Vertical . . . 51
Gas piping . . . . . . . . . . . . . 52
Connecting gas supply piping. . . . . . . 52
Natural Gas. . . . . . . . . . . . . . . . . 53
Propane Gas . . . . . . . . . . . . . . . . 53
Wiring . . . . . . . . . . . . . . . 54
Start-up. . . . . . . . . . . . . . . 57
Freeze protection (when used) . . . . . . 57
Clean system to remove sediment . . . . 57
Water chemistry . . . . . . . . . . . . . . 57
Antifreeze. . . . . . . . . . . . . . . . . . 57
Check for gas leaks. . . . . . . . . . . . . 58
Fill and test water system . . . . . . . . . 58
Verify gas/air orifice plate . . . . . . . . . 59
Check thermostat circuit(s) . . . . . . . . 59
Inspect/fill condensate system . . . . . . 59
Final checks before starting boiler . . . . 60
To start the boiler . . . . . . . . . . . . . 60
If boiler does not start correctly . . . . . 60
Check system and boiler after start-up . . 60
Gas valve adjustment - altitude
over 5,500 feet ONLY . . . . . . . . . . . 60
Final checklist . . . . . . . . . . . . . . . 62
Annual start-up and general mainte-
nance schedule . . . . . . . . . . 65
Annual start-up . . . . . . . . . . 66
Address reported problems . . . . . . . . 66
Inspect boiler area . . . . . . . . . . . . . 66
Inspect boiler interior . . . . . . . . . . . 66
Inspect condensate drain system . . . . . 66
Inspect all piping for leaks . . . . . . . . 66
Inspect gas piping . . . . . . . . . . . . . 66
Inspect the water system. . . . . . . . . . 66
Check water system chemistry . . . . . . 66
Inspect expansion tank . . . . . . . . . . 67
Inspect air openings . . . . . . . . . . . . 67
Inspect vent system and air piping . . . . 67
Inspect boiler heating surfaces . . . . . . 67
Inspect igniter . . . . . . . . . . . . . . . 67
Inspect recuperator . . . . . . . . . . . . 68
Inspect temperature mixing system . . . 68
Inspect limit controls and cutoffs. . . . . 68
Inspect gauges . . . . . . . . . . . . . . . 68
Inspect blower motor . . . . . . . . . . . 68
Inspect oiled-bearing circulators . . . . . 68
Inspect boiler relief valve . . . . . . . . . 69
To complete Annual Start-up, perform
startup and checks: . . . . . . . . . . . . 69
Review with owner. . . . . . . . . . . . . 69
Service & maintenance . . . . . . 70
Cleaning boiler heating surfaces . . . . . 70
Inspecting and cleaning the recuperator . 71
Troubleshooting . . . . . . . . . . 73
VERIFY PROPER OPERATION AFTER
SERVICING. . . . . . . . . . . . . . . . . 73
Before troubleshooting . . . . . . . . . . 73
Check the following . . . . . . . . . . . . 73
Checking the air pressure switch . . . . . 73
Igniter. . . . . . . . . . . . . . . . . . . . 74
Gas Valve . . . . . . . . . . . . . . . . . . 74
Blower Housing . . . . . . . . . . . . . . 74
Thermal fuse . . . . . . . . . . . . . . . . 74
Return temperature sensor . . . . . . . . 74
IBC (integrated boiler control) . . . . . . 75
IBC indicator lights - lockout modes . . 75
IBC indicator lights -
non-lockout modes . . . . . . . . . . . . 75
Replacement parts . . . . . . . . 87
Dimensions and ratings. . . . . . 98
NOTES . . . . . . . . . . . . . . 102
Handling ceramic fiber and
fiberglass materials . . . . . . . 103
Installation and service
certificate . . . . . . . . . . . . 104
Part number 550-142-056/0411