Operating instructions

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Part Number 550-101-010/0703

GWA

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.

Contents Page

1 Prepare boiler location ........................................................ 2

2 Prepare boiler ..................................................................... 6

3 Install water piping ............................................................ 10

4 Install gas piping ............................................................... 13

5 Field wiring ....................................................................... 14

6 Start-up ............................................................................ 15

7 Checkout procedure ......................................................... 18

8 Sequence of operation — standing pilot boilers ................. 19

9 Lighting instructions — GWA standing pilot boilers ........... 20

10 Service and maintenance ................................................. 22

11 Troubleshooting ................................................................ 27

12 Replacement parts ........................................................... 29

13 Dimensions ...................................................................... 34

14 Ratings ............................................................................. 35

Boiler Manual

Gas-Fired Water Boilers

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.

Hazards that will cause severe personal injury,

death or substantial property damage.

Hazards that can cause severe personal injury,

death or substantial property damage.

Hazard definitions

Summary of content (36 pages)

PAGE 1
GWA 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 ..
PAGE 2
GWA Gas-Fired Water Boilers – Boiler Manual Read this first! 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 23 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.
PAGE 3
GWA Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Clearances Service clearances Small space installations 1. Provide minimum clearances for cleaning and servicing the 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.
PAGE 4
GWA Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued 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. 2. Do not alter boiler draft hood or place any obstruction or non-certified vent damper in breeching or vent system.
PAGE 5
GWA Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air contamination Air openings Please review the following information on potential combustion air contamination problems. See Table 2 for products and areas which may cause contaminated combustion air. 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.
PAGE 6
GWA Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air openings continued Exhaust fans and air movers Motorized air dampers The appliance space must never be under a negative pressure. 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.
PAGE 7
GWA Gas-Fired Water Boilers – Boiler Manual 2 Prepare boiler continued Pressure test Perform hydrostatic pressure test Fill and pressure test Pressure test boiler before attaching water or gas piping or electrical supply (except as noted below). 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.
PAGE 8
GWA Gas-Fired Water Boilers – Boiler Manual 2 Prepare boiler continued Draft hood & spill switch Install vent piping Draft hood installation 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.
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GWA Gas-Fired Water Boilers – Boiler Manual 2 Prepare boiler continued Vent damper continued Damper installation Figure 4 Vent damper assemblies 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.
PAGE 10
GWA Gas-Fired Water Boilers – Boiler Manual 3 Install water piping General Near-boiler piping continued If installation is to comply with ASME or Canadian requirements, 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 page 19 for wiring.
PAGE 11
GWA Gas-Fired Water Boilers – Boiler Manual 3 Install water piping continued Near-boiler piping continued Figure 5 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.
PAGE 12
GWA Gas-Fired Water Boilers – Boiler Manual 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 Boiler bypass method 1.
PAGE 13
GWA Gas-Fired Water Boilers – Boiler Manual 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.
PAGE 14
GWA Gas-Fired Water Boilers – Boiler Manual 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.
PAGE 15
GWA Gas-Fired Water Boilers – Boiler Manual 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.
PAGE 16
GWA Gas-Fired Water Boilers – Boiler Manual 6 Start-up continued 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 . . .
PAGE 17
GWA Gas-Fired Water Boilers – Boiler Manual 6 Start-up continued Verify operation Check the pilot ignition system used for the boiler. The boiler model suffix will contain an “S” for standing pilot or an “I” for spark-ignited pilot. See Section 9, pages 20 and 21, for standing pilot boiler “Lighting Instructions”, or the Control Supplement for sparkignited pilot “Operating Instructions”. Check burner flame — Pilot burner Proper pilot flame (see Figure 12): 1. Blue flame. 2.
PAGE 18
GWA Gas-Fired Water Boilers – Boiler Manual 7 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Checkout procedure Boiler and heat distribution units filled with water? Automatic air vent, if used, open one full turn? Air purged from system? Air purged from gas piping? Piping checked for leaks? 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.
PAGE 19
Part Number 550-101-010/0703 Figure 14 Wiring diagram — Standing pilot system Burners remain ignited until thermostat circuit or limit circuit opens. Burners and circulator are de-energized when call for heat stops. Burners are de-energized, but circulator remains on, if the limit circuit opens. 3. Limit operation: When a limit control opens, the main gas valve is de-energized, but circulator continues to run.
PAGE 20
GWA Gas-Fired Water Boilers – Boiler Manual 9 Lighting Instructions — GWA standing pilot boilers Honeywell VR8200/VR8300 gas valve FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot, which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. Before LIGHTING, smell all around the appliance area for gas.
PAGE 21
GWA Gas-Fired Water Boilers – Boiler Manual 9 Lighting Instructions — GWA standing pilot boilers Robertshaw 7200 gas valve FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot, which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. Before LIGHTING, smell all around the appliance area for gas.
PAGE 22
GWA Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance Table 6 Service and maintenance schedules (service technician and owner) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) ❏ Inspect: ❏ Daily • Check boiler area • Reported problems • Check boiler pressure/ temperature gauge • Boiler area • Air openings • Check air openings • Flue gas vent system • Pilot and main burner flames • Water piping ❏ Monthl
PAGE 23
GWA Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance continued Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.
PAGE 24
GWA Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance 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 22 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.
PAGE 25
GWA Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance continued ❏ Service. . . . . . . . . . ❏ Check/test. . . . . . . . . . Oiled-bearing circulators Air vents and air elimination 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. 1. Inspect automatic air vents (if used).
PAGE 26
GWA Gas-Fired Water Boilers – Boiler Manual 10 Service and maintenance ❏ 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.
PAGE 27
GWA Gas-Fired Water Boilers – Boiler Manual 11 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 “Chart 1”, page 28. Severe personal injury, death or substantial property damage can result.
PAGE 28
GWA Gas-Fired Water Boilers – Boiler Manual 11 Troubleshooting continued Chart 1 — Standing pilot — Boiler will not fire Before proceeding, follow "Troubleshooting sequence" on page 27. If problem persists, then: Is damper harness securely plugged in at both ends? Secure connections. No Check for loose wire connections or bad relay on transformer.
PAGE 29
GWA Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts Figure 16 Section assembly, flue collector, draft hood and vent damper Part Number 550-101-010/0703 29
PAGE 30
GWA Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts continued Figure 17 Base assembly, manifold, orifices and burners 30 Part Number 550-101-010/0703
PAGE 31
GWA Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts continued Figure 18 Jacket assembly The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 23 of this manual. Failure to comply could result in severe personal injury.
PAGE 32
GWA Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts Figure 19 32 continued Trim assembly Part Number 550-101-010/0703
PAGE 33
GWA Gas-Fired Water Boilers – Boiler Manual 12 Replacement parts Figure 20 continued Gas control assembly Part Number 550-101-010/0703 33
PAGE 34
GWA Gas-Fired Water Boilers – Boiler Manual 13 Dimensions Figure 21 Boiler model number GWA-052 GWA-070 GWA-105 GWA-140 GWA-175 GWA-210 GWA-245 Note 3: 34 Dimensional drawing — ALL DIMENSIONS IN INCHES Supply tapping Return tapping Gas connection & manifold size (inches NPT) (inches NPT) (Note 3) (inches NPT) 1/ 11/4 11/4 11/4 11/4 11/4 11/4 1/ 11/4 11/4 11/4 11/4 11/4 11/4 12 14 14 / / 1/2 1/2 1/2 3/4 3/4 12 “A” Vent location “D” Vent diameter “W” Jacket width “H” Damper height (inche
PAGE 35
GWA Gas-Fired Water Boilers – Boiler Manual 14 Ratings DOE 1. Based on standard test procedures prescribed by the United States Department of Energy. 2. Net I=B=R 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.
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GWA Gas-Fired Water Boilers – Boiler Manual W-T 8201 W. Calumet Rd.