Williamson-Thermoflo 18SRA-HE Operating instructions

GWA

Series 2

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 Department of Energy Compliance .................................19

9 Sequence of operation ...................................................19

10 Operating Instructions ....................................................23

11 Service and maintenance .................................................25

12 Troubleshooting ................................................................29

13 Replacement parts ...........................................................40

14 Dimensions .......................................................................45

15 Ratings .............................................................................46

16 Notes ................................................................................47

Hazard definitions

Hazards that will cause severe personal injury, death or substantial property damage.

Hazards that can cause severe personal injury, death or substantial property damage.

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.

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.

USER — Please read the following. Failure to comply could result in severe personal injury, death or substantial property damage.

• This manual is for use only by your qualified

heating installer/service technician.

• Please see the User’s Information Manual for your reference.

• Have the boiler serviced by a qualified service technician, at least annually.

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.

Part Number 550-142-784/0812

2

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Read this first!

1 Prepare boiler location

Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 39 of this manual. Failure to comply could result in severe personal injury.

When servicing boiler —

1. To avoid electric shock, disconnect electrical supply before performing maintenance.

2. To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation —

3. Do not block flow of combustion or ventilation air to boiler.

4. Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator.

Instead, shut off the gas supply at a location external to the appliance.

5. Do not use this boiler if any part has been under water.

Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Boiler water —

6. DO NOT use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, causing leakage between boiler sections, circulator flanges, diaphragm tanks or other system components. This can result in substantial property damage.

7. DO NOT use “homemade cures” or “boiler patent medicines”. Serious damage to boiler, personnel and/ or property may result.

8. Continual fresh makeup water will reduce boiler life. Mineral buildup in sections reduces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

9. Do not add cold water to hot boiler. Thermal shock can cause sections to crack.

Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property damage from fire and/or structural damage:

• Never store glycol of any kind near the boiler or any potential ignition source.

• Monitor and inspect the system and boiler regularly for leakage. Repair any leaks immediately to prevent possible accumulation of glycol.

• Never use automotive antifreeze or ethylene glycol in the system. Using these glycols can lead to hazardous leakage of glycol in the boiler system.

Codes & checklist

Installations must follow these codes:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1–latest edition.

• Standard for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

• For Canada only: B149.1 or B149.2 Installation Code, CSA

C22.1 Canadian Electrical Code Part 1 and any local codes.

Certification

The GWA boiler gas manifold and controls met safe operating and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

Before locating the boiler:

o Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power o Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids.

Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

o Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

o If new boiler will replace existing boiler, check for and correct system problems, such as:

1. System leaks causing oxygen corrosion or section cracks from hard water deposits.

2. Incorrectly-sized expansion tank.

3. Lack of antifreeze in boiler water causing system and boiler to freeze and leak.

Part Number 550-142-784/0812


1 Prepare boiler location continued

Clearances

Service clearances

1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as listed in the table below:

2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing.

Service clearances:

Top (for cleaning flueways)

Front (for access to controls and components)

Back

Left side (for cleaning and servicing)

Right side

Minimum

35"

18"

7"

24"

7"

Small space installations

1. When the boiler is located in a closet or small space, provide clearances no less than those shown in Figure 1. The clearances are required to any surface, whether combustible or non-combustible.

Figure 1 Minimum clearances

Minimum clearance to combustible materials

1. Hot water pipes must be at least ½” from combustible material.

2. Single-wall vent pipe must be at least 6 inches from combustible material.

3. Type B double-wall metal vent pipe — See vent manufacturer’s recommendation for clearances to combustible material.

Clearances from combustible materials:

Front (provide means of access)

Back

Left side (provide means of access)

Right side

Top

GWA-052 to GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

Minimum

3"

7"

6"

2"

H

35”

35½”

38½”

39¾”

42½”

Table 1

Boiler model

Minimum foundation size

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

Minimum foundation length

25”

25”

25”

25”

25”

25”

25”

Minimum foundation width

12”

12”

15”

18”

21”

24”

27”

Residential garage installation

Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph 5.1.9:

• Mount the boiler a minimum of 18 inches above the floor of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

Flooring and foundation

Flooring

The GWA boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

1. Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:

• floor can become flooded.

• the boiler mounting area is not level.

Part Number 550-142-784/0812 3



Vent system

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Inspect existing chimney before installing boiler.

Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death.

Do not alter boiler draft hood or place any obstruction or non-certified vent damper in breeching or vent system. CSA certification will become void. Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death.

The following requirements apply when you remove an existing boiler from a vent system shared with other appliances. If the new boiler will not use the

common vent, you must test (as described below) each remaining appliance — operating by itself — to verify that the vent system operates adequately.

When removing boiler from existing common vent system:

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

c. Test vent system — Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow the operating instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

f. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas

Code, ANSI Z223.1–latest edition. Correct by resizing to approach the minimum size as determined using the appropriate tables in

Part 11 of that code. Canadian installations must comply with

B149.1 or B149.2 Installation Code.

Chimney or vent requirements

1. Venting must be installed according to Part 7, “Venting of

Equipment”, of National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

2. See “Ratings” on Page 46 for minimum chimney or vent sizes.

Chimney or vent termination:

• A chimney, or any vent other than a Type B vent with listed vent cap, must extend at least 3 feet above the highest point where it passes through a roof of a building, and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet.

• Type B vents with listed caps may terminate as in Figure 2 if no closer than 8 feet from a vertical wall or similar obstruction.

• Otherwise, Type B vents must terminate at least 2 feet above the roof penetration and at least 2 feet higher than any portion of a building within 10 feet.

3. A lined chimney is preferred and must be used when required by local, state, provincial and national codes, laws, regulations and ordinances. Vitreous tile linings with joints that prevent retention of moisture and linings made of noncorrosive materials are best. Advice for flue connections and chimney linings can be obtained from local gas utility. Type B doublewall metal vent pipe or single-wall vent pipe may be used as a liner.

4. Cold masonry chimneys, also known as outside chimneys, typically have one or more walls exposed to outside air.

When any atmospheric gas-fired boiler with automatic vent damper is vented through this type of chimney, the potential exists for condensation to occur. Condensation can damage a masonry chimney. The following are recommended to prevent possible damage.

a. Line chimney with corrosion-resistant metal liner such as

AL29-4C® single-wall stainless steel or B-vent. Size liner per National Fuel Gas Code ANSI Z223.1–latest edition.

b. Provide drain trap to remove any condensate.

5. Where two or more gas appliances vent into a common chimney or vent, equivalent area should be at least equal to area of vent outlet on largest appliance plus 50 percent of vent outlet area of additional appliance.

Figure 2 Terminations with Type B vent fitted with listed cap, provided vent is at least 8 feet from any vertical wall or similar obstruction

4 Part Number 550-142-784/0812



Air contamination

Please review the following information on potential combustion air contamination problems.

See Table 2 for products and areas which may cause contaminated combustion air.

To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found:

• Remove contaminants permanently.

— OR —

• Isolate boiler and provide outside combustion air.

See national, provincial or local codes for further information.

Air openings

Combustion air and ventilation openings must comply with Section 5.3, “Air for Combustion and Ventilation”, of National Fuel

Gas Code ANSI Z223.1–latest edition, or applicable local building codes. Canadian installations must comply with B149.1 or B149.2

Installation Codes.

See table below for minimum combustion/ventilation air opening sizes. Where openings are required, provide two (2) openings — one within 12 inches of the ceiling, the other within 12 inches of the floor, as shown in the table illustrations.

Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury, death or substantial property damage caused by flue gas spillage and carbon monoxide emissions.

Table 2 Corrosive contaminants and likely locations

Products to avoid

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Part Number 550-142-784/0812 5

6



Air openings

continued

Exhaust fans and air movers

The appliance space must never be under a negative pressure.

Always provide air openings sized not only to the dimensions required for the firing rate of all appliances, but also to handle the air movement rate of the exhaust fans or air movers using air from the building or space.

Motorized air dampers

If the air openings are fitted with motorized dampers, electrically interlock the damper to:

• Prevent the boiler from firing if the damper is not fully open.

• Shut the boiler down should the damper close during boiler operation.

To accomplish this interlock, wire an isolated contact (proving the damper open) in series with the thermostat input to the boiler.

The boiler will not start if this contact is open, and will shut down should it open during operation.

2 Prepare boiler

Placement and setup

Place boiler/crate near position

1. Leave boiler in crate and on pallet until installation site is ready.

2. Move entire crate and pallet next to selected location.

3. Remove crate. Leave boiler on pallet.

4. Remove boiler from pallet as follows: a. Tilt left side of boiler up and place a board under left legs.

b. Tilt boiler the other way and place a board under right legs.

c. Slide boiler backwards off pallet and into position.

Do not drop boiler or bump jacket on floor or pallet.

Damage to boiler can result.

5. Check level.

a. Shim legs, if necessary.

b. Do not alter legs.

Correctly-sized manifold orifices must be used.

Failure to do so will result in severe personal injury, death or substantial property damage.

3. Level and straighten burners.

Burners must be properly seated in slots in burner rest with their openings face up. Main burner orifices must inject down center of burner. Failure to properly seat burners will result in severe personal injury, death or substantial property damage.

4. Reinstall access panel.

Do not operate boiler without access panel secured in place. Failure to comply could cause momentary flame rollout on ignition of main flame, resulting in possible fire or personal injury hazard.

Table 3 Manifold orifice sizing


Inspect orifices and burners

1. Remove front jacket door. Remove base access panel (See

Figure 19, item 4, page 40).

2. Check for correctly-sized manifold orifices. See Table 3 for sizing. (The orifice size is stamped on the orifice spud barrel.)

Location Natural gas

Sea level –

2,000 ft over

2,000 ft

Propane gas

Sea level –

2,000 ft over

2,000 ft

U. S.

2.00 mm

Sea level –

2,000 ft

(Note 1)

2,000 –

4,500

1.30 mm

Sea level –

2,000 ft

(Note 1)

2,000 –

4,500

Canada

2.00 mm #49 1.30 mm #56

Note 1: For U. S. elevations above 2,000 feet, contact your local supplier for

details.

Part Number 550-142-784/0812


2 Prepare boiler continued

Pressure test

Perform hydrostatic pressure test

Pressure test boiler before attaching water or gas piping or electrical supply (except as noted below).

Prepare boiler for test

1. Remove the shipping nipple (from GWA supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug.

2. Remove 1¼” nipple, reducing tee and drain valve from accessory bag. Install in boiler return connection as shown on in Figure 21, item 3, page 42. Install circulator on either the return or supply.

3. Remove 1¼” nipple, 1¼” tee, bushing and pressure/ temperature gauge from accessory bag. Pipe to boiler supply connection as shown in Figure 21, item 2, page 42. (Use pipe dope sparingly.)

4. Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test.

5. Connect a nipple and shutoff valve to system supply connection on the 1¼” tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

6. Connect a nipple and shutoff valve to system return connection

(at circulator flange if circulator installed on return). This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

7. Temporarily plug the air elimination tapping (next to supply tapping).

Fill and pressure test

1. Open the shutoff valves you installed on supply and return connections.

2. Slowly open boiler drain valve and fresh water supply to fill boiler with water.

3. When water flows from shutoff valves, close boiler drain valve.

4. Close shutoff valves.

5. Slowly reopen boiler drain valve until test pressure of not more than 45 psi is reached on the pressure/temperature gauge.

6. Test at no more than 45 psi for no more than 10 minutes.

Do not leave boiler unattended. A cold water fill could expand and cause excessive pressure, resulting in severe personal injury, death or substantial property damage.

7. Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once. Failure to do so can damage boiler, resulting in substantial property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Drain and remove fittings

1. Disconnect fill water hose from water source.

2. Drain boiler at drain valve or out hose, whichever provides best access to drain. Remove hose after draining if used to drain boiler.

3. Remove nipples, valves and plus unless they will remain for use in the system piping.

4. Remove plug from relief valve tapping. See Section 3,

page 10, to replace relief valve.

Part Number 550-142-784/0812 7

8



Draft hood & spill switch

Draft hood installation

1. Orient draft hood with spill switch mounting holes to front of boiler as shown in Figure 3.

2. Secure draft hood to outlet at top of boiler with sheet metal screws.

3. Bottom of draft hood or skirt must have clearance dimension above jacket top panel as indicated on draft hood.

Do not alter boiler draft hood or place any obstruction or non-approved vent damper in breeching or vent system. CSA certification will become void. Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death.

Improper orientation of spill switch may cause boiler to shut down. The loss of heat can result in significant damage due to freezing.

Spill switch installation

1. Fasten spill switch to draft hood as shown in Figure 3.

2. See Wiring diagram to connect wires:

Spark-ignited pilot boiler — see pages 21 & 22.

Install vent piping

1. Connect from draft hood or vent damper outlet to chimney or vent with same size vent connector.

2. Where possible, vertical venting to the outside from the draft hood or vent damper outlet will offer best performance.

3. Where horizontal vent connector is used, slope upward at least ¼” per lineal foot toward chimney or vent and support with hangers to prevent sagging.

4. Breeching must not be connected to any portion of a mechanical draft system that can operate under positive pressure.

Long horizontal vent connector, excessive number of elbow or tees, or other obstructions that restrict the flow of combustion gases should be avoided.

Severe personal injury, death or substantial property damage could result.

Vent damper

Figure 3 Spill switch with wire harness

These systems are used on gas-fired boilers with vent dampers as shipped from factory. Boiler will not operate without vent damper installed.

Only vent dampers listed in the Replacement parts list on Page 40 are certified for use with GWA boilers. Any other vent damper installed could cause severe personal injury or death.

Damper blade

Standing pilot ignition systems— See vent manufacturer’s instructions to install plug (shipped with damper) in damper hole.

For standing pilot boilers only, install plug with in vent damper hole.

3 /

8

” diameter hole

Spark-ignited pilot systems— See vent manufacturer’s instructions to install plug (shipped with damper) in damper hole.

For spark-ignited pilot boilers only, install plug with no hole in vent damper hole.

Minimum clearances

Provide a minimum of 6” between the vent damper and any combustible material. (See “Minimum clearance to combustible materials,” page 3, for minimum clearance from jacket top to ceiling to maintain this dimension.)

Part Number 550-142-784/0812



Vent damper

continued

Figure 4 Vent damper assemblies

Effikal or Field

Controls damper Johnson Controls damper

Refer to vent manufacturer’s instructions to install plug (shipped with damper) in damper hole.

Damper blade indicator

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 warranty. Any changes will cause severe personal injury, death or substantial property damage.

1. Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions. Vent damper must be installed so that it serves only one boiler and so damper blade indicator is visible to the user. See Figure 4.

2. Screws or rivets used to secure the vent damper to the draft hood must not interfere with rotation of the damper blade.

3. Install damper harness between damper actuator and hole in jacket left side panel. See Figure 3, page 8.

Use strain relief connectors and locknuts to secure both ends of damper harness.

Keep wiring harness clear of all hot surfaces.

Wire insulation could be damaged, causing risk of electrical short-circuit.

4. Read and apply the harness plug warning label (shown upperleft) so that it is visible after installation

5. Plug damper harness receptacle into damper harness plug.

Bypassing (jumpering) vent damper will cause flue products such as carbon monoxide to escape into the house. This will cause severe personal injury or death.

After boiler has operated once, if either end of harness is disconnected, the system safety shutdown will occur. The boiler will not operate until harness is reconnected.

Effikal or Field Controls damper — Damper hold open switch must be in Automatic Operation position for system to operate properly.

Hold-open switch (Effikal only) —

Install vent damper so that switch is visible and accessible to user.

72519

Part Number 550-142-784/0812 9


3 Install water piping

General

If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20 °F above setpoint of first control. Maximum allowable setpoint is 240 °F. See pages 21 & 22 for wiring.

A low water cutoff device is required when boiler is installed above radiation level or by certain state or local codes or insurance companies. Use low water cutoff designed for water installations.

Electrode probe-type is recommended. Purchase and install in tee supply piping above boiler.

Use backflow check valve in cold water supply if required by local codes.

Near-boiler piping

continued

Table 4 Water pipe size (based on 20 °F rise)

Boiler model number

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

To system

¾"

1"

1"

1"

1¼"

1¼"

1½"

From system

¾"

1"

1"

1"

1¼"

1¼"

1½"

Near-boiler piping

See Table 4 and Figure 5 (diaphragm-type or bladder-type expansion tank) or Figure 6 (closed-type expansion tank) on page 11 for near-boiler piping for systems designed for return water at least 130 °F.

See page 12, (Figures 8 and 9) for near-boiler piping for lowtemperature or high-volume systems.

See page 11, (Figure 7) for boilers used with refrigeration systems.

Isolation valves

Isolation valves are required to enable servicing of the boiler’s temperature sensor. Install as shown in appropriate piping diagram.

Relief valve

Install relief valve vertically in ¾” tapping on side of boiler. See the tag attached to the relief valve for manufacturer’s instructions.

To avoid water damage or scalding due to valve operation, discharge line must be connected to relief valve outlet and run to a safe place of disposal.

Terminate the discharge line to eliminate possibility of severe burns should the valve discharge.

• Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain where any discharge will be clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of

375 °F or greater.

• Do not pipe the discharge to any place where freezing could occur.

• No shutoff valve shall be installed between the relief valve and boiler, or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Failure to comply with the above guidelines could result in failure of the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.

• Test the operation of the valve after filling and pressurizing system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

Circulator

The circulator is shipped loose (wiring pre-attached to boiler) to allow you to locate it either in the return or supply piping, as desired. See page 11 for a typical installation. Pipe the expansion tank to the suction side of the circulator whenever possible. Install an air separator in the supply piping. Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system. Figures 5 and 6 show typical near-boiler piping connections.

Expansion tank

Diaphragm-type or bladder-type expansion tank —

Figure 5

1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator. See tank manufacturer’s instructions for details.

2. Install an automatic air vent as shown.

Closed-type expansion tank — Figure 6

1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank manufacturer’s instructions for details.

2. Connect tank to ½” NPT tapping located behind supply outlet, using ½” NPT piping. Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping.

Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve. Eventual section failure can result.

Water piping — multiple zone systems

Install system piping using either circulator zoning or zone valve zoning. Install expansion tank on suction side of system circulator. Always connect fill line only at the expansion tank — never at another point in the system.

10 Part Number 550-142-784/0812


3 Install water piping continued

Near-boiler piping

continued

Figure 5 Diaphragm- or bladder-type expansion tank:

Piping to single-zone system using diaphragm-type or bladder-type expansion tank. See Table 4 for piping sizes.

Figure 6 Closed-type expansion tank: Piping to singlezone system using closed-type expansion tank. See Table 4 for piping sizes.

Use Figure 5 or Figure 6 only for systems designed for return water at least 130 °F. For systems with low return water temperature possible, such as converted gravity systems and radiant heating systems, install bypass piping (see page 12) to protect boiler against condensation. Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

If system includes radiant heating circuits, provide piping and controls to regulate the temperature supplying the radiant circuits. Failure to comply could result in substantial property damage.

Install boiler so that chilled medium is piped in parallel with heating boiler ( Figure 7). Use appropriate valves to prevent chilled medium from entering boiler. Consult AHRI Installation and Piping

Guides.

If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle. Circulation of cold water through the boiler could result in damage to the heat exchanger, causing possible severe personal injury, death or substantial property damage.

Water piping — refrigeration systems

Prevent chilled water from entering boiler

Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 7 for typical installation of balancing valve and check valve.

Figure 7 Piping refrigeration systems

Part Number 550-142-784/0812 11


3 Install water piping continued

Near-boiler piping

continued

Figure 8 System bypass piping in boiler loop with separate system circulator, using primary/ secondary piping.

Figure 9 Boiler bypass piping — use only for high water content systems —DO NOT use for radiant panel systems.

System bypass method

1. Apply bypass piping of Figure 8 to high water content systems, radiant panel systems or any system that is likely to operate with low return water temperature for extended periods.

2. The bypass arrangement shown protects the boiler from damage caused by condensate corrosion due to low return water temperature and protects low temperature systems from too high a supply temperature.

3. Adjust the bypass valves as indicated below.

Adjust Bypass valves 1 and 2 as follows:

1. Start with valve 2 fully closed, valve 1 fully open.

2. Slowly open valve 2 while closing valve 1. Adjust the valves until the boiler pressure/temperature gauge reads 160 °F or higher. As you open the valves, pause long enough to allow temperatures to level off. It takes a while for the boiler water temperature to rise as the flow changes.

3. Bypass valve 2 allows hot boiler outlet water to blend with colder return water, raising the supply temperature to the boiler.

Bypass valve 1 balances the pressure drop through valve 2.

4. The purpose of this piping is to raise the return water temperature to the boiler enough to prevent condensation of flue gases.

Boiler bypass method

1. Apply bypass piping of Figure 9 to high water content systems, such as converted gravity systems.

2. The bypass arrangement shown protects the boiler from damage caused by condensate corrosion due to low return water temperature. This method does not provide protection from high temperature water being supplied to the system.

3. DO NOT apply this piping to radiant panel systems.

4. Adjust the bypass valves as indicated below.

Adjust Bypass valves 1 and 2 as follows:

1. Start with valve 1 fully closed, valve 2 fully open.

2. Slowly open valve 1 while closing valve 2. Adjust the valves until the boiler pressure/temperature gauge reads approximately 60

°F higher than the system temperature gauge. As you open the valves, pause long enough to allow temperatures to level off. It takes a while for the boiler water temperature to rise as the flow changes.

3. Bypass valve 1 controls system flow rate. Bypass valve 2 controls flow through the boiler.

4. The purpose of this piping is to cause a high enough temperature rise in the boiler that the average temperature will be warm enough to prevent condensation of flue gases.

Install all components specified above and adjust valves as described to prevent low temperature in the boiler. Failure to prevent low water temperature in the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

12 Part Number 550-142-784/0812


4 Install gas piping

Connecting gas supply piping to boiler

1. Remove jacket front panel and see Figure 10 to pipe gas to boiler.

a. Install drip leg at inlet of gas connection to boiler. Where local utility requires drip leg to be extended to the floor, use appropriate length of nipple between cap and tee.

b. Install ground joint union for servicing, when required.

c. Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements.

d. In Canada — When using manual main shutoff valve, it must be identified by the installer.

2. Support piping with hangers, not by boiler or its accessories.

3. Purge all air from gas supply piping.

4. Before placing boiler in operation, check boiler and its gas connection for leaks.

a. Close manual main shutoff valve during any pressure testing at less than 13” w.c.

b. Disconnect boiler and gas valve from gas supply piping during any pressure testing greater than 13” w.c.

Do not check for gas leaks with an open flame — Use bubble test. Failure to use bubble test or check for gas leaks can cause severe personal injury, death or substantial property damage.

5. Use pipe dope compatible with propane gases. Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow.

Failure to apply pipe dope as described in this manual can result in severe personal injury, death or substantial property damage.

Natural Gas:

Table 5 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 5 is only for gas with specific gravity 0.60, with a pressure drop through the gas piping of 0.30” w.c. For additional gas pipe sizing information, see ANSI Z223.1 (B149.1 or B149.2 for

Canadian installations).

2. Inlet pressure required at gas valve inlet:

• Maximum: 13” w.c.

• Minimum: 5” w.c.

• Manifold gas pressure: 3.5” w.c.

3. Install 100% lockup gas pressure regulator in supply line if inlet pressure exceeds 13” w.c. Adjust for 13” w.c. maximum.

Propane Gas:

1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

2. Adjust propane supply regulator provided by gas supplier for

13” w.c. maximum pressure.

3. Inlet pressure required at gas valve inlet:

• Maximum: 13” w.c.

• Minimum: 11” w.c.

• Manifold gas pressure: 10” w.c.

Figure 10 Gas supply piping

Gas pipe length

(feet)

50

75

100

150

10

20

30

40

Table 5 Pipe capacity for 0.60 specific gravity natural gas

56

45

38

31

92

73

63

½"

132

Capacity of pipe for pipe size of:

(Capacity in standard cubic feet gas per hour)

¾"

278

1"

520

1¼"

1050

1½"

1600

190

152

130

350

285

245

730

590

500

1100

860

760

115

93

79

64

215

175

150

120

440

360

305

250

670

545

460

380

Part Number 550-142-784/0812 13


5 Field wiring

For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard.

Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If rollout thermal fuse element wire as supplied with boiler must be replaced, type 200 °C wire or equivalent must be used. If other original wiring as supplied with boiler must be replaced, use only type

105 °C wire or equivalent.

Boiler must be electrically grounded as required by

National Electrical Code ANSI/NFPA 70–latest edition.

Electrical installation must comply with:

1. National Electrical Code and any other national, state, provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired, except spill switch and vent damper. See wiring diagram on pages 21 & 22 for spark-ignited pilot boiler. Circulator is shipped loose, but wiring harness is pre-attached to the boiler. Connect wires in circulator junction box.

Thermostat

1. Connect thermostat as shown on wiring diagram on boiler.

2. Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sun rays or fireplaces.

3. If thermostat has a heat anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.4 amps.

For other devices, see manufacturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

DHW

(if used)

Connect DHW aquastat as shown in wiring below. Economy function isn’t utilized with DHW input.

R & C Connections

(if used)

24 Vac leads should be used for power stealing thermostats only!

Junction box (furnished)

1. Connect 120 VAC power wiring (Figure 11).

2. Fused disconnect or service switch (15 amp. recommended) may be mounted on this box. For those installations with local codes which prohibit installation of fused disconnect or service switch on boiler, install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code.

Wiring multiple zones

See zone valve manufacturer’s literature for wiring and application.

A separate transformer is required to power zone valves. Zoning with circulators requires a relay for each circulator.

DO NOT connect directly from 3-wire zone valves to the T-T terminals on the boiler .

When using 3-wire zone valves, install an isolation relay. Connect the zone valve end switch wires to the isolation relay coil. Connect the isolation relay contact across the boiler T-T terminals. Failure to comply can result in damage to boiler components or cause unreliable operation, resulting in severe property damage.

Figure 11 Field wiring connections — service switch, DHW (if used) and thermostat (or end switch) provided by installer.

14 Part Number 550-142-784/0812


6 Start-up

Preparation

Check for gas leaks

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas leak. Repair any leak at once.

Propane boilers only — Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade and the gas may no longer have an odor.

• Propane gas can accumulate at floor level. Smell near the floor for the gas odorant or any unusual odor.

If you suspect a leak, do not attempt to light the pilot.

• Use caution when attempting to light the propane pilot. This should be done by a qualified service technician, particularly if pilot outages are common.

• Periodically check the odorant level of your gas.

• Inspect boiler and system at least yearly to make sure all gas piping is leak-tight.

• Consult your propane supplier regarding installation of a gas leak detector. There are some products on the market intended for this purpose. Your supplier

may be able to suggest an appropriate device.

Determine if water treatment is needed


Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

Verify water chemistry

Consult local water treatment companies for unusually hard water areas (above 7 grains hardness) or low pH water conditions (below

7.0). Boiler water pH of 7.0 to 8.5 is recommended.

Freeze protection (when used)

Use antifreeze made especially for hydronic systems. Inhibited propylene glycol is recommended.

Do not use ethylene glycol, automotive or undiluted antifreeze. Severe personal injury or death can result.

1. Determine antifreeze quantity according to system water content. Boiler water content is listed on Page 46. Remember to include expansion tank water content.

2. Follow antifreeze manufacturer’s instructions.

3. A 50% solution of propylene glycol/water provides maximum protection to about -30 °F.

4. Local codes may require back flow preventer or actual disconnect from city water supply.

5. When using antifreeze in a system with automatic fill, install a water meter to monitor water makeup. Glycol will leak before the water begins to leak, causing glycol level to drop. Added water will dilute the antifreeze, reducing the freeze protection level.

Fill the system with water

1. Close manual and automatic air vents and boiler drain cock.

2. Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a residential system is 12 psi.

3. Purge air from system: a. Connect a hose to purge valve or valves, if installed. Route hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between the purge valve and fill connection to the system.

c. Close zone isolation valves.

d. Open quick-fill valve on cold water makeup line.

e. Open purge valve.

f. One zone at a time, open the isolation valves. Allow water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while, eliminate any residual air by using the manual air vents located throughout the system.

i. If purge valves are not installed in system, open manual air vents in system one at a time, beginning with lowest floor.

Close vent when water squirts out. Repeat with remaining vents.

4. Open automatic air vent (diaphragm-type or bladder-type expansion tank systems only) one turn.

5. Open other vents: a. Starting on the lowest floor, open air vents one at a time until water squirts out.

b. Repeat with remaining vents.

6. Refill to correct pressure.

Inspect system water piping

After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair immediately.

Repeat this inspection after the boiler has been started and the system has heated up.

Leaks must be repaired at once. Failure to do so can damage the boiler, resulting in substantial property damage.


Inspect base insulation


Check to make sure insulation is secure against all four sides of the base. If insulation is damaged or displaced, do not operate boiler. Replace or reposition insulation.

Failure to replace damaged insulation or reposition insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

Part Number 550-142-784/0812 15


Operate boiler

DO NOT proceed with boiler operation unless boiler and system have been filled with water and all instructions and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage. Before starting the boiler . . .

• See manual Section 10 for spark-ignited pilot

“ Operating Instructions” procedure (see Table 6, below).

• Verify the boiler and system are full of water (or glycol/water mixture, if used).

• Verify the “Preparation” procedures of page 15 have been completed.

Table 6 Operating instruction locating guide

GWA Spark-ignited pilot

Honeywell VR8200/VR8300

White-Rodgers 36C

White-Rodgers 36E

Robertshaw 7200

Page

23

24

Adjust boiler control settings

BOILER OPERATING TEMPERATURE

With power turned on, control module receives a signal from the temperature sensor. The control knob labeled BOILER TEMP is used to adjust the operating temperature setpoint, turning clockwise to increase temperature setting and counterclockwise to decrease.

• ADJUST BOILER OPERATING TEMPERATURE TO

DESIRED SETPOINT.

BOILER ECONOMY SETTING

To comply with Department of Energy regulations, the control module circulates available hot water before turning on the boiler to attempt to satisfy a call for heat. While attempting to satisfy the heat demand, the control module also monitors the boiler temperature changes via the temperature sensor and determines whether or not the available hot water will satisfy the demand, adjusting the time delay to turn on the boiler until it determines that additional heat will be needed. The knob labeled ECONOMY

ADJUST provides an adjustment between maximize (MAX) and minimize (MIN) the delay. The maximum (MAX) adjustment position should be used to maximize energy savings. Turning the knob counterclockwise decreases the delay time and should only be used in the event that the heated space becomes uncomfortable.

• ADJUST ECONOMY TO DESIRED POSITION (MAX ISTHE

PREFERRED SETTING).

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST

ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

Start the boiler

Follow the “Operating Boiler Instructions” from:

• Spark-ignited pilot boilers — See Section 10.

Remove boiler jacket door and note the gas valve manufacturer and model number.

If boiler fails to start, see “If boiler doesn’t start . . . Check for:” on this page.

Check system and boiler

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected. Failure to comply could result in severe personal injury, death or substantial property damage.


1. Check system piping for leaks. If found, shut down boiler and repair immediately.

16 Part Number 550-142-784/0812


Verify operation

2. Vent air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

3. Inspect vent system thoroughly for signs of deterioration from corrosion, physical damage or sagging. Verify that masonry chimney liners are in good condition, with no obstructions, and there are no openings into the chimney.

4. Check around the boiler for gas odor following the procedure of “Check for gas leaks”, page 15.

5. Verify operation using procedures below. Perform “Checkout procedure”, page 18, and fill in the “Installation and service certificate”.

If boiler doesn’t start . . . Check for:

1. Loose connections, blown fuse or service switch off?

2. Boiler temperature adjustment, set below boiler water temperature?

3. Thermostat set below room temperature?

4. Gas not turned on at meter or boiler?

5. Incoming gas pressure less than:

5” w.c. for natural gas? 11” w.c. for propane gas?

6. If none of the above corrects the problem, see “Troubleshooting”,

Section 12, page 29.

Figure 12 Typical pilot burner flame

Figure 13 Typical main burner flame

Check the pilot ignition system used for the boiler.

The boiler model suffix will contain an “I” for sparkignited pilot. See Section 10 for spark-ignited pilot

“Operating Instructions”.

Check burner flame — Pilot burner

Check vent damper operation

1. Raise room thermostat to call for heat — Vent damper actuator will slowly open vent damper.

2. When vent damper is fully open — Pilot will light, then allow main burners to ignite.

Proper pilot flame (see Figure 12):

1. Blue flame.

2. Inner cone engulfing pilot flame sensor (spark-ignited pilot).

3. Pilot flame sensor glowing cherry red.

Improper pilot flame:

1. Overfired — Large flame lifting or blowing past pilot flame sensor.

2. Under fired — Small flame. Inner cone not engulfing pilot flame sensor.

3. Lack of primary air — Yellow flame tip.

4. Incorrectly heated pilot flame sensor.

Check burner flames — Main burner

Proper main burner flame (see Figure 13):

1. Yellow-orange streaks may appear (caused by dust).

Improper main burner flame:

1. Overfired — Large flames.

2. Under fired — Small flames.

3. Lack of primary air — Yellow tipping on flames (sooting will occur).

Vent damper must be fully open before main burners light. If vent damper does not fully open, flue products such as carbon monoxide will escape into house, causing severe personal injury or death.

3. Lower thermostat setting — Main burner flames will go out, then vent damper will close.

4. Repeat Steps 2 through 4 several times to verify operation.

5. Return thermostat to normal setting.

6. Set thermostat heat anticipator setting indicated on wiring diagram.

Check venting system operation

1. With boiler firing, hold a candle or match below lower edge of draft hood “skirt.” If flame does not blow out, but burns undisturbed, the vent system is working properly. If flame blows out or flickers severely, the vent system must be checked for obstructions or other causes of improper venting.

Part Number 550-142-784/0812 17


7 Checkout procedure o Boiler and heat distribution units filled with water?

o Automatic air vent, if used, open one full turn?

o Air purged from system?

o Air purged from gas piping? Piping checked for leaks?

o Correctly-sized manifold orifices installed? See Table 3,

page 6, to check size and fuel type.

Correctly sized manifold orifices must be used.

Failure to do so will cause severe personal injury, death or substantial property damage.

o Followed “Operating Instructions” on boiler or in Manual

Section 10, pages 23 & 24 for proper start-up?

o Proper burner flame observed? See “Verify operation”, Manual

Section 6, page 17.

o Test temperature limit — While burners are operating, turn

Boiler Temp adjustment knob counterclockwise until setting is below actual boiler water temperature. Burners should go off while circulator continues to operate. Turn Boiler Temp

Adjustment knob clockwise until setting is above boiler water temperature and ignition sequence should resume.

o Test additional field-installed controls — If boiler has a low water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burners should be operating and should go off when controls are tested. When controls are restored, burners should reignite.

o Button on spill switch pushed in?

o Test ignition system safety device:

Spark-ignited pilot — Connect manometer to outlet side of gas valve. Start boiler, allowing for normal start-up cycle to occur and main burners to ignite. With main burners on, manually shut off gas supply at manual main shutoff gas valve. Burners should go off. Open manual main shutoff gas valve. Manometer should confirm there is no gas flow.

Pilot will relight, flame sensing element will sense pilot flame and main burners reignite.

o Set Boiler Temp adjustment knob to system temperature requirements. Adjust balancing valves and controls to provide design temperature to system.

o Set Economy mode, fully clockwise.

o For multiple zones, adjust flow so it is about the same in each zone.

o Verify thermostat heat anticipator (if available) set properly?

See “Field wiring”, Manual Section 5, page 14, “Thermostat”.

o Cycle boiler with thermostat — Raise to highest setting and verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off.

o Cycle DHW Aquastat if used.

o Measure natural gas input: a. Operate boiler 10 minutes.

b. Turn off other appliances.

c. At natural gas meter, measure time (in seconds) required to use one cubic foot of gas.

d. Calculate gas input:

3600 x 1000

= Btuh number of seconds from step c e. Btuh calculated should approximate input rating on boiler rating label.

o Check manifold gas pressure by connecting manometer to downstream test tapping on main gas valve. Manifold pressure for natural gas should be 3.5" w.c. and for propane gas should be 10" w.c.

o Observe several operating cycles for proper operation.

o Set room thermostat to desired room temperature.

o Fill in Installation and service certificate below?

o Review all instructions shipped with this boiler with owner or maintenance person. Return instructions to envelope and give to owner.

18

Installation and service certificate

Boiler model _______________________________________________________________ Series ____________

CP number _______________________________________ Date installed _________________________________

Measured Btuh input ____________

Installer _______________________ ______________________________ ____________________________

(company) (address) (phone)

__________________________________

(installer’s signature)

Part Number 550-142-784/0812


8 Department of Energy – Compliance

This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water temperature changes. The control calculates a suitable delay based on temperature measurements and turns the boiler on only after it determines that the demand for heat cannot be satisfied with the available hot water,

Due to the wide variety of controls used in boiler installations, this control is also equipped with an adjustment for the calculated time delay period (ECONOMY ADJUST). In the MIN position, the time delay is zero and the

IMPORTANT notice below must be observed:

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

9 Sequence of operation – spark-ignited pilot boilers

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.

1. Standby: With no call for heat, the vent damper and circulator are de-energized. No gas flows to pilot or main gas valve.

2. Call for heat (thermostat circuit closes): a. While attempting to satisfy the heat demand, the control module monitors the boiler temperature changes via the temperature sensor and determines whether or not the available hot water will satisfy the demand, only running the circulator. If additional heat is needed, the sequence continues. When DHW (if used) calls for heat, sequence above is bypassed.

b. Vent damper and circulator energized if pilot status acceptable. Vent damper drives open. When vent damper end switch makes circuit, ignition control begins pilot ignition attempt.

c. Ignition control checks for false flame signal: If ignition control senses pilot signal when no pilot gas should be present, control will lockout, requiring reset procedure as given in Figure 14, page 20.

3. Pilot ignition: Control module sparks the pilot and opens pilot valve in main gas valve. a. If pilot does light and control module senses flame current, spark generator is turned off and main valve opens.

b.

Natural Gas -

If pilot does not light within 15 seconds, pilot valve is closed and spark generator is turned off.

Control module waits 5 minutes, then attempts to ignite pilot again. This cycle will continue indefinitely if pilot ignition control does not sense pilot flame.

4. Main burner operation: a. Control module monitors pilot flame current. If signal is lost, main valve closes, spark generator activates and sequence returns to step 4.

b. If power is interrupted, control system shuts off pilot and main gas valves and restarts at step 1 when power is restored.

c. In the event the limit control shuts down the boiler —

The control module closes the main gas valve, but keeps the circulator operating and the vent damper open.

Part Number 550-142-784/0812 19



5. Thermostat satisfied (thermostat circuit opens) — Pilot and main gas valves are closed — Vent damper is deenergized, and cycles to closed position. Circulator is shut off.

6. Boiler is now in the standby mode.

7. Thermostat anticipator setting: Set thermostat heat anticipator as instructed in Figure 15b, page 22.

Figure 14 Ignition control module sequence of operation – status light indications

Steps

(following step 7, cycle goes back to step 1.)

Call for heat?

POWER

TSTAT

CIRC

LIMIT DAMPER FLAME

1. Standby

• Waiting for call for heat

2. Call for heat

• Circulator on

3. Limit circuit

• Limit controls closed

4. Damper circuit

• Damper proven open

5. Pilot flame proven *

• Gas valve open

• Pilot remains on

• Boiler producing heat

6. Limit cycle

• Limit circuit open

7. Flame outage

• Flame out

• Boiler recycles

8. Thermostat satisfied

• Circulator off

9. Circulator exercise routine

• Circulator turns on for 30 seconds if

boiler not operated for 30 days

NO

YES

YES

YES

YES

YES

YES

NO

NO

= “ON” = “OFF”

* See Section 9, Items 3b for control response to failure to proven pilot flame.

Control will lockout under the following conditions:

· Line voltage polarity is reversed

· Stray voltage is sensed on thermostat line

· Damper end switch not proven within 5 minutes from thermostat call for heat

· Flame is sensed when it shouldn’t be there

Control will reset after these lockouts if any of the following occur

· 1 hour waiting period

· Opening and closing of thermostat circuit for

2 to 20 seconds

TIMING

–––

–––

–––

–––

15 sec

–––

–––

15 sec

30 sec

59340 GWA

20 Part Number 550-142-784/0812



Figure 15a Schematic wiring diagram — Spark-ignited pilot system

Part Number 550-142-784/0812 21



Figure 15b Schematic wiring diagram — Spark-ignited pilot system

22 Part Number 550-142-784/0812


10 Operating instructions – spark-ignited pilot boilers

Gas valve — Honeywell VR8204 or VR8304 — White-Rodgers 36C or 36E

FOR YOUR SAFETY READ BEFORE OPERATING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do

not try to light the pilot by hand.

B. Before OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

C. Use only your hand to depress or move the selector arm. Never use tools.

If the selector arm will not depress or move by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

WHAt tO DO IF yOu SMEll GAS

• Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

OPERATING INSTRUCTIONS

1. Stop! Read the safety information above on this label. Vent damper operations below apply only to GWA boilers. Find vent damper manufacturer and model on vent damper nameplate.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold

Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper Model M35, manually rotate damper blade in direction of arrow to Open position indicated on damper assembly.

6. This appliance is equipped with an ignition device which automatically lights the pilot.

Do not try to light the pilot by hand.

7. Turn gas control knob clockwise to OFF. (Press down on White-Rodgers 36C valve knob to turn.)

8. When equipped with vent damper, verify damper blade is in full open position.

9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.

10. Turn gas control knob counterclockwise to ON. (Press down on White-Rodgers 36C valve knob to turn.)

11. Turn on all electric power to the appliance.

12. When equipped with Effikal vent damper, place service switch in Automatic Operation position.

13. Set thermostat to desired setting.

14. If the appliance will not operate, follow the instructions To Turn Off Gas To The Appliance and call your service technician or gas supplier.

15. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove front panel.

4. Turn gas control knob clockwise to OFF. Do not force.

(Press down on 36C valve knob to turn.)

5. Replace front panel.

Part Number 550-142-784/0812 23


10 Operating instructions – spark-ignited pilot boilers

Gas valve — Robertshaw 7200

24 Part Number 550-142-784/0812


11 Service and maintenance

Table 6 Service and maintenance schedules (service technician and owner)

Service technician

(see following pages for instructions) o Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Water piping

• Boiler heating surfaces

• Burners, base and inlet air box o Service:

• Oiled-bearing circulators

• Temperature sensor o Start-up:

• Perform start-up per manual o Check/test:

• Gas piping

• Cold fill and operating pressures

• Air vents and air elimination

• Limit controls and cutoffs

• Expansion tank

• Boiler relief valve o Review:

• Review with owner o

Daily

Owner maintenance

(see User’s Information Manual for instructions) o Monthly o

Periodically o Every 6 months o

End of season

• Check boiler area

• Check boiler pressure/ temperature gauge

• Check air openings

• Check boiler piping

• Check venting system

• Check boiler relief valve

• Check automatic air vents (if used)

• Check pilot and main burner flames

• Test low water cutoff (if used)

• Operate relief valve

• Shut down procedure

Follow the “Service and maintenance” procedures given throughout this manual and in component literature shipped with the boiler. See “Read this first” on page 2. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

Part Number 550-142-784/0812 25


11 Service and maintenance continued

The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in

Table 6, page 25 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Electrical shock hazard — Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.


o

Inspect . . . . . . . . . .

Reported problems

Inspect any problems reported by owner and correct before proceeding.

Boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that boiler area (and air intake) is free of any of the contaminants listed in Table 2 on page 5 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, install combustion air piping to the boiler in accordance with national, provincial or local codes.

Air openings

1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed. Check operation and wiring of automatic combustion air dampers, if used.

2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

Flue gas vent system

1. Visually inspect entire flue gas venting system for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions.

2. Verify that masonry chimneys are lined, lining is in good condition, and there are not openings into the chimney.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Pilot and main burner flames

1. Visually inspect pilot burner and main burner flames as directed under Section 6, page 17 of this manual.

o

Inspect . . . . . . . . . .

Water piping

1. Check the boiler interior piping and all system piping for signs of leaks.

2. Repair any leaks before proceeding.


Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. Leaking water may also cause severe property damage.

Boiler heating surfaces

1. Disconnect the vent pipe at the boiler draft hood and remove draft hood after turning off power to the boiler.

2. Use a bright light to inspect the boiler flue collector and heating surfaces.

3. If the vent pipe or boiler interior surfaces show evidence of soot, follow “Cleaning boiler heating surfaces” in this manual section, page 28. Remove the flue collector and clean the boiler if necessary after closer inspection of boiler heating surfaces.

4. If there is evidence of rusty scale deposits on boiler surfaces, check the water piping and control system to make sure the boiler return water temperature is properly maintained (per this manual).

5. Reconnect vent and draft hood. Replace all boiler components before returning to service.

6. Check inside and around boiler for evidence of any leaks from the boiler. If found, locate source of leaks and repair.

Burners and base

1. After turning off power to the boiler, remove the jacket door and base access panel ( Figure 19, item 4, page 40).

2. Inspect burners and all other components in the boiler base.

3. If burners must be cleaned, raise rear of each burner to release from support slot, slide forward and remove. Then brush and vacuum the burners thoroughly, making sure all ports are free of debris. Carefully replace all burners, making sure burner with pilot bracket is replaced in its original position and all burners are upright (ports up).

4. Inspect the base insulation.

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 39 of this manual. Failure to comply could result in severe personal injury.

a. Verify that the insulation is intact and secure against all four sides of the base.

If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary. Failure to replace damaged insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

26 Part Number 550-142-784/0812


11 Service and maintenance continued o

Oiled-bearing circulators

1. The circulator shipped with the GWA boiler is water-lubricated.

No oiling is required.

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions.

Over-oiling will damage the circulator.

Temperature sensor

1. The temperature sensor may accumulate deposits on the probe surface. Annual inspection and cleaning of the probe will improve boiler performance.

Disconnect power, unplug harness from sensor.

a. Drain boiler water to a level below the sensor.

b. Remove sensor from boiler.

c. Wipe any built up contaminates from probe and insulator surfaces.

d. Reinstall sensor into boiler. Do not overtightenen.

o

Service. . . . . . . . . .

Start-up. . . . . . . . . .

1. Perform start-up procedures Section 6, pages 15–17, including “Verify operation” of burners and vent damper on page 17.

2. Verify cold fill pressure is correct and that fill system is working properly.

3. Verify antifreeze level (if used) is at the right concentration and that inhibitor level is correct.

4. Check gas piping, per Manual Section 4, page 13 and Section

6, page 15, verifying no indications of leakage and all piping and connections are in good condition.

5. Read and start the boiler following the “Operating Instructions”

(Manual Section 9 and 10, pages 19 through 24.

o

Check/test. . . . . . . . . .

Air vents and air elimination

1. Inspect automatic air vents (if used). Also inspect air separators to ensure they are operational.

2. The cap must be unscrewed one turn to allow air to escape.

3. If the air vent is leaking, remove cap and briefly push valve

— then release to clean the valve seat.

4. Replace cap by twisting all the way onto valve and then unscrewing one turn.

Limit controls and cutoffs

1. Inspect and test the boiler limit control. Verify operation by turning control set point below boiler temperature. Boiler should cycle off. Return dial to original setting.

2. Inspect and test additional limit controls or low water cutoffs installed on system.

Expansion tank

1. Expansion tanks provide space for water to move in an out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 3, page 10 of this manual for suggested locations of expansion tanks and air eliminators.

Open-type — located above highest radiator or baseboard unit, usually in the attic or closet. Has a gauge glass and overflow pipe to a drain.

Closed-type — welded gas tight and located above boiler.

Tank is partially filled with water, leaving an air cushion for expansion.

• Make sure this type of tank is fitted with a tank fitting, such as the B & G Tank-Trol or Taco Taco-Trol. This fitting reduces gravity circulation of air-saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system.

• Do not use automatic air vents in systems with closedtype tanks. The air will escape from the system instead of returning to the tank. Eventually, the tank will waterlog and no longer control pressurization. The boiler relief valve will weep frequently.

o

Check/test. . . . . . . . . .

Gas piping

1. Sniff near floor and around boiler area for any indication of a gas leak.

2. Test gas piping using bubble test, per Section 4, page 13 of this manual, if there is any indication of a leak.

Cold fill and operating pressures

1. While the system is cold, note the pressure reading on the boiler pressure/temperature gauge. Verify that cold fill pressure is correct.

2. Watch the pressure as the boiler and system heat up to ensure pressure rise is normal. Too high a rise would indicate a waterlogged or undersized expansion tank.

Part Number 550-142-784/0812 27


11 Service and maintenance continued o

Check/test. . . . . . . . . .

continued

Diaphragm- or bladder-type — welded gas tight with a rubber membrane to separate the tank pressurizing air and the water. May be located at any point in the system, but most often found near the boiler.

• Systems with this type of expansion tank require at least one automatic air vent, preferably located on top of an air eliminator, as shown in examples in Manual Section 3, page 10.

2. If relief valve has tended to weep frequently, the expansion tank may be waterlogged or undersized.

Closed-type tank — tank is most likely waterlogged. Install a tank fitting if not already installed. Then check fill level per fitting manufacturer’s instructions. If fill level is correct, check tank size against manufacturer’s instructions. Replace with a larger tank if necessary.

Diaphragm- or bladder-type — first, check tank size to be sure it is large enough for the system. If size is too small, add additional tank(s) as necessary to provide sufficient expansion.

If tank size is large enough, remove tank from system and check charge pressure (usually 12 psig for residential applications). If tank won’t hold pressure, membrane has been damaged. Replace tank.

Boiler relief valve

1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Manual Section 3, page

10, before proceeding further.

Safety relief valves should be reinspected AT LEAST

ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency — not by the owner.

Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death or substantial property damage.

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal otherwise severe personal injury may result. If no water flows, valve is inoperative.

Shut down boiler until a new relief valve has been installed.

2. After following the preceding warning directions, if the relief valve weeps or will not seat properly, replace the relief valve.

Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or under sizing.

o

Review with owner

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in this manual as well).

3. Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

o

Cleaning boiler heating surfaces


1. Shut down boiler:

• Follow “To Turn Off Gas to Appliance” instructions on boiler and “Operating Instructions”.

• Do not drain boiler unless it will be exposed to freezing temperatures. If using antifreeze in system, do not drain.

2. Follow shutdown procedure.

3. Remove venting system connection to boiler.

4. Remove top jacket panel. Turn back insulation.

5. Remove flue collector. Clean sealant from assembly and sections.

6. Remove radiation plates hanging between sections.

7. Remove burners from base. Brush and vacuum burners to remove all dust and lint. Verify that all burner ports are free of debris.

8. Place newspapers in base of boiler to collect soot.

9. Clean between sections with wire flue brush.

10. Remove newspaper and soot. Vacuum or brush base and surrounding area.

11. Reinstall radiation plates.

12. Replace collector box/transition assembly. Seal with sealant.

Obtain gas-tight seal to prevent flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.

13. Replace insulation and jacket top panel.

14. Start up boiler following Section 6, pages 15–17 of this manual and the boiler “Operating Instructions”, pages 23 and

24. Excessive sooting indicates improper gas combustion. If found, check for proper combustion and make any necessary adjustments.

28 Part Number 550-142-784/0812


12 Troubleshooting

Label all wires prior to disconnection when servicing 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 Charts. Severe personal injury, death or substantial property damage can result.

Burner access panel must be in position during boiler operation to prevent momentary flame rollout on ignition of main flame. Severe personal injury or substantial property damage will result.

Before troubleshooting:

1. Have the following items: a. Voltmeter that can check 120 VAC and 24 VAC.

b. Microammeter with a scale range of 0-10.

c. Continuity checker.

d. U-tube manometer.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to boiler.

3. Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground.

Troubleshooting sequence:

1. Before proceeding, check for:

• Loose connections, blown fuse or service switch off?

• Boiler temperature adjustment, set below boiler water temperature?

• Thermostat set below room temperature?

• Gas not turned on at meter or boiler?

• Incoming gas pressure less than:

5” w.c. for natural gas? 11” w.c. for propane gas?

2. If all of the above check correctly, check gas pressures: a. With boiler off

• 13” w.c. maximum natural or propane gas pressure upstream of gas valve.

b. With boiler on:

• 5” w.c. minimum natural gas pressure or 11” w.c. propane gas pressure upstream of gas valve.

• 3.5” w.c. minimum natural gas pressure or 10” w.c. propane gas pressure downstream tapping on gas valve — Can be adjusted by regulator on gas valve.

c. If gas pressure is incorrect or gas is not available to boiler, contact gas supplier to correct before proceeding further.

3. Check pilot operation - Follow “Operating Instructions”, pages

23 and 24.

• If gas is available and you cannot obtain a pilot flame, try purging the gas line and cleaning pilot and pilot gas tubing.

Follow “Operating Instructions” again.

In event of vent damper failure:

Effikal or Field Controls vent damper

If troubleshooting chart recommends replacing actuator and actuator is not immediately available, damper blade can be fixed in an open position to allow boiler operation. Manually turning blade can cause actuator damage. Follow these instructions only in case of no heat or damper actuator malfunction.

1. Move damper service switch to Hold Damper Open position.

Apply call for heat to boiler. Damper blade should then rotate to Open position and boiler will fire.

2. If step 1 does not open damper, manually rotate damper blade to open position using wrench or pliers on flat shaft between damper and actuator. Boiler will fire. Verify that damper service switch is in Hold Damper Open position. ( Figure 15)

3. Do not leave vent damper permanently in this position. Replace actuator immediately. If vent damper is left in Open position, boiler will not operate at published efficiencies.

Johnson Controls vent damper

If troubleshooting chart recommends replacing actuator and actuator is not immediately available, damper blade can be fixed in an open position to allow boiler operation. Follow these instructions only in case of no heat or damper actuator malfunction.

See Figure 15.

1. Turn off power to boiler.

Failure to turn off power to boiler can result in severe personal injury, death or substantial property damage.

2. See vent damper manufacturer’s instructions for procedure to fix vent damper in open position.

3. Turn on power to boiler.

4. Using wrench or pliers on flat shaft section, manually rotate damper blade until green light turns on. Boiler will fire.

( Figure 15)

5. Do not leave vent damper permanently in this position. Replace actuator immediately. If vent damper is left in Open position, boiler will not operate at published efficiencies.

Figure 15 Manually opening vent damper

Effikal or Field

Controls damper

Closed

Wrench or pliers

Open

Damper blade indicator

Johnson Controls damper

72508

Part Number 550-142-784/0812

Verify proper operation after servicing. • See vent damper manufacturer’s instructions packed with vent damper for additional information. Failure to comply could result in severe personal injury, death or substantial property damage.

29


11 Troubleshooting – spark-ignited pilot boilers

Temperature sensor

1. The boiler temperature sensor is a resistance-type device.

2. The Chart below shows the correct value for the sensor at various temperatures.

3. Use the resistance values at 32°F, 60°F, 70°F and 212°F to measure the sensor resistance at known temperatures (ice point, room temperature and sea level boiling point). For ice point and boiling point, insert the sensor in water at that temperature. Use an ohmmeter to read resistance value between thermister # and thermistor common. See Figure 30, page 50, for sensor plug details.

The information on this page and pages

31 through 38 apply only to spark-ignited pilot GWA boilers. These boilers are equipped with an ignition control module that has indicator lights to show control status. See Charts 1 through 6, pages 32-38, help you identify problems based on indicator light conditions.

Figure 16 GWA Ignition cntrol module

Sensor resistance values

Sensor resistance values

Temp

(°F)

32

40

50

60

70

80

90

100

110

Sensor ohms

Temp

(°F)

Min Max

34265 37871 120

27834 30764 130

21630 23907 140

16944 18727 150

13372 14780 160

10629 11747 170

8504

6847

5545

9399

7568

6129

180

190

200

Sensor ohms

2517

2091

1744

1461

Min

4517

3698

3043

1229

1038

2782

2311

1928

1615

Max

4992

4088

3364

1359

1147

Control module

Solder or water splatter between plugs and circuit board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation.

Failure to comply could result in severe personal injury, death or substantial property damage.

Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.

30 Part Number 550-142-784/0812



Control indicator lights —

HARD LOCKOUT Summary (Flashing LED’s)

MAY remove 120VAC power for more than 2 seconds to clear lockout OR ignition control will automatically restart sequence of operation after 1 hour waiting period after fault condition is cleared.

INDICATOR LIGHT

POWER

Flashes once per second

Flash code 2*

Flash code 3*

Flash code 4*

Flash code 5*

Flash code 6*

CONDITION

120 VAC connection to boiler reversed.

Internal fault, microprocessor or memory.

Unused.

Unused.

Internal fault, water thermistors disagree.

Internal fault, gas valve circuit.

* Flash code pattern: POWER LED flashes 2, 3, etc. times rapidly followed by 2 seconds off, then repeats.

ALL LED’S FLASHING Failure to establish pilot flame after 4 attempts. Follow Manual

(Propane Gas Only) Reset Procedure on page 19 to correct.

SOFT LOCKOUT Summary (Flashing LED’s)

MAY remove 120VAC power for more than 2 seconds, cycle thermostat for between 2 and 20 seconds, OR ignition control will automatically restart sequence of operation after 1 hour waiting period.

I NDICATOR LIGHT CONDITION

POWER + TSTAT/CIRC

POWER + DAMPER

High voltage detected on TSTAT circuit.

Damper stuck closed or unable to close end switch within 45 seconds from TSAT call.

POWER + FLAME Flame sensed without call for heat or out of sequence during ignition trial.

CAUTION Summary (Flashing LED’s)

INDICATOR LIGHT

DAMPER

LIMIT

CONDITION

Damper end switch opened after it had been proven closed.

Fault detected in temperature sensing hardware.

FLAME Flame loss or flame not sensed during trial for ignition.

Troubleshooting the control module

See Figure 17, page 32, for location of harness plug receptacles and plugs on the control module.

Part Number 550-142-784/0812 31



Figure 17 Control module connections

32 Part Number 550-142-784/0812



CHART 1 — Spark-ignited pilot — 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.

Is POWER light off?

No

Flashing alone

Is POWER light...

Flashing with another light

Yes

On steady

(not flashing)

• Make sure service switch or circuit breaker is on or fuses are good.

• Remove 120 VAC IN plug (Figure 17, Item 3, page 32) on control module.

• Using voltmeter, check across black and white wire pins of 120 VAC IN plug.

Does voltmeter indicate 120 VAC?

No Yes

TSTAT CIRC light flashing

DAMPER light flashing

FLAME light flashing

Chart

3

Chart

4

Chart

5

Chart

6

For insufficient heat or no heat problem, go to

Chart 6, page 38, if POWER light is on steady, with no other light flashing.

• Usually indicates polarity on incoming 120 VAC power line is wrong.

•  TURN OFF POWER at service switch or breaker, then reverse the HOT and NEUTRAL wires entering the boiler in the J-box.

• Restore POWER at service switch or breaker.

Is POWER light flashing now?

No Yes

Boiler should now operate normally.

Have system checked by a licensed electrician.

If problem persists, call your local Williamson-Thermoflo sales representative.

Problem is with incoming electricity. Have licensed electrician repair circuit.

• Reconnect 120 VAC IN plug.

• Remove transformer plug ( Figure 17, Item 2, page

32) on control module.

• Using voltmeter, check across left side top and bottom pins of transformer receptacle.


No Yes

Replace control module.

Retest.

• Reinstall transformer plug.

• Remove TSTAT transformer plug (Figure 17, Item 5, page 32) on control module.

• Using voltmeter, check across left and right pins of receptacle.


No Yes

Replace transformer.

Retest.


Retest.

Part Number 550-142-784/0812 33



CHART 2 — Spark-ignited pilot — TSTAT CIRC & POWER lights flashing

— Usually indicates 48 VAC on thermostat circuit (stray voltage) —


• Disconnect the two external wires connected to the boiler thermostat leads (two black low voltage leads in J-box).

• Connect a voltmeter across these two incoming wires.

Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the wires.

• There should NEVER be a voltage reading.

• If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

• Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle.

Did you find a voltage across the two external thermostat circuit wires?

Yes No

• Leave external boiler thermostat connection wires disconnected from boiler.

• Troubleshoot the external thermostat circuit until you find the source of the stray voltage. (Pay close attention to the wiring connections to 3-wire zone valves.)

• Correct the problem and repeat the voltmeter test above, verifying there is no longer a voltage reading under any condition in the external thermostat circuit.

• If no voltage is found under any condition of the external thermostat circuit, connect the two boiler thermostat connection leads together (or jumper the boiler aquastat

T-T terminals).

• Turn off power to the boiler for 1 minute.

• Turn on power and allow boiler to cycle.

Do the TSTAT and POWER lights still flash?

No Yes

• Boiler should now operate per the normal sequence of operation shown in Figure 14, page 20.

34

• Replace control module.

• Retest.

Part Number 550-142-784/0812



CHART 3 — Spark-ignited pilot — DAMPER light flashing

— If POWER light is flashing: Usually indicates vent damper failed to prove open within 5 minutes —

— If POWER light is steady: Usually indicates vent damper closed during run cycle —


• Reset boiler control by turning off power at service switch or turning down thermostat for 2 to 20 seconds.

• Thermostat should call for heat and appropriate zone valves open. The TSTAT CIRC and LIMIT lights should come on.

Does vent damper operate?

No Yes

• Wait 45 seconds.

No

Does vent damper operate?

Yes

• Wait 5 minutes.

Is DAMPER light flashing?

No Yes

• Remove DAMPER plug (Figure 17, Item 6, page 32) from plug receptacle of control module.

• Place voltmeter leads across the top two pins (1 and 4) of the DAMPER receptacle.

Does the voltmeter indicate 24 VAC?

No Yes

• Try reseating plug in module receptacle and restart.

• If vent damper still does not work, replace vent damper assembly or actuator.

• Retest.

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied.

Does vent damper actuator indicator show damper is open?

No Yes

Are the TSTAT CIRC and LIMIT lights on steady?

Yes No


• Retest.

• Make sure thermostat is calling for heat. If lights still don't come on, see

Chart 6, page 38.

• Replace vent damper assembly or actuator.

• Retest.

• Remove damper wiring plug at damper and firmly reconnect.

• Recheck boiler operation.

• If problem persists, replace vent damper assembly or actuator.

Part Number 550-142-784/0812 35



CHART 4 — Spark-ignited pilot — FLAME & POWER lights flashing

— Usually indicates flame sensed when it shouldn't be there —


Are manual main shutoff valve and gas valve open?

No Yes

• Leave main manual gas valve closed.

• Turn off power to boiler at service switch or breaker.

• Wait at least 45 seconds.

• Turn on power to boiler.

• Restart boiler, following Operating instructions in this manual (Section 10) or on boiler label.

Do FLAME and POWER lights still flash?

No Yes


• Retest.

• Turn off power to the boiler at service switch or breaker.

• Wait at least 45 seconds.

• Turn on power to boiler.

• Restart boiler, following Operating instructions in this manual (Section 10) or on boiler label.

• Look through the pilot inspection port to see if the pilot is burning.

Is pilot burning?

No Yes

• Allow boiler to continue cycling.

Are FLAME and POWER lights flashing?

No Yes

•  TURN OFF POWER to boiler at service switch or breaker.

• Open main manual gas valve.

• Turn on power to boiler at service switch or breaker.

• Restart boiler per operating instructions.

• Perform start-up procedures in boiler manual to verify proper operation.

• Boiler may now be operating normally.

• Perform start-up procedures in boiler manual to verify proper operation.


• Retest.

• Replace gas valve.

• Retest boiler.

Are FLAME and POWER lights flashing?

No Yes

• Boiler should now operate normally.

• Original flashing

FLAME light caused by gas valve not operating properly.

• See normal sequence of operation,

Figure 14, page 20.


• Retest.

36 Part Number 550-142-784/0812



CHART 5 — Spark-ignited pilot — FLAME light flashing and POWER light on steady

ALSO — Troubleshooting failure to establish main flame


• Are main manual shutoff valve and boiler gas valve open?

No Yes

•  TURN OFF POWER  to boiler at service switch or breaker.

• Open main manual shutoff valve and boiler gas valve (per

Operating instructions in this manual). Wait at least 45 seconds.

• Turn on power at service switch or breaker. Allow boiler to cycle.

Does FLAME light flash now?

No Yes

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied and vent damper has closed.

• Verify inlet gas pressure at gas valve:

Natural gas — 5.0" w.c. min/14.0" w.c. max

Propane — 11.0" w.c. min/14.0" w.c. max

Is gas present at gas valve inlet and within above range?

Yes No

• Is pilot flame visible through inspection port?

No Yes

• Check the voltage across main gas valve terminals of the gas valve.

Is 24 VAC present there?

Yes No

• If the wiring from the control module to gas valve is intact, replace the control module.

• Retest.

• Make sure ground wire terminal is securely fastened to control module mounting screw.

• Check the voltage across main gas valve terminals of the gas valve.

Is 24 VAC present there?

No Yes

• Verify inlet gas pressure at gas valve:

Natural gas — 5.0" w.c. min/14.0" w.c. max

Propane — 11.0" w.c. min/14.0" w.c. max

Is gas present at gas valve inlet and within above range?

No Yes


• Remove base access panel

(see Figure 19, item 4, page 41 for location).

• Verify pilot gas line is not kinked, obstructed or damaged and is correctly attached to pilot and gas valve.

• Verify pilot ignition electrode, electrode ceramic and spark lead wire from control are in good condition. Spark gap should be approximately 1/8".

• Correct any above problems, replacing pilot if burner or wiring is damaged.

• Reinstall base access panel to operate boiler for retest after any changes or corrections.

• If none of the above corrects problem, then replace the control module, reinstall base access panel, and retest.

• Contact gas supplier to correct pressure or gas supply.


• Remove base access panel (see

Figure 19, item 4, page 41 for location).

• Verify pilot burner is securely attached to pilot bracket, bracket is securely attached to cross tie, and there is no corrosion on the parts which would affect the ground path for flame sense.

• Verify that pilot flame rod, flame rod ceramic and lead wire from control module to flame rod are in good condition.

• Correct any above problems, replacing pilot if burner or wiring is damaged.


• Check flame signal — Detach sense lead from igntion control

( Figure 17, item 8, page 32).

• Connect negative lead of MICROAMMETER to control sense terminal ( Figure 17, item 8, page 32). Connect positive lead of

MICROAMMETER to sense wire.

• DISCONNECT red wire connected to main gas valve terminal of the gas valve.

• Turn on power to boiler and allow to cycle. As soon as pilot is burning, the MICROAMMETER should read at least 1.0

microamp.

Is flame signal at least 1.0 microamp?

No Yes

• If none of the previous steps

(including replacing pilot) corrects problem, then replace the control module, reinstall base access panel and retest.

• If the wiring from the control module to gas valve is intact, replace the control module and retest.

Part Number 550-142-784/0812 37



CHART 6 — Spark-ignited pilot — Insufficient heat or no heat (POWER light on steady)

• Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes. Is system heating?

• Is thermostat set to call for heat? Remove thermostat wires at boiler and check continuity across the two wires.

If circuit isn't closed, check external thermostat (zone valve, relay, etc.) wiring. Correct problems and retry.

• Reconnect external thermostat wiring at boiler.

Is thermostat circuit closed (continuity across wires)?

No Yes

Are all red lights off?

No

Wait 30 seconds.

Are all red lights off?

No


Yes

Yes

• Boiler is in standby.

• Set thermostat to call for heat and recheck operation.

• Verify Sequence of

operation, Figure 14, page 20.

Is boiler System circulator operating?

No module.

• Retest.

No

• Remove CIRCULATOR harness plug from

CIRCULATOR plug receptacle ( Figure 17,

Item 7, page 32). Check with voltmeter across pins of control module receptacle.

Does voltmeter show 120 VAC across pins?

• Replace control

• Wait 5 minutes.

Yes

Yes

• Repair/replace circulator. Retest.

• Repair/replace wiring. Retest.

Is FLAME light on?

Yes

No


Retest.

• If you have sufficient heat — boiler should be in normal operating sequence. (See normal sequence of operation,

Figure 14, page 20.)

• If you have less than sufficient heat —

Is vent or combustion air piping free of blockage?

No Yes

• Correct conditions and recheck operation.

• See Figure 14, page 20 for normal sequence of operation.

Contact your Williamson-

Thermoflo sales representative.

No

• Check temperature sensor for correct resistance.

Is LIMIT light on?

Are resistance values correct?

No Yes


• Retest.

Yes

• Replace temperature sensor.

• Retest.

Check spill switch and rollout switch continuity — are switches closed?

No Yes

• Reset spill switch, or replace rollout switch.

If rollout thermal fuse element or spill switch has opened, determine cause and correct condition.

Failure to do so will cause severe personal injury, death or substantial property damage.

• Check any other limit controls wired into the limit circuit. If all are

OK, then replace control module.

• Retest.

38 Part Number 550-142-784/0812


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 sources is carcinogenic to humans (Group 1).”: o Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://

www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

o Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.

o Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.

o Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

o Eye: Irrigate immediately o Breathing: Fresh air.

REMOVAL OF FIBERGLASS WOOL — OR —

INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASE

PANELS:

This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or base panels in gas fired products. Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation.

o Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://

www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

o Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiring additional protection.

o Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

o Eye: Irrigate immediately o Breathing: Fresh air.

Part Number 550-142-784/0812 39


13 Replacement parts

Figure 18 Section assembly, flue collector, draft hood and vent damper

Item number

Description not shown

1

Replacement section assembly

Radiation plate

(1 per joint)

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

2 Collector hood

3 Drafthood

Part number

321-114-345WT

321-114-345WT

321-114-346WT

321-114-347WT

321-114-348WT

321-114-349WT

321-114-350WT

460-003-700WT

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

381-354-625WT

381-354-626WT

381-354-627WT

381-354-628WT

381-354-629WT

381-354-630WT

381-354-631WT

450-021-240WT

450-021-241WT

450-021-242WT

450-021-243WT

450-021-244WT

450-021-245WT

450-021-246WT

Item number

4

5

6

7

8

Description Part number

Temperature sensor Tasseron

TSL055D

381-356-577 WT

Spill switch

Vent damper

4” GWA-052

GWA-070

Effikal RVGP-KS-4BKF

* Johnson Controls Q35GB-2

Field Controls GVD-4

5” GWA-105 Effikal RVGP-KS-5BKF

* Johnson Controls Q35GD-2


6” GWA-140

GWA-175


* Johnson Controls Q35GF-2


7” GWA-210

GWA-245


* Johnson Controls Q35GH-2


510-300-014WT

381-800-474WT

381-800-475WT

381-800-476WT

381-800-477WT

* Johnson Controls damper assemblies consists of M35BC actuator and Y15 vent pipe

Vent damper actuator Effikal RVGP 510-512-337WT

Vent damper harness 591-391-795WT

40 Part Number 550-142-784/0812


13 Replacement parts continued

Figure 19 Base assembly, manifold, orifices and burners

Item number

Description

7

8

9

5

6

3

4

1

2

10

11

12

13

14

15

Base assembly kit GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

Base side panel (in Base assembly)

Base front cross-tie assembly (in Base assembly)

Base back cross-tie assembly (in Base assembly)

Base access panel (in Base assembly)

Base pan angle, left side (in Base assembly)

Base pan angle, right side (in Base assembly)

Base pan (in Base assembly)

Burner rest (in Base assembly)

Base insulation kit

(includes insulation for all base parts above plus gasket material needed between block assembly and base)

Boiler leg kit

GWA-052 to GWA-140

GWA-175 to GWA-245

Manifold

Main burner orifice, sea level

Burner, stainless steel

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

Natural gas

Propane gas

Burner with pilot bracket

(not shown)

Standing pilot (natural)

Standing pilot (propane)

Spark-ignited pilot (nat.)

Screw, 10-32 x ⅜ STP Type D Hex, washer head slot ZP

16 Rollout thermal fuse element

Part number

381-354-355WT

381-354-356WT

381-354-357WT

381-354-358WT

381-354-359WT

381-354-360WT

381-354-361WT

381-354-518WT

381-354-519WT

590-424-252WT

591-126-615WT

591-126-616WT

591-126-617WT

591-126-618WT

591-126-619WT

591-126-556WT

591-126-557WT

560-528-997WT

560-528-998WT

512-200-077WT

512-200-079WT

512-200-078WT available at local supply house

512-050-230WT

Part Number 550-142-784/0812 41



Figure 20 Jacket assembly

Item number

1

Description

Junction box, 2 x 4

(Available at local supply house)

2

3

4

Part number Part number

Jacket panel, left side with insulation

Jacket panel, right side with insulation

Jacket panel, door

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

GWA-052 & 070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

Natural Gas

431-223-571WT

431-223-573WT

431-223-575WT

431-223-577WT

431-223-579WT

431-223-581WT

431-223-583WT

Propane Gas

431-223-585WT

431-223-586WT

431-223-587WT

431-223-588WT

431-223-589WT

431-223-590WT

431-223-591WT

431-223-572WT

431-223-574WT

431-223-576WT

431-223-578WT

431-223-580WT

431-223-582WT

431-223-584WT

431-223-592WT

431-223-593WT

431-223-594WT

431-223-595WT

431-223-596WT

431-223-597WT

Item number

5

Description

Jacket panel, top

6

7

8

Jacket cross-tie

Jacket panel, interior, with insulation

Jacket panel, rear, with insulation

GWA-052 & GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

GWA-052 & GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

GWA-052 & GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

GWA-052 & GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

GWA-245

Part number

431-223-433WT

431-223-434WT

431-223-435WT

431-223-436WT

431-223-437WT

431-223-438WT

431-223-507WT

431-223-508WT

431-223-509WT

431-223-510WT

431-223-511WT

431-223-512WT

431-223-427WT

431-223-428WT

431-223-429WT

431-223-430WT

431-223-431WT

431-223-432WT

431-223-444WT

431-223-445WT

431-223-446WT

431-223-447WT

431-223-448WT

431-223-449WT

42

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 39 of this manual. Failure to comply could result in severe personal injury.

Part Number 550-142-784/0812



Figure 21 Trim assembly

Item number

Description

1

2

3

4

5 not shown

6

Pressure relief valve, ASME, 30 PSIG, ¾” male inlet

Pressure relief valve, ASME, 30 PSIG, ¾” female inlet

(Fittings shown are factory-installed on boiler.)

Combination pressure-temperature gauge, with 2½ short shank

Drain valve, ¾” NPT, 1-½ Shank

(Fittings shown are included with boiler.)

Circulator (Fittings shown are shipped loose with boiler.)

Circulator gasket, universal (2 per boiler)

Circulator hardware kit, includes:

2 flanges, 4 nuts, 4 bolts, 2 pipe nipples —

1” NPT — GWA-052 through GWA-140

1¼” NPT — GWA-175 through GWA-245

Circulator wiring harness

Manufacturer

Watts

Watts

Amekai

Manufacturer’s

Part number

M330

Part number

511-546-920WT

335 511-546-924WT

OS234JDTW003 510-218-099WT

511-210-423WT

Taco 007 511-405-113WT

590-317-535WT

381-354-525WT

381-354-526WT

591-391-976WT

Part Number 550-142-784/0812 43



Figure 22 Gas control assembly

Item number

Description

Natural gas components

1 Gas valve, ½” x ½”

Boiler model

GWA-052 through GWA-175

Gas valve, ¾ ” x ¾ ” GWA-210 through GWA-245

2 Pilot kit w/orifice & aluminum pilot gas tubing

Liquefied Petroleum (Propane) gas components

1 Gas valve, ½” x ½” GWA-052 through GWA-175

Gas valve, ¾ ” x ¾ ”

GWA-210 through GWA-245

Manufacturer

Honeywell

White-Rodgers

Robertshaw

Honeywell

White-Rodgers

Williamson-Thermoflo

Honeywell

Honeywell

Manufacturer’s part number

VR8204A2001

36E-266

7200IPER

VR8304M4348

36C74-474

VR8204M2701 LP

VR8304M4010 LP

2 Pilot kit w/orifice & aluminum pilot gas tubing Williamson-Thermoflo

Natural gas and Liquefied Petroleum (Propane) gas components

3 Control module - Natural gas United Technologies 1135-601

- Liquefied Petroleum (Propane) gas not shown Wiring harness, junction box to control module not shown Wiring harness, controls to control module not shown Wiring harness, thermostat not shown Wiring harness, sensor

4 Control transformer





Honeywell

1135-602

44

Part number

511-044-381WT

511-044-382WT

511-330-218WT

511-044-354WT

511-044-355WT

511-330-219WT

381-330-014WT

381-330-016WT

591-391-975 WT

591-391-977 WT

591-391-994 WT

591-391-995 WT

381-356-578WT

Part Number 550-142-784/0812


14 Dimensions

Figure 23 Dimensional drawing — ALL DIMENSIONS IN INCHES


Supply tappings

(inches NPT)

Return tappings

(inches NPT)

Gas connection

& manifold size

(Note 3)

(inches NPT)

“A”

Vent location

(inches)

GWA-052

GWA-070

GWA-105

GWA-140

GWA-175

GWA-210

1¼

1¼

1¼

1¼

1¼

1¼

1¼

1¼

1¼

1¼

1¼

1¼

½

½

½

½

½

½

5

5

6½

8

9½

11

GWA-245 1¼ 1¼ ½ 12½

Note 3: Size gas piping from meter to boiler per local utility requirements.

“D”

Vent diameter

(inches)

7

7

6

6

4

4

5

Part Number 550-142-784/0812

“W”

Jacket width

(inches)

16

19

22

25

10

10

13

“H”

Damper height

(inches)

45⅜

52⅜

54⅜

57⅞

60⅜

62⅛

64⅞

45


15 Ratings

DOE


(Note 3)

GWA-052

GWA-070

0-2,000 feet altitude

Input

(Btuh)

52,000

DOE Heating Capacity

(Output)(Btuh)

(Note 1)

43,000

70,000

GWA-105 105,000

58,000

88,000

2,000-4,500 feet altitude

Input

(Btuh)

(Note 4)

Output

(Btuh)

46,800 37,400

63,000

94,500

50,400

75,600

Net

AHRI ratings

(Btuh)

Boiler water content

(gallons)

DOE

Seasonal efficiency

(% A.F.U.E.)

N - L

Chimney and breeching size

(Note 2)

37,000

50,000

1.5

1.5

(Note 3)

83.0

83.0

Note 5

4”I.D.x20”

4”I.D.x20”

77,000 2.1

83.0

5”I.D.x20”

GWA-140 140,000

GWA-175 175,000

GWA-210 210,000

GWA-245 245,000

117,000

145,000

175,000

202,000

126,000

157,500

189,000

220,500

100,800 102,000

126,000 126,000

151,200 151,000

2.7

3.3

3.8

176,400 176,000 4.4

82.5

82.2

82.4

82.2

6”I.D.x20”

6”I.D.x20”

7”I.D.x20”

7”I.D.x20”

46

1. Based on standard test procedures prescribed by the United States Department of

Energy.

2. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup.

Ratings are based on a piping and pickup allowance of 1.15. An additional allowance should be made for unusual piping and pickup loads.

3. See information at right for model number suffixes. Letters shown are model number suffixes. An “N” after the model number designates natural gas. An “L” designates propane gas. The letter after the “-” designates the pilot ignition system — “I” for spark-ignited pilot. For example, a suffix “L-I” means a propane spark-ignited pilot boiler.

4. Contact your local dealer regarding information and parts for high altitude applications.

DOE heating capacity output for this unit is 59,000 Btuh & Net AHRI rating is

50,000 Btuh.

Install GWA boilers for residential radiant panel systems, converted gravity heating systems or other low water temperature applications per instructions in this manual to avoid damage due to condensation.

GWA boilers are CSA design certified for installation on combustible flooring.

GWA boilers are ASME rated for 50 psig working pressure.

Part Number 550-142-784/0812

16 Notes


Part Number 550-142-784/0812 47


48

W-T

8201 W. Calumet Rd.

Milwaukee, WI 53223

Part Number 550-142-784/0812

Williamson-Thermoflo 18SRA-HE Operating instructions

Series 2

Gas-Fired Water Boilers

Boiler Manual

Contents

Hazard definitions

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

When servicing boiler —

Boiler operation —

Boiler water —

Glycol — potential fire hazard —

Codes & checklist

Installations must follow these codes:

Certification

Before locating the boiler:

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Clearances

Service clearances

Small space installations

Minimum clearance to combustible materials

Residential garage installation

Flooring and foundation

Flooring

Foundation

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Vent system

When removing boiler from existing common vent system:

Chimney or vent requirements

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Air contamination

Air openings

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Air openings

Exhaust fans and air movers

Motorized air dampers

Placement and setup

Place boiler/crate near position

Inspect orifices and burners

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Pressure test

Perform hydrostatic pressure test

Prepare boiler for test

Fill and pressure test

Drain and remove fittings

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Draft hood & spill switch

Draft hood installation

Spill switch installation

Install vent piping

Vent damper

Damper blade

Minimum clearances

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Vent damper

Damper installation

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

General

Near-boiler piping

Near-boiler piping

Isolation valves

Relief valve

Circulator

Expansion tank

Water piping — multiple zone systems

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Near-boiler piping

Water piping — refrigeration systems

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Near-boiler piping

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Connecting gas supply piping to boiler

Natural Gas:

Propane Gas:

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual

Electrical installation must comply with:

Wiring connections

DHW

R & C Connections

Wiring multiple zones

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual