Operating instructions

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Part Number 550-110-732/0703

Contents Page

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

2 Prepare boiler ..................................................................... 8

3 Install water piping .............................................................. 9

4 Venting and combustion air ............................................... 12

5 Gas piping ........................................................................ 12

6 Field wiring ....................................................................... 13

7 Start-up ............................................................................ 14

8 Checkout procedure ......................................................... 16

9 Sequence of operation ...................................................... 17

10 Operating instructions ....................................................... 19

11 Service and maintenance ................................................. 20

12 Troubleshooting ................................................................ 25

13 Replacement parts ........................................................... 33

14 Dimensions ...................................................................... 38

15 Ratings ............................................................................. 39

Boiler Manual

GWS

Gas-Fired Water Boilers

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 16.

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 (40 pages)

PAGE 1
GWS Gas-Fired Water Boilers Boiler Manual Contents Page 1 Prepare boiler location ........................................................ 2 2 Prepare boiler ..................................................................... 8 3 Install water piping .............................................................. 9 4 Venting and combustion air ............................................... 12 5 Gas piping ........................................................................ 12 6 Field wiring .......
PAGE 2
GWS 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 21 of this manual. Failure to comply could result in severe personal injury. 1 Codes & checklist Installations must follow these codes: • • • When servicing boiler — 1.
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GWS Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Clearances Residential garage installations Service clearances 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.
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GWS 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. Do not install the GWS into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage. Inspect existing chimney before installing boiler.
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GWS Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air contamination Please review the following information on potential combustion air contamination problems. See Table 3 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.
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GWS Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location continued Air openings Using inside air — direct exhaust venting Louver allowance The GWS boiler can use inside air if no contaminants are present in the boiler space. If contaminants are likely to be present, install the GWS boiler as a direct vent appliance, using the appropriate instructions in the GWS Venting Manual and the instructions in this manual.
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GWS Gas-Fired Water Boilers – Boiler Manual 1 Prepare boiler location Figure 2 continued Provide minimum air openings for GWS boiler installations based on following: Part Number 550-110-732/0703 7
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GWS Gas-Fired Water Boilers – Boiler Manual 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. b. c. Tilt left side of boiler up and place a board under left legs. Tilt boiler the other way and place a board under right legs.
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GWS 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 18 for wiring.
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GWS Gas-Fired Water Boilers – Boiler Manual 3 Install water piping Figure 3 continued Use Figure 3 or Figure 4 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 11) to protect boiler against condensation.
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GWS Gas-Fired Water Boilers – Boiler Manual 3 Install water piping continued Near-boiler piping continued Figure 6 System bypass piping in boiler loop with separate system circulator, using primary/ secondary piping Figure 7 Boiler bypass piping — use only for high water content systems — DO NOT use for radiant panel systems System bypass method Boiler bypass method 1.
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GWS Gas-Fired Water Boilers – Boiler Manual 4 Venting and combustion air Install vent piping and air piping (if used) per appropriate instructions in the GWS Venting Manual, included in boiler envelope assembly. Refer to GWS Venting Manual and to Boiler Manual Section 1, page 4, regarding requirements for: GWS Boiler must be vented and supplied with combustion and ventilation air as described in GWS Venting Manual, packed in envelope assembly with boiler, and Section 1 of this manual, page 4.
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GWS Gas-Fired Water Boilers – Boiler Manual 6 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 original wiring as supplied with boiler must be replaced, use only type 105 °C wire or equivalent.
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GWS Gas-Fired Water Boilers – Boiler Manual 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.
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GWS Gas-Fired Water Boilers – Boiler Manual 7 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 . . . • Read manual Sections 8 and 9 and “Operating instructions”, page 19. • Verify the boiler and system are full of water.
PAGE 16
GWS Gas-Fired Water Boilers – Boiler Manual 8 ❏ ❏ ❏ ❏ ❏ 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 4, page 8 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 17
GWS Gas-Fired Water Boilers – Boiler Manual 9 Sequence of operation Follow all procedures given in this manual and “Operating Instructions”, Section 10, page 19 and on the inside of the boiler jacket panel, when operating the boiler. Failure to do so could result in severe personal injury, death or substantial property damage. 1. Raise room thermostat to call for heat. 2. Inducer and circulator energize. After pressure switch proves proper airflow, control module initiates 10-second prepurge. 3.
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Wiring diagram — GWS boilers Figure 13 9 Sequence of operation continued GWS Gas-Fired Water Boilers – Boiler Manual Part Number 550-110-732/0703
PAGE 19
GWS Gas-Fired Water Boilers – Boiler Manual 10 Operating instructions Applies to all gas valves used on GWS boilers 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.
PAGE 20
GWS Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance Table 6 Service and maintenance schedules (service technician and user) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) ❏ Inspect: • Reported problems ❏ Daily • Check boiler area • Check boiler pressure/ temperature gauge • Boiler area • Air openings • Check air openings • Flue gas vent system • Pilot and main burner flames • Water piping ❏ Monthly
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GWS Gas-Fired Water Boilers – Boiler Manual 11 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.
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GWS Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance continued The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury. ❏ Inspect . . . . . . . . . . Reported problems Boiler heating surfaces Inspect any problems reported by owner and correct before proceeding. 1.
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GWS Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance ❏ Service. . . . . . . . . . Inducer motor 1. With boiler power OFF, place a few drops of S.A.E. 20 motor oil in each of the two motor oiling cups. Use only S.A.E. 20 motor oil to lubricate inducer motor. Do not universal household oils. Motor could be damaged, resulting possible severe property damage. Oiled-bearing circulators 1. The circulator shipped with the GWS boiler is water-lubricated. No oiling is required. 2.
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GWS Gas-Fired Water Boilers – Boiler Manual 11 Service and maintenance continued ❏ Check/test. . . . . . . . . . continued ❏ Review with owner Boiler relief valve 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.
PAGE 25
GWS Gas-Fired Water Boilers – Boiler Manual 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, pages 26-32. Severe personal injury, death or substantial property damage can result.
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting 26 continued Part Number 550-110-732/0703
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting Part Number 550-110-732/0703 continued 27
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting 28 continued Part Number 550-110-732/0703
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting Part Number 550-110-732/0703 continued 29
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting 30 continued Part Number 550-110-732/0703
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting Part Number 550-110-732/0703 continued 31
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GWS Gas-Fired Water Boilers – Boiler Manual 12 Troubleshooting 32 continued Part Number 550-110-732/0703
PAGE 33
GWS Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts Figure 15 Section assembly, flue collector, draft hood and vent damper The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury.
PAGE 34
GWS Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 16 Base assembly, manifold, orifices and burners The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury.
PAGE 35
GWS Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 17 Jacket assembly The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 21 of this manual. Failure to comply could result in severe personal injury.
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GWS Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts continued Figure 18 Trim assembly 36 Part Number 550-110-732/0703
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GWS Gas-Fired Water Boilers – Boiler Manual 13 Replacement parts Figure 19 continued Gas control assembly Part Number 550-110-732/0703 37
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GWS Gas-Fired Water Boilers – Boiler Manual 14 Dimensions Figure 20 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler model number Supply Return Gas tapping tapping connection size (inches NPT) (inches NPT) Note 3 (inches NPT) Gas manifold size Note 3 (inches NPT) “A” Air inlet pipe center (inches) “W” Jacket width (inches) GWS-063 1¼ 1¼ ½ ½ 6½ 13 GWS-095 1¼ 1¼ ½ ½ 8 16 GWS-127 1¼ 1¼ ½ ½ 9½ 19 GWS-158 1¼ 1¼ ½ ½ 11 22 Note 3: Gas piping from meter to boiler to be sized
PAGE 39
GWS Gas-Fired Water Boilers – Boiler Manual 15 Ratings DOE 1. Add “N-I” for natural gas boiler — “P-I” for propane gas boiler. 2. Based on standard test procedures prescribed by the United States Department of Energy. 3. 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.
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GWS Gas-Fired Water Boilers – Boiler Manual W-T 8201 W. Calumet Rd.