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GWS-090E - Williamson

1. 3SN3S Se N 0L 30u d ee M i e e mmm mm wd wm em H adad A va XE HOLIMS e JJIAYIS P ONDOHg LN3WdINDS M9 wg 28 viele Mm aj z _ 97 bo on p a 0u YOLOW V d HOLIMS ONI Y0 X IVISOWYJHL s19 10q JO60 SMD weep DOUIAA EL eanbiy penuiuoo YOIZeABdO zo 9Uu nb S S 6 TT GW S O90 E Gas Fired Water Boiler Boiler Manual 10 Operating instructions NN FOR YOUR SAFETY READ BEFORE OPERATING P This appliance does not have a pilot Itis equipped C Use only your hand to turn the gas control knob Never use tools If the with an ignition device which automatically lights knob will not turn by hand don t try to repair it call a qualified service the burner Do not try to light the burner by hand technician Force or attempted repair may result in a fire or explosion BEFORE OPERATING smell all around the D Do not use this appliance if any part has been under water appliance area for gas Be sure to smell next to the Immediately call a qualified service technician to inspect the appliance floor because some gas is heavier than air and will and to replace any part of the control system and any gas control settle on the floor See below which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance e Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions pho
2. j w temperature VW p gau ge W BR ff m ZE D Drain 2223 e Circulator valve 72806 W Figure 4 Closed type expansion tank Piping to single 10 zone system using closed type expansion tank See Table 5 page 9 for piping sizes CLOSED type expansion tank k t syo Cold water fill St Ru l Isolation Isolation valve valve S Relief valve Circulator A e alternate Jee location Pressure W temperature VW ee gauge 8 AN Drain EEEE BBS Circulator valve 72807 Install water piping 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 con verted gravity systems and radiant heating systems install bypass piping see page 11 to protect boiler against condensation Failure to prevent low return water temperature to the boiler could cause corro sion 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 sup plying the radiant circuits Failure to comply could result in substantial property damage Install boiler so that chilled medium is piped in par allel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult l B R Installation and Piping Guides I
3. Bypass valve 2 Boiler loop circulator System bypass method 1 Apply bypass piping of Figure 6 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 dam age 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 tem perature to the boiler enough to prevent condensation of flue gases Boiler bypass piping use only for high water content systems DO NOT use for radiant panel systems Figure 7 To system Adjust bypass valves 1 and 2 until the boiler pressure temperature gauge r
4. GWS 090E Gas Fired Water Boiler Boiler Manual CERTIFIED ENERGY STAR Contents Page 1 Prepare boiler location cccccccseeeeeeeeeeeeeeeeeeeeseeeseeeeeeeeas 2 CR Ee EE 8 3 Install water DID ING ege 9 4 Venting and combustion air 12 BD Ee Tt E 12 6 PSO Wing E 13 7 Start up WEE 14 8 Checkout procecdure 16 9 Sequence of operation ccccccccccccceeeceeseeeeeeeeeeeeeeeseeeaes 17 10 Operating instructions EN 19 11 Service and maintenanmce 20 12 deele dE 25 13 Replacement parts cccccssssceccesseeecceeseeceeeeeeeesssaeeess 33 14 lee OS vriticctetcesrccadedeainenesencindenutondendetencndecunseoutmenduncanns 38 19 MAUNGO ores eE A 39 Hazard definitions Yisa Hazards that will cause severe personal injury a caytion Hazards that will or can cause minor personal death or substantial property damage IA CAUTION injury or property damage AWARNING Hazards that can cause severe personal injury NOTICE Special instructions on installation operation or death or substantial property damage maintenance that are important but not related to personal injury or property damage AWARNING INSTALLER Read all instructions before AWaARNING USER Please read the following Failure to installing Read page 2 first Follow all instruc comply could result in severe personal injury tions in proper order to prevent personal injury or death or substantial property damage death This manual is for
5. control module receptacle Is thermostat circuit closed continuity across wires Does voltmeter show 120 VAC across pins No Yes NO a y Are all red lights off e Boiler is in standby No ie ee SR e Replace control e Repair replace gt module circulator Retest Wait 30 seconds W s operation Eeer Repair replace Are all red lights off e Verify Sequence of wiring Retest No ies operation Figure 12 l l Replace control module E M Retest e Wait 5 minutes _ Is FLAME light on e If you have sufficient heat boiler should be in normal operating sequence See normal sequence of operation Yes No Figure 12 page 17 WE e If you have less than sufficient heat Are vent and combustion air piping free of blockage Is LIMIT light on No mes No Yes y e Correct conditions and Is manifold pressure i recheck operation 3 50 w c on natural gas e Check limit switch e Replace control module e See Figure 12 page 17 10 0 w c on propane contacts with continuity Retest for normal sequence of Yes No checker operation Are limit switch contacts ES closed e Check heat loss calculation No gar Check rollout switch versus boiler size continuity is switch e Clock gas input e Replace timer relay FK closed e Wait for boiler water to cool to temperature 20 to 30 F No Yes lower than temperature set on limit switch Are limit Switch contacts closed e Replace rollout switch No Yes y e Check any other e Boiler
6. LI Check for nearby connection to e System water piping e Venting connections e Gas supply piping e Electrical power LI Check area around boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free of com bustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage _1 Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service 1 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 when required in boiler water causing system and boiler to freeze and leak Part Number 550 110 737 1108 1 Prepare boiler location Clearances Service clearances 1 Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as listed in Table 1 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 Table 1 Minimum service clearances Service clearances Min
7. check for proper combustion and make any necessary adjustments Og H gt Verifying gas manifold pressure downstream of gas valve a Natural gas Manifold pressure high fire 3 50 w c Manifold pressure low fire 0 90 w c while in low fire at Start up 60 seconds Propane gas Manifold pressure high fire 10 0 w c Manifold pressure low fire 3 50 w c while in low fire at start up 60 seconds If necessary adjust gas pressure on the gas valve as shown below After adjustments refer to page 34 to check the flame High fire gas pressure adjustment Low fire gas pressure adjustment Honeywell VR8204Q two stage gas valve Part Number 550 110 737 1108 12 Troubleshooting Label all wires prior to disconnection when servic ing 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 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 minimum scale range of 0 10 c Continuity checker
8. loose fitting clothing gloves and eye protection M Operations such as sawing blowing tear out and spraying may generate airborne fiber concentration requiring additional protection m Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid M Eye Irrigate immediately M Breathing Fresh air Part Number 550 110 737 1108 21 GW S O90 E Gas Fired Water Boiler 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 _J Inspect 200 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 3 on page 5 of this manual If any of these are present in the boiler intake air vicinity they must be removed 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 Verify that boiler vent discharge and air intake are clean and free of obstructions N
9. 1 1 Inlet air box front panel in Inlet air box front panel kit 34 Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual 13 Replacement parts continued Figure 17 Jacket assembly AWARNING 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 T3252 em numer Some O OO SO Jacket panel left side with insulation Natural gas 431 223 490WT Propane 431 223 496WT i ae Junction box 2 x 4 available at local supply house 8 Jacket panel right side with insulation 431 223 488WT i wa Jacket panel top GWS 090E 431 223 493WT O s eaens ams mmm O o mesom ams ams O e earen ams mmm O o wmm rT SCC a ner mmm Part Number 550 110 737 1108 35 GW S O90E Gas Fired Water Boiler Boiler Manual emm 13 Replacement parts continued Figure 18 Trim assembly T3253 i Eiaa BA part number 1 Pressure relief valve ASME 30 PSIG 34 male inlet Conbraco 10 407 10 511 546 920WT Watts M330 Pressure relief valve ASME 30 PSIG 3 female inlet Conbraco 10 408 05 511 546 924WT Fittings shown are factory installed on boiler Watts 335 2 V HA Si Combination pressure temperature gauge with 21 2 short shank Ametek PTA 1088 510 218 099WT ENFM 4104 3 Drain valve 3 4 Conbraco 31 606 01 Fittings shown are
10. 3 of this manual lianc 2 2 For installations with clearances less than shown in GWS GWS 1 page 3 of this ar Ger provide e 4 die 050E 090E each with 1 square inch of free area per 1 000 Btuh o eu total input of all appliances aioe e Ze A Air frm Inside KA f Air 2 Openings each NO Openings are ine V 4 square inch free area per needed provided 5 6 1 000 Biuh input EE aaa Te D Air of other appliances a Table 1 page 3 SC Gws iz ii Pag 090E Max i a alle do not include GWS input this manual AR 7 B Air Directly from Outside A 2 Openings each NO Openings are EI 4 square inch free area per needed provided 6 4 000 Btuh input Clearance ground bier Air i is NO an shown GWS wo E do not include GWS input this manual 090E Max C Airfrom Outside v r 2 Openings each NO Openings are Using horizontal ducts p e 2 p 9 adel Geck opening Kl E 1 square inch free area per H 2 000 Btuh input tee end A is an shown 2 of other appliances in Table 1 page 3 of GWS 1 do not include GWS input this manual 090E Max i Air from Outside or Attic Lower lee in Floor or Vertical Duct l Openings each NO Openings are Outside or ventilated attic 1 needed provided CI square inch free area per D 4 000 Btuh input ole recor is SBS than shown Duet a of other appliances in Table 1 page 3 of E do not include GWS input this manual Bin malli rat Gws r 090E Me i Fo a e ee
11. 70 latest edition Electrical installation must comply with 1 National Electrical Code and any other national state provin cial or local codes or regulations 2 InCanada 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 page 18 Circulator is shipped loose but wiring harness is pre attached to the boiler Connect wires in circulator junction box GW S O90 E Gas Fired Water Boiler Boiler Manual 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 sunrays or fire places 3 Ifthermostat has a heat anticipator set heat anticipator in ther mostat to match power requirements of equipment connected to it If connected directly to boiler set per wiring diagram Figure 13 on page 18 For other devices see manufacturer s specifications Also see instructions with thermostat Junction box furnished 1 Connect 120 VAC power wiring See Figure 9 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 require
12. 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 instruc tions 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 di rected under Section 7 page 15 of this manual Water piping 1 Check the boiler interior piping and all system piping for signs of leaks 2 Repair any leaks before proceeding AWARNING Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheat ing 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 inducer outlet connection after turning off power to the boiler 22 2 Use a bright light
13. 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 _J Start up 1 Perform start up procedures of Section 7 pages 14 15 in cluding procedure to verify operation of burners on page 15 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 5 page 12 and section 7 page 14 verifying no indications of leakage and all piping and connections are in good condition Read Operating instructions Section 10 page 19 Start the boiler following Operating instructions Section 10 page 19 LI Check test eu 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 5 page 12 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 en sure pressure rise is normal Too high a rise would indicate a waterlogged or undersized expansion tank Part Number 550 110 737 1108 Air vents and air eli
14. Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual 1 Prepare boiler location continua Air contamination Table 3 Corrosive contaminants and likely locations Please review the following information on potential combustion Products to avoid air contamination problems See Table 3 for products and areas which may cause contami Spray cans containing chloro fluorocarbons nated combustion air Permanent wave solutions AWARNING The GWS 90E boiler must be direct vented using Chlorinated waxes cleaners ducted outside air Chlorine based swimming pool chemicals The vent air termination must be installed in a location that is free of the contaminants listed in Calcium chloride used for thawing Table 3 Sodium chloride used for water softening Allowing the boiler to operate with contaminated air can cause damage to the boiler and vent system Refrigerant leaks resulting in possible severe personal injury death Paint or varnish removers or substantial property damage 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 Refrigera
15. 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 e 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 pos sible 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 1 Prepare boiler location Codes amp checklist Installations must follow these codes e Local state provincial and national codes laws regulations and ordinances e National Fuel Gas Code ANSI Z223 1 latest edition e Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required e National Electrical Code e For Canada only B149 1 or B149 2 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE Read and follow the special instructions for the Com monwealth of Massachusetts located on page 40 of this manual Certification NOTICE The GWS O90E boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21 13 latest edition Before locating the boiler
16. and POWER light on steady Usually indicates pressure switch opened during run cycle May also be caused by wind gusts in excess of 31 mph for non direct vent sidewall vented boilers AWARNING 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 e Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds e Thermostat should call for heat and appropriate zone valves open Does blower motor operate No Yes l l e Remove INDUCER plug from plug receptacle on control module e Place voltmeter leads across the 120 VAC N and e Wait 5 minutes 120 VAC H pins of the INDUCER receptacle left column Is PRESS SWITCH light flashing center and right column bottom pins Does the voltmeter indicate 120 VAC No Yes No Yes e Replace inducer assembly e Boiler should be in e Retest normal operating sequence e Observe operation until Remove one of the wires connected to the pressure switch Check continuity across the switch terminals Does the ohmmeter indicate the switch is closed No Yes thermostat is satisfied and inducer has completed its post purge cycle l Inspect and check wire harne
17. 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 and valves unless they will remain for use in the system piping 4 Remove plug from relief valve tapping See Section 3 page 9 to replace relief valve Part Number 550 110 737 1108 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 page 18 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 Elect
18. cool before per forming 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 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 DONOT use petroleum based cleaning or sealing com pounds in boiler system Water seal deterioration will oc cur causing leakage between boiler sections circulator flanges diaphragm tanks or other system components This can result in substantial property damage DO NOT use homemade cures or boiler patent medicines Serious damage to boiler personnel and or property may result Continual fresh makeup water will reduce boiler life Min eral 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 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
19. do so can damage the boiler resulting in substantial property damage A DANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Inspect base insulation AWARNING he 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 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 dam age Part Number 550 110 737 1108 D Start up continued Operate boiler DO NOT proceed with boiler operation unless boiler and system have been filled with water and all in structions and procedures of previous manual sec tions 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 e Verify the boiler and system are full of water e Verify the Start up preparation procedures of this section have been completed Start the boiler Follow Operating instructions
20. from ac cessory bag Install in boiler return connection as shown on in Figure 18 item 3 page 36 Install circulator on either the return or supply 3 Remove 1 nipple 1 tee bushing and pressure tempera ture gauge from accessory bag Pipe to boiler supply connec tion as shown in Figure 18 item 2 page 36 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 connec tion on the 114 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 connec tion 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 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 WARNING Po not leave boiler unattended A cold water fill could expand and
21. gas Fuel L Propane Pilot Configuration Intermittent pilot T Taco pump GWS OS90EN I T e Install GWS O90E boilers for residential radiant panel systems converted NOTICE SE gravity heating systems or other low water temperature applications per instructions in this manual to avoid damage due to condensation GWS O90E boilers are CSA design certified for installation on combustible flooring GWS O90E boilers are ASME rated for 50 psig working pressure Part Number 550 110 737 1108 39 GW S O90E Gas Fired Water Boiler Boiler Manual Addendum Instruction for the Commonwealth of Massachusetts a 40 This addendum must only be used by a qualified heating installer service technician Read these instructions completely before beginning the installation Failure to comply could result in severe personal injury death or substantial property damage For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETEC TORS At the time of installation of the side wall horizon tal vented gas fueled e
22. included with boiler Hammond Valve 710 Matco Norca 205F04 GAN 007 511 405 113WT not shown Circulator hardware kit includes 2 flanges 4 nuts 4 screws 2 pipe nipples 1 NPT 381 354 525WT SC Circulator gasket universal 2 per boiler 590 31 7 535WT GE Circulator wiring harness kit with Molex loose 381 354 528WT 36 Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual 13 Replacement parts continued Figure 19 Gas control assembly fis eh KN N ah Oe VW N V KAN e K SA N Wi AAA i hh Ki T x AS 2 KWAN Re yi x AN deal Bi q cy A A yh WW V i NY bal L KKK T SN MN A CS i A x O GA A SS Ae H ec Kc 2 d e r w A 73254 Af a Manufacturer s Di Bremen Manutasturor Wonutaeturors part number Natural gas components Gas valve 2 x 27 two stage Natural gas Honeywell VR820402426 511 044 507WT TEEN kit with orifice and aluminum pilot gas Weil McLain ee 511 330 O80WT Propane gas components iiae e oe wus mmm Natural gas and propane gas components netshown Wiring harness control WeikMcLain mmm enen eines 1200 Wues mmm Air pressure switch oo 1 71 1 W C GWS 090E Cleveland NS2 1047 08 511 624 656WT FE TS12190 510 350 468WT Tubing air pressure switch 0 12 I D silicone not shown red to collector hood Lydall 590 317 650WT white to tra
23. metal or plastic identification plate shall be permanently mounted to the exterior of the build ing at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BE LOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equip ment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer f
24. of the direct vent systems combustion air ducted to boiler covered in GWS Venting Manual included in the boiler envelope assembly The GWS vent starter is a special item designed only for GWS and GWS 90E available from each vendor Do not attempt to connect the vent to a GWS 090E boiler with any other means AWARNING DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Vent termination and combustion air supply The GWS 090E boiler may be vented through the roof or through a side wall Follow the appropriate instructions in the GWS Venting Manual for the vent system chosen The maximum vent length depends on boiler size Refer to the GWS Venting Manual to determine acceptable vent length Combustion air for the GWS O90E boiler must be ducted directly to the boiler from outside For outside air direct vent installa tion two options are available for the flue air termination The air supply must ALWAYS terminate at the same location as the flue using either 1 Vertical direct vent installation Obtain the Through Roof or Through Unused Chimney Termination Kit Refer to the GWS Venting Manual packed with the kit and to the vent manufac turer s instructions for the vent material chosen 2 Sidewall direct vent installation Use the Vent Air Intake Termination Kit shipped with the boiler Refer to the GWS Venting Manual shipped with the boiler
25. page 19 If boiler fails to start see If boiler doesn t start Check for on this page Check system and boiler G 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 se vere personal injury death or 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 Check system piping for leaks If found shut down boiler and repair immediately sch 2 Vent air from system using manual vents Air in the system will interfere with circulation and cause heat distribution prob lems 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 Venting system must be sealed gas tight to prevent flue gas spillage and carbon monoxide emissions Failure to comply could result in severe personal injury or death 4 Check around the boiler for gas odor following the proce dure of Sec
26. rating label Check manifold gas pressure by connecting manometer to downstream test tapping on main gas valve Manifold pres sure for natural gas should be 3 5 w c and for propane gas should be 10 w c Observe several operating cycles for proper operation Set room thermostat to desired room temperature Fill in Installation and service certificate below Review all instructions shipped with this boiler with owner or maintenance person Return instructions to envelope and give to owner or place in pocket inside front panel in boiler Installation and service certificate Boiler model CP number Series Date installed O Installation instructions have been followed O Checkout sequence has been performed Measured Btuh input O Above information is certified to be correct O Information received and left with owner maintenance person Installer company address 16 phone installer s signature Part Number 550 110 737 1108 9 Sequence of operation AWARNING Follow all procedures given in this manual and Op erating 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 Raise room thermostat to call for heat 2 Inducer and circulator energize After pressure switch proves proper airflow control module initiates 10 second prepu
27. 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 accesso ries 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 AWARNING 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 Table 6 Pipe capacity for 0 60 specific gravity natural gas Capacity of pipe for pipe size of Capacity in standard cubic feet gas per hour Gas pipe length 12 Natural Gas 1 See Table 6 for pipe length and diameter Base on rated boiler input divide by 1 000 to obtain cubic feet per hour Table 6 is only for gas with specific gravity 0 60 with a pressure drop through the gas piping of 0 30 w c For addit
28. to inspect the flue pipe interior and inducer interior 3 Inspect the boiler vent outlet area and heating surfaces by looking through the opening 4 Ifthe vent pipe or inducer interior show evidence of soot fol low Cleaning boiler heating surfaces in this manual section to remove the flue collector and clean the boiler if necessary after close inspection of boiler heating surfaces If there is evidence of rusty scale deposits check the water piping and control system to make sure the boiler return water temperature is properly maintained per this manual 5 Reconnect vent to inducer outlet and replace all boiler com ponents 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 inlet air box top panel Figure 16 item 13 page 34 2 Inspect gasket Figure 16 item 14 page 34 2 Inspect burners and all other components in the inlet air box and boiler base 3 If burners must be cleaned access the burner assembly by first removing the burner baffle Figure 16 item 4 page 34 Then remove the screws securing the burner tray to the manifold Slide the burner tray out Then brush and vacuum the burners thoroughly making sure all ports are free of debris 4 Inspect the base insulation Verify that the insulation is intact and secure against all four side
29. to the system and prevents the air from bubbling up through the water as it returns from the system e Donotuse automatic air vents in systems with closed type 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 Diaphragm or bladder type welded gas tight with a rub ber 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 e 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 ad ditional 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 I
30. valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line e Failure to comply with the above guidelines could result in failure of the relief valve to operate result ing in possibility of severe personal injury death or substantial property damage e Test the operation of the valve after filling and pres surizing 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 Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual Near boiler piping continued Table 5 Water pipe size based on 20 F rise To From system system Boiler model number 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 de sired See Figures 3 and 4 page 10 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 Expansion tank Diaphragm or bladder type expansion tank Figure 3 page 10 1 Ensure expansion tank size will handle boiler and system water volume and tempe
31. water temperature exceeded setting If rollout thermal fuse element has limit controls wired on limit switch with thermostat calling for opened determine cause and into the limit heat Boiler is OK See normal sequence correct condition Failure to do so circuit If all are Replace ion Fi ill cause severe personal injur eeu te of operation Figure 12 page 17 wi P jury OK then replace Retest e Also check setting on limit switch should death or substantial property control module be above 140 F damage e Retest 32 Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual 13 Replacement parts Figure 15 Section assembly flue collector draft hood and vent damper AWARNING 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 q mn e men rn pe gen SS is H T3250 E E 3 High limit 30 differential with well Honeywell L4080D1036 510 312 250WT White Rodgers 11B81 3 Inducer fan assembly kit includes inducer fan assembly gasket and 381 356 499WT nuts Part Number 550 110 737 1108 33 GW S O90E Gas Fired Water Boiler Boiler Manual emm 13 Replacement parts continued Figure 16 Base assembly manifold orifices and burners AWARNING The boiler contains ceramic fiber and
32. Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the wires e There should NEVER be a voltage reading e Once the external thermostat circuit wiring is checked and Did you find a voltage across the two external thermostat circuit wires e f a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves corrected if necessary reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle Yes E e Leave external boiler thermostat connection wires disconnected from boiler e 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 e 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 e An isolating relay may be required y e Boiler should now operate per the normal sequence of Operation shown in Figure 12 page 17 Part Number 550 110 737 1108 No E e f 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 e Turn off power to th
33. 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 Part Number 550 110 737 1108 11 GW S O90 E Gas Fired Water Boiler Boiler Manual 4 Venting and combustion air Install vent piping and air piping if used per appropriate instruc tions 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 e vent system e combustion air openings e combustion air quality Wy ia The GWS O90E boiler must be direct vented only combustion air ducted to boiler 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 Failure to do so will cause severe personal injury or death Read and follow the special instructions for the Com monwealth of Massachusetts located on page 40 of this manual 5 Gas piping 1 Remove jacket front panel and see Figure 8 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
34. as aBeyon Mo SNIJIAYIS YO ONITIWLSNI 340438 H3MOd 8060 9SL SZZ 0SS LOINNODSIG H1Y30 Y0 AYNENI 3H3A3S 3SNVO NYJ GYVZVH NOOHS 1V91NL9373 EZZES IM GEM e peoy JBLUN ED ISAM LOCH e LA jnpow jonuop EREN gef wosnas ONINUYMY lH Sue Y SR pA z man 10 9eUU09 UI Bnig pen UYM z dr ec s Le 49018 TWNIWY3L au e YOUMS SS ld H HOLIMS S i A JUNSS3Ud HI E e lt r mm La LO LJ _ E YAW z aou pasn p SLIWIT o o o o MES yani TYNOILIOOY E n S SR Sa ale mun ly G r D i H W 38 y oTi D ee A HOLIMS LNT EEN II eh ee aae o H KIT SY9 LO T ak IWLSOWYSHL y au ANH U3WNIL samod O 5 3 A s 2 OWA bz S e omg als ga A LOOO Wat Te 300419313 E NOILIND e LO Q g ya JA n A oi D eege dea HOLY INOUIO 3 VLOA O eege a HOI H ep se z a fetta e N bh A INGON 8 d JINON E Je NY TOXLNOOD JOVIIOA HOH NOILINSI HOLOW Y3JNANI LA HOLIMS ve i e io gou JJIAYIS JJ JVA OZI DN SY Yt M o N HOLIMS JYNSSIYd YJWYOJSNYYL JOEQUNN Wed H3ONGNI up se winejosjed Gauanbu 10 EIDEN e JEyEM p 910J e Part Number 550 110 737 1108 uomuft ojd Weu 11 e 4060 SMD ONIMIM AYOLOVI IVA O21 J1SV9 NOILIND ONIMIM 01314 JDVLIOA MOT ONIMIM AXOLOVS SDVLIOA MOT ONIYIM 0134 JVA OZI mm pua a 341 LNOTIOY EST A 1 A A D OG oOo oO HOLIMS LIN 2 9 0u JUNIVHIdGW3L Pesn ul SLIWIT HIM WNOILLIGOY fa X08 NOILONAL bt l 9 SLNN 2HINM
35. ces 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 Place in operation the appliance being inspected Follow the lighting 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 ez d a 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 GWS 090E special vent system required Vent system The GWS 090E boiler requires a special vent system designed for pressurized venting Model GWS O90E is rated ANSI 221 13 Category IV pressurized vent likely to condense in the vent You may use any
36. d U tube manometer and inclined manometer with 0 2 w c range 2 Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler 3 Make sure thermostat is calling for heat and contacts includ ing appropriate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground Check the following 1 Wire connectors to control module are securely plugged in at module and originating control 2 Gas pressures a With boiler off 13 w c maximum natural or propane gas pres sure upstream of gas valve b With boiler on e 5 w c minimum natural gas pressure or 11 w c propane gas pressure upstream of gas valve e 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 Verify gas manifold pressure as shown on page 24 Check pressure switch setting Make sure boiler water temperature is 100 F or cooler before starting procedure to obtain appropri ate readings 1 See Figure 14 and Table 8 Table 8 Pressure switch setpoint for elevations above 2 000 ft contact your local supplier for details Boiler model number Inches W C Remove both air pressure switch hoses from air pressure switch 3 Install tees and tubing as shown in Figure 14 to inclined ma nometer Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual Figure 14 Checking
37. d 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 Figure 9 Field wiring connections service switch and thermostat or end switch provided by installer E 120 VAC Hot Neutral Ground CH Thermostat Z e or end switch not provided WW Service S switch not provided 7 i I d A J J f Q 7 7 SA mb EI Ground screw Wire nuts CH Z s Green Black Black gt O 5 saps cei is hice al H Thermostat Junction box NOTICE oiler circulator is shippe 1 loose with wiring leads through boiler left side circulator is piped connect wires to circulator Jacket left side WD0O0O1 and secure harness conduit connector to circulator junction box NOTICE The GWS 090E control module is polarity sensitive The hot and neutral wires must be connected to the correct leads A flashing POWER light usually indicates reversed polarity of 120 VAC lead wires Part Number 550 110 737 1108 13 GW S O90E Gas Fired Water Boiler Boiler Manual 7 Start up Check for gas leaks AWARNING Before starting the boiler and during initial opera tion smell near the floor and around the boiler for gas odorant or any unusual odor Do not proceed with start up if the
38. e OE T Saw space TTT NO combustion air openings are needed when the boiler and other appliances are installed in a space with a volume NO LESS than 50 cubic feet per 1 000 Btuh of all installed appliances Sum the total input of all appliances in MBH 1 000 s of Btuh and multiply this number times 50 Building must not be of Tight construction see page 6 Example For total input of 100 MBH 100 000 Btuh minimum volume is 50 x 100 5 000 cubic feet At a ceiling height of 8 feet space must have at least 5 000 8 625 square feet 25 feet x 25 feet for instance 73201E Exception to combustion air opening rules Part Number 550 1 10 737 1108 7 GW S O90 E Gas Fired Water Boiler 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 Move entire crate and pallet next to selected location Remove crate Leave boiler on pallet 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 NOTICE Damage to boiler can result 5 Check level a Shim legs if necessary b Do not alter legs PED Inspect orifices and burners connect air adapt er 1 Remove front jacket door Remove a
39. e boiler for 1 minute e Turn on power and allow boiler to cycle Do the TSTAT and POWER ights still flash No Yes y e Replace control module e Retest 27 GW S O90E Gas Fired Water Boiler Boiler Manual emm 12 Troubleshooting continued CHART 3 PRESS SWITCH amp POWER lights flashing Usually indicates pressure switch stuck closed or failed to make within 5 minutes AWARNING 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 e Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds e Thermostat should call for heat and appropriate zone valves open Does inducer motor operate No Yes yp e Wait 45 seconds Does inducer motor operate Z Yes o al INDUCER plug from plug receptacle on control x Waite minutes l i Inn e Place voltmeter leads across the 120 VAC N and SEENEN 120 VAC H pins of the INDUCER receptacle left column No Yes center and right column bottom pins Does the voltmeter indicate 120 VAC No Yes a e Try reseating plug in module receptacle and restart e If inducer still does not e Boiler should be in normal operating wor
40. e operation until thermostat is satisfied and blower has completed its post purge cycle 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 e TURN OFF POWER to boiler at service switch or breaker e Remove air inlet box top see Figure 16 page 34 for location e Verify pilot gas line is not kinked obstructed or damaged and is correctly attached to pilot and gas valve e Verify pilot ignition electrode electrode ceramic and spark lead wire from control are in good condition Spark gap should be approximately 1 8 e Correct any above problems replacing pilot if burner or wiring is damaged e Reinstall burner shield to operate boiler for retest after any changes or corrections e If none of the above corrects problem then replace the control module reinstall air inlet box top and retest Part Number 550 110 737 1108 a Contact gas supplier to correct pressure or gas supply A TURN OFF POWER to boiler at service switch or breaker Remove burner shield see Figure 16 page 34 for location a O 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 fla
41. eads approximately 60 F higher than the System temperature gauge system temperature gauge valve 2 Bypass valve 1 Circulator gz Isolation valve BPOOO2 Boiler bypass method 1 Apply bypass piping of Figure 7 to high water content systems such as converted gravity systems 2 The bypass arrangement shown protects the boiler from dam age 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 approxi mately 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 tem perature 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
42. essure unless the appliances are installed as direct vent 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 e Prevent the boiler from firing if the damper is not fully open e 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 Part Number 550 110 737 1108 GW S O90 EE Gas Fired Water Boiler Boiler Manual 1 Prepare boiler location continued Figure 2 Provide minimum air openings for GWS O90E boiler installations based on following Direct vent installation combustion air must be piped to GWS 090E Room Air Openings See Exception Required area of the air openings given in this table are free area after the correction for louver obstruction a Wi Apply sizing information in this table Figure 2 only Vent ie Vent Combustion to installations with clearances no smaller than those Other piping air piping piping air pi shown in Table 1 page
43. f 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 au tomatic 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 ing valve and boiler See Figure 5 for typical installation of balanc check valve Figure 5 System supply ES d Circula System return gt 72510 tor ts ch Piping refrigeration systems Expansion tank Water chiller cb Vv Strainer Check valve Wi Dill Wi Wii Boiler t Balancing valve Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler 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 SE 12 System circulator ge system Be Max by others system Adjust bypass valves 1 and 2 to maintain 160 F or higher in boiler Bypass valve 1 Isolation lt valve
44. f tank won t hold pressure membrane has been damaged Replace tank 23 GW S O90O0E Gas Fired Water Boiler Boiler Manual 11 Service and maintenance continued LI Check test continued 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 manu facturer 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 9 before proceeding further Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumb ing 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 plumb ing 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 2 After following the above warning directio
45. facturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection mM Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust Mm Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for dis posal m Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid M Eye Irrigate immediately M Breathing Fresh air REMOVAL OF FIBERGLASS WOOL OR INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS AWARNING 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 M 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 de pending on the job site conditions Current NIOSH recommendations can be found on the NIOSH web site at htto www cadc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved
46. 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 Wen mm mm mm vn mm mm vu mm e 73251 Item Description Partnumber item Description 1 Partnumber Base insulation kit includes insulation for GWS O90E 381 356 516WT Inlet air box front panel gasket use Gasket kit all base parts shown above plus gasket Inlet air box top panel in Inlet air box top panel kit WEE ER ae seine Inet air d top panel gasket use Gasket kit and base Base assembly kit includes base panels GWS O90E 381 356 523WT tems 1 2 3 4 5 6 7 8 11 13 22 and 23 plus insulation Air box gaskets and EE 20 Burner orifice Natural gas sea level 560 529 126WT 1 _ Base pan n Base seb Boiler leg kit 950 320 219WT 22 Grommet for sealing pilot tubing wiring opening 591 850 064WT Heat shield in Base assembly to Air box Burner baffle in Base assembly Inspection port clear plug 591 491 216WT Base left side panel in Base assembly Hex nut for burner end stud 5 mm 550 320 170WT 6 _ Base right side panel in Base assembly Gasket for Air inlet box covers 8 foot length 590 317 400WT Base back panel in Base assembly Le Base front cross tie assembly in Base assembly Pilot bracket 450 003 689WT Pilot burner assembly Natural gas 511 330 080WT Pilot burner assembly Propane gas 511 330 081WT
47. he system c Close zone isolation valves d Open quick fill valve on cold water makeup line e f Ge Open purge valve 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 sys tem 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 Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 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 g1 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 AWARNING Leaks must be repaired at once Failure to
48. imum Top for cleaning flueways Front for access to controls and components Left side for cleaning and servicing Right side Minimum clearance to combustible materials 1 Hot water pipes must be at least 1 2 from combustible mate rial 2 Vent pipe must be at least 2 inches from combustible material except where otherwise noted in GWS Venting Manual Figure 1 Minimum clearances in small spaces Fresh air openings each air opening must have free area at least 1 square inch y oe Fa jf ff fff fe E F FaFa FFA Lee E Ee 7 F4 CEE fs Bee Li wi d ai wl Ge a Ce OOF il e wi ee Fa d E fa al Pa it al Pl Ee E d Ai a Ee E Ee tb ral ra F A e ral Wei A per 1 000 Btuh of GWS 4 hp r A input A e Ee H Ee Sa Fa ra ae Ee E G E KE E Fa Ee Fa r i 1 5 E Fa Fil YM 7 Y a d A e Te Le e a L ei A G Gel f y re Led S CG A ZA kk 3 g gt 2 lt s be 4 A F d ff J A Fa Ge A Ge Kee l A dE PA A amp 10 a of A AA A SEES KA G Sh Lee 4 G GG A gf H Le d a A A g Z 6 A A y A 7 E o H Lieber K dE Top view Side elevation 73202 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 clear ances are required to any surface whether combustible or non combustible Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual c
49. ing occurs e 1 hour waiting period e Opening and closing of thermostat circuit Part Number 550 110 737 1108 e Removal of 120 VAC power for at least 45 seconds 73203 17 GW S O90 E Gas Fired Water Boiler Boiler Manual Papinoid jou sway We J8 10G 3 349 JOU jim pue pasamod uaym WD YIMOd SU YSEI WM 103709 pasuanal S uejod i amod OYA OZ Buiwoaui au 0 aAn suas uejod et anpow jOJUOD dU OL Asea Kew suoneaol ybi snyers pue s0 98uUU04 E padde samod Out umoys IE UOD UN 9 UMOUS SB 0J3 U09 yw 331109 ym sanas u 943 mu YBIy euonppe JO ND J33em MOJ S OIJUOD pwj peuoippe Aue aM Z UONPULOJU UONPD dde 104 331100 3y YM payaed SUOIJINIJSU JUBUODWOD J01 u09 0 13434 0 suonsebins Buin pue uonesidde 10 jenuew siy pue suononaysul S JOINIIE NUEW JUIUOGWOD dU 0 13434 SIOEN JO S AJEA auoz sayla asn Guiuoz ajdn nw 104 Ss sdwe 9 0 au0z aurs Humas sozedidnue yesoway L p quajeainba J0 4 00Z 30 snw 341 nojo e 0 saim uondaaxg yUafeAINDS JO aM 5 SOL wnuwiuiw asn pasejdas aq snw asuerdde ay YIM paddns se as jeulbuo ay jo Aue UC Auessaoau u Ajquasse youd asejd y ajqeavejda pja JOU BIE saim peal Olid Z Syuawainbas BPOd e20 JO Jeunosd euoneu 13430 Aue pue ped 9 79 1229 ve epeueg g Syuawanbas apoa e30 JO ayeys jeuoneu Jayjo Aue puy 9 3 N YSN Y UUM BOURPIOIIE UI Pajeysu aq ISNW BULMA UN UL S8 ON AN OH uonoe
50. ional gas pipe sizing information see ANSI 2223 1 B149 1 or B149 2 for Canadian installations 2 Inlet pressure required at gas valve inlet e Maximum 13 w c e Minimum 5 w c e Manifold gas pressure 3 5 w c at high fire 0 90 w c at low fire while in low fire at start up 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 e Maximum 13 w c e Minimum 11 w c e Manifold gas pressure 10 w c at high fire 3 5 w c at low fire while in low fire at start up Figure 8 po Manual main shutoff gas valve when required Ground joint union when required 72811 Part Number 550 110 737 1108 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 NOTICE 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 Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA
51. ir adapter fitting from air inlet hose see Figure 17 page 35 items 9 and 10 and screw into opening on jacket top Reconnect air hose to bottom of air adapter fitting Remove inlet air box top panel See Figure 16 item 13 page 34 2 Check for correctly sized manifold orifices See Table 4 for siz ing The orifice size is stamped on the orifice spud barrel A DANGER Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury death or substantial property damage 3 Reinstall inlet air box top panel and jacket door AWARNING Do not operate boiler without inlet air box top panel secured in place Failure to comply could result in severe personal injury death or substantial property damage Table 4 Manifold orifice sizing Natural gas Sea level Sea level 2 000 ft 2 000 ft 2 55 mm 1 60 mm Sea level 2 000 ft 1 60 mm Sea level 2 000 ft 2 55 mm Canada Note 1 For U S elevations above 2 000 feet contact your local supplier for details Pressure test Perform hydrostatic pressure test Pressure test boiler before attaching water or gas piping or elec trical supply except as noted below Prepare boiler for test 1 Remove the shipping nipple from GWS O90E supply tapping and remove the boiler relief valve Temporarily plug the relief valve tapping with a 34 NPT pipe plug 2 Remove 11 nipple reducing tee and drain valve
52. k replace inducer SE b Are vent or combustion air assembly Observe operation until passages blocked DEE thermostat is satisfied and inducer has completed its post purge e Remove one of the wires connected to the pressure cycle switch e Check continuity across the switch terminals No Yes Does the ohmmeter indicate the switch is closed No Yes Replace control e Check air pressure switch modile per manual Section 12 e Clear passages and See e Replace if necessary recycle boiler l e Retest e Recheck boiler operation 28 Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual 12 Troubleshooting continued CHART 4 FLAME amp POWER lights flashing Usually indicates flame sensed when it shouldn t be there AWARNING 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 Are manual main shutoff valve and gas valve open No Yes e Turn off power to the boiler at service switch or breaker e Wait at least 45 seconds e Turn on power to boiler e Restart boiler following Operating instructions in this manual Section 10 e Look through the pilot inspection port in front of air inlet box to see if the pilot is burning during the prepurge period first 30 seconds of operation e Leave mai
53. low 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 20 Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler 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 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 WE 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 manu
54. me 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 No Yes e Check the voltage across Make sure ground wire terminals PV and C of the terminal is securely fastened gas valve to control module mounting Is 24 VAC present there Screw Yes If the wiring from the e Check the voltage across control module to gas terminals MV and C of the valve is intact replace the gas valve control module Is 24 VAC present there Retest No VEE ee L 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 Oo yo TURN OFF POWER to boiler at service switch or breaker Check flame signal Detach sense lead from ignition control Connect negative lead of MCROAMMETER to control sense terminal Connect positive lead of MICROAMMETER to sense wire DISCONNECT red wire connected to terminal MV 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 E e If the wiring from the contr
55. mination 1 Inspect automatic air vents if used Also inspect air separa tors to ensure they are operational The cap must be unscrewed one turn to allow air to escape 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 un screwing one turn Limit controls and cutoffs 1 Inspect and test the boiler limit control Verify operation by turn ing 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 9 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 e Make sure this type of tank is fitted with a tank fitting such as the B amp G Tank Trol or Taco Taco Trol This fitting reduces gravity circulation of air saturated tank water back
56. n manual gas valve closed e Turn off power to boiler at service switch or breaker e Wait at least 45 seconds e Turn on power to boiler e Restart boiler following Operating instructions in this manual Section 10 Do FLAME and POWER lights still flash No Yes Is pilot burning during prepurge period l No Yes e Replace control module e Retest e Replace gas valve e Retest boiler Are FLAME and POWER lights flashing e Allow boiler to continue cycling Are FLAME amp POWER lights flashing No Yes No Yes TURN OFF POWER e Boiler may now be e Replace control e Boiler should now Replace control Holler absence Sich operating module operate normally module or breaker homme e Retest e Original flashing Retest Open main manual gas Perform start up FLAME light valve procedures in caused by gas Turn on power to boiler boiler manual to valve not at service switch or breaker Restart boiler per lighting instructions Perform start up procedures in boiler manual to verify proper operation verify proper operation Part Number 550 110 737 1108 operating properly e See normal sequence of operation Figure 12 page 17 29 GW S O90E Gas Fired Water Boiler Boiler Manual emm 12 Troubleshooting continued CHART 5 PRESS SWITCH light flashing
57. nditions 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 39 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 discon nect 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 14 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 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 t
58. ne in your building e fyou cannot reach your gas supplier call the fire department ED OPERATING INSTRUCTIONS B STOP Read the safety information above on this label Set the thermostat to lowest setting Honeywell VR8204 or Turn off all electrical power to the appliance VR8304 Remove jacket front panel Gas valve This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn Gas control knob clockwise x to OFF 7 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 8 Turn Gas control knob counterclockwise to ON 9 Turn on all electric power to the appliance led bi 10 Set thermostat to desired setting Gas valve P EN 11 If the appliance will not operate follow the instructions TO TURN OFF GAS TO Position indicator Eo OF APPLIANCE below and call your service technician or gas supplier shown in ON position Z 12 Replace jacket front panel Gas control knob Position indicator shown in ON position DI TO TURN OFF GAS TO THE APPLIANCE es 1 Setthermostat to lowest setting 4 Turn Gas control knob clockwise xv to OFF Do not force 2 Turn off all electric power to the appliance if service is tobe 5 Replace jacket front panel performed 3 Remove jacket fr
59. ns if the relief valve weeps or will not seat properly replace the relief valve En sure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing Following installation the valve lever must be op erated 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 direct ing 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 LI 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 24 LI Cleaning boiler heating surfaces The boiler contains ce
60. nsition 590 317 651WT The ABB timer relay TS12190 is designed for 90 second delay but operates for 60 seconds in the GWS O90E boiler Part Number 550 1 10 737 1108 37 GW S O90E Gas Fired Water Boiler Boiler Manual emm 14 Dimensions Figure 20 Dimensional drawing ALL DIMENSIONS IN INCHES Supply 144 NPT NPT Note 7 2 Return 1 NPT Note 1 3 Relief valve 34 NPT 4 12 NPT to expansion tank air vent 3 Diameter vent 3 3 2 Diameter combustion air pipe connection 7 Gas supply piping Drain valve Gas supply entrance right or left side TOP VIEW Note 1 Boiler supply and return tappings are both 144 NPT See Table 5 page 9 for recommended system supply and re turn piping sizes Note 3 Boiler circulator is shipped loose Circulator may be mounted on either boiler supply or return piping Circulator flange provided with boiler is same size as rec ommended pipe size in Table 5 page 9 Pressure temperature gauge ALL DIMENSIONS IN INCHES gt La 23 V 12 lt 2314 73260 LEFT SIDE RIGHT SIDE Boiler Supply Return Gas Gas A W model tapping tapping connection size manifold size Air inlet Jacket number inches NPT inches NPT Note 3 Note 3 pipe center width inches NPT inches NPT inches inches Note 3 Gas piping from meter to boiler to be sized per local utility requirements 38 Part Number 550 110 737 1108 GW S O90 EE Ga
61. ol module sequence of operation based on indicator light status Steps Following step 8 cycle goes back to step 1 1 Standby Waiting for call for heat 2 Call for heat Circulator on Blower on 3 Limit circuit Limit controls closed Block switch contacts closed 4 Pressure circuit Pressure switch contacts closed Prepurge for 10 seconds 5 Pilot flame proven Gas valve open Pilot remains on Boiler producing heat 6 Limit cycle Limit circuit open Gas valve closed 7 Flame outage Flame out Boiler recycles 8 Thermostat satisfied Circulator off Blower postpurge 9 Circulator exercise routine Circulator turns on for 30 seconds if boiler not operated for 30 days CALL FOR HEAT NO YES YES YES YES YES YES NO NO POWER TSTAT LIMIT PRESS FLAME Timing CIRC SWITCH ap 8 35 sec O 15 sec CO O 15 sec 30 sec If pilot flame is not proven in 15 seconds control module will flash the FLAME light but will continue indefinitely with attempts to light the pilot burner The control module will not lockout on a failure to establish flame It will lockout if line voltage polarity is reversed stray voltage is sensed on thermostat line pressure switch sticks closed or fails to make within 5 minutes or if flame is sensed when it shouldn t be there The boiler will reset after these lockouts if any of the follow
62. ol module to gas valve is intact replace the control module and retest including replacing pilot corrects problem then replace the control module reinstall burner shield and retest 31 GW S O90 E Gas Fired Water Boiler Boiler Manual 12 Troubleshooting continued CHART 7 Insufficient heat or no heat to system POWER light on steady AWARNING 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 e Has it been at least 5 minutes since setting thermostat to A Is boiler System circulator operating call for heat If not wait 5 minutes Is system heating e Is thermostat set to call for heat Remove thermostat No Yes wires at boiler and check continuity across the two wires y If circuit isn t closed check external thermostat zone e Remove CIRCULATOR harness plug from valve relay etc wiring Correct problems and retry CIRCULATOR plug receptacle on control e Reconnect external thermostat wiring at boiler module Check with voltmeter across pins of D SR
63. ont panel 550 223 237 1108 Part Number 550 1 10 737 1108 19 GW S O90O0E Gas Fired Water Boiler Boiler Manual 11 Service and maintenance Table 6 Service and maintenance schedules service technician and user Service technician see following pages for instructions E D I lt ke N al lt wi Lj 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 Condensate drain system Service Inducer motor Oiled bearing circulators Start up Perform start up per manual Check test Gas piping Cold fill and operating pressures Air vents and air elimination Limit controls and cutoffs Expansion tank Boiler relief valve Review Review with owner Cleaning boiler heating surfaces Owner maintenance see User s Information Manual for instructions _J Monthly LI Periodically _J Every 6 months _1 End of season Check boiler area Check boiler pressure temperature gauge Check air openings Check boiler piping Check venting system Check condensate drain system Check boiler relief valve Check automatic air vents if used Check pilot and main burner flames Check and clean vent termination amp air intake screens Test low water cutoff if used Oil inducer motor Operate relief valve Shut down procedure Fol
64. ontinued Residential garage installations Take the following special precautions when installing the boiler in a residential garage If the boiler is located in a residential garage per ANSI 2223 1 paragraph 5 1 9 e 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 e Locate or protect the boiler so it cannot be damaged by a moving vehicle Flooring and foundation Flooring The GWS O90E 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 founda tion pad if any of the following is true e floor can become flooded e the boiler mounting area is not level 2 See Table 2 below for minimum foundation dimensions Table 2 Minimum foundation size Minimum foundation width Minimum foundation length Boiler model number GWS 090E GW S O9O0OE Gas Fired Water Boiler 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 O90E into a common vent
65. or installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufac turer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the follow ing requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall in clude a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation W T 8201 W Calumet Rd Milwaukee WI 53223 Part Number 550 110 737 1108
66. oss top and bottom pins of 120 VAC IN plug Does voltmeter indicate 120 VAC No Yes Problem is with incoming electricity Have licensed electrician repair circuit e Reconnect 120 VAC IN plug e Remove 120 VAC IN transformer PRIMARY plug on control module e Using voltmeter check across top and bottom pins of PRIMARY receptacle Does voltmeter indicate 120 VAC No Yes l Replace control module Retest e Reinstall 120 VAC transformer PRIMARY plug e Remove 24 VAC transformer plug on control module e Using voltmeter check pins of plug Does voltmeter indicate 24 VAC No Yes H Replace transformer Retest and check for back feed of voltage from Replace control module system wiring Retest Part Number 550 110 737 1108 12 Troubleshooting continued GW S O90 E Gas Fired Water Boiler Boiler Manual CHART 2 TSTAT CIRC amp POWER lights flashing Usually indicates 48 VAC on thermostat circuit stray voltage AWARNING 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 e Disconnect the two external wires connected to the boiler thermostat leads two black low voltage leads in J box e Connect a voltmeter across these two incoming wires
67. pressure switch Pressure va Suction Flue collector Rear panel Interior Side panel panel White 72809 4 Turn off gas valve and set thermostat to call for heat Inducer will run but burners will not ignite 5 Check for 24 VAC between both air pressure switch termi nals 6 If manometer reading is above the setpoint of the switch see Table 8 but there is not 24 VAC between both air pressure switch terminals replace air pressure switch Troubleshooting air pressure reading 1 If manometer reading is lower than the setpoint of the switch see Table 8 check for possible causes e blockage in hoses e obstruction in inducer housing outlet e loose inducer wheel on motor shaft e inducer motor not in proper rom e inducer back plate not sealed properly e blockage in block assembly e blockage in flue pipe or termination e incorrect pressure switch Return to normal operation When pressure reading is correct and air pressure switch is operating properly remove tees and reinstall hoses to air pressure switch The boiler will not operate correctly unless pressure NOTICE switch hoses are correctly located The red hose connects from the right side negative hose barb to the flue collector The white hose connects from the left side positive hose barb of the switch to the connector box between flue collector and inducer as shown in Figure 14 25 GW S O90O0E Gas Fired Water Boiler Boile
68. quipment the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or struc ture served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed profes sionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b Inthe event that the requirements of this subdivision can not be met at the time of completion of installa tion the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A
69. r Manual 12 Troubleshooting continued CHART 1 Troubleshooting POWER light status Usually indicates reversed 120 VAC polarity if POWER light flashes by itself AWARNING 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 obt off Is POWER ight Flashing Flashing with On steady alone another light not flashing TSTAT CIRC Chart light flashing 2 PRESS SWITCH Chart Chart light flashing 3 5 FLAME Chart Chart light flashing 6 For insufficient heat or no heat problem go to Chart 7 if POWER light is on steady with no other light flashing e Usually indicates polarity on incoming 120 VAC power line is wrong e TURN OFF POWER at Service switch or breaker then reverse the HOT and NEUTRAL wires entering the boiler in the J box e Restore POWER at service switch or breaker Is POWER ight flashing now No Yes Have system checked by a licensed electrician If problem persists call your local Weil McLain sales representative Boiler should now operate normally 26 No Yes _ e Make sure service switch or circuit breaker is on or fuses are good e Remove 120 VAC IN plug on control module e Using voltmeter check acr
70. ramic 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 Shut down boiler e Follow To Turn Off Gas to Appliance instructions on boiler and Operating instructions page 19 e Do not drain boiler unless it will be exposed to freezing tempera tures If using antifreeze in system do not drain Follow shutdown procedure Remove venting system connection to boiler Remove top jacket panel Turn back insulation Remove collector box transition assembly Clean sealant from assembly and sections 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 7 pages 14 15 of this manual and the boiler Operating instructions page 19 Excessive sooting indicates improper gas combustion If found
71. rature 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 4 page 10 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 2 NPT tapping located behind supply outlet using Le NPT piping Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping ACAUTION 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 pump Always connect fill line only at the expansion tank never at another point in the system GW S O9O0OE Gas Fired Water Boiler Boiler Manual 3 Figure 3 Diaphragm or bladder type expansion tank Piping to single zone system using diaphragm type or bladder type expansion tank See Table 5 page 9 for piping sizes Cold water fill From i m Isolation syste y ep on valve G To xp ns ee tyP ae tank Automatic Solation air vent valve Relief KO valve 8 aN A Circulator AAAA alternate Pressure BSS location
72. re 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 e 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 e Use caution when attempting to light the propane pilot This should be done by a qualified service technician particularly if pilot outages are common e Periodically check the odorant level of your gas e Inspect boiler and system at least yearly to make sure all gas piping is leak tight e 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 Miia Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage 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 co
73. rge 3 Control module sparks the pilot and opens pilot valve in main gas valve a If pilot does not light within 15 seconds pilot valve is closed and spark generator is turned off Control module initiates a 15 second postpurge then starts a new cycle b If pilot does light and control module senses flame current spark generator is turned off and main valve opens 4 The GWS O90E timer relay delays high fire for the first 60 seconds of main flame 10 11 GWS 090EF Gas Fired Water Boiler Boiler Manual During 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 In the event the limit control shuts down the boiler The control module closes the gas valve but keeps the inducer operating for 15 second posipurge The circulator continues to operate Lower room thermostat setting to stop call for heat Thermostat is satisfied Pilot and main gas valves are closed Inducer operates for 15 second postpurge Circulator is shut off Boiler is now in the off cycle Repeat steps 1 through 6 several times to verify operation Return the thermostat to normal setting Set thermostat heat anticipator setting per wiring diagram page 18 Figure 12 GWS 090E contr
74. rode probe type is recommended Purchase and install in tee in supply piping above boiler Use backflow check valve in cold water supply if required by lo cal codes Near boiler piping See Figure 3 diaphragm type or bladder type expansion tank or Figure 4 closed type expansion tank on page 10 and Table 5 for near boiler and single zone systems designed for return water at least 130 F See page 9 for multiple zone systems See page 10 for boilers used with refrigeration systems Relief valve Install relief valve vertically in 34 tapping on side of boiler See the tag attached to the relief valve for manufacturer s instructions AWARNING To avoid water damage or scalding due to valve operation discharge line must be connected to re lief valve outlet and run to a safe place of disposal Terminate the discharge line to eliminate possibility of severe burns should the valve discharge e Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length e Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain where any discharge will be clearly visible e The discharge line shall terminate plain not thread ed with a material serviceable for temperatures of 375 F or greater e Do not pipe the discharge to any place where freez ing could occur e No shutoff valve shall be installed between the relief
75. s 3 Lack of primary air Yellow tipping on flames sooting will occur Figure 10 Typical pilot burner flame Spark electrode Pilot flame sensor Y 72813 Figure 11 Typical main burner flame Transparent blue flame 15 GW S O90E Gas Fired Water Boiler Boiler Manual emm 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 Refer to manual Section 2 to check size and fuel type ASA Correctly sized manifold orifices must be used Failure to do so will cause severe personal injury death or substantial property damage _1 Followed operating instructions on boiler or in manual Sec tion 9 for proper start up LJ Verify that the boiler switches to high fire after 60 seconds of main flame operation Proper burner flame observed at high fire Refer to Check burner flame manual Section 7 1 Test limit control While burners are operating move indi cator on limit control below actual boiler water temperature Burners should go off while circulator continues to operate Raise setting on limit control above boiler water temperature and burners should reignite LI Test additional field installed controls H boiler has a low water cutoff additional high limit or other controls test for operation a
76. s Fired Water Boiler Boiler Manual 15 Ratings a ENERGY STAR Boiler 0 2 000 feet altitude 2 000 4 500 feet altitude Net Boiler DOE Vent model Canada I B R water seasonal size number ratings content efficiency DOE Heating Capacity Input Output Btuh gallons A EU E Output Btuh Btuh Btuh GWS 090E 90 000 77 000 81 000 69 300 67 000 2 1 85 0 Note 5 1 Add N I for natural gas boiler P I for propane gas boiler GWS Gas Water Boiler Sealed Combustion 2 Based on standard test procedures prescribed by the United States Department Or Energy _ 7 l Input in MBH 3 Net l B R ratings are based on net installed radiation of sufficient quantity for additional allowance should be made for unusual piping and pickup loads 4 The GWS O90E boiler requires special venting consistent with Category III or IV boiler Use only the vent materials and methods specified in GWS Vent Manual The GWS O90E boiler may be direct vented using 3 diameter air piping as specified in the GWS Vent Manual 5 Asan Energy Star Partner W T has determined that the GWS O90E meets the Energy Star guidelines for energy efficiency 6 The boiler must be equipped with specially sized orifices for high altitude ap plications See page 8 for details 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 f Natural
77. s of the base 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 If insulation is damaged or displaced do not oper ate 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 5 Replace inlet air box top panel Do not operate boiler without inlet air box top panel secured in place Failure to comply could result in severe personal injury death or substantial property damage Condensate drain system 1 If vent system is equipped with a condensate drain check the hose and connections for tightness 2 Verify the hose is unobstructed and in good condition and that condensate can flow freely Replace hose if necessary Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual 11 Service and maintenance continued LI Service ee bw 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 O90E boiler is water lubricated
78. s outlined by manufacturer Burners should be operating and should go off when controls are tested When controls are restored burners should reignite LI Test ignition system safety device a Connect manometer to outlet side of gas valve Start boiler allowing for normal start up cycle to occur and main burn ers 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 LU UU UU KE E EA KE Set limit control s to system temperature requirements Adjust balancing valves and controls to provide design temperature to system For multiple zones adjust flow so it is about the same in each zone Verify thermostat heat anticipator if available set properly Refer to Field wiring manual Section 6 Thermostat s 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 Measure natural gas input a Operate boiler 10 minutes b Turn off other appliances c Atnatural gas meter measure time in seconds required to use one cubic foot of gas d Calculate gas input 3600 x 1000 a Bu number of seconds from step c e Btuh calculated should approximate input rating on boiler
79. ss from control module to pressure switch Reseat connector in control module receptacle If harness is intact and Are vent or combustion air passages blocked No Yes properly seated but e Clear passages and recycle problem persists replace e Check air pressure switch per manual Section 12 control module S boiler lt Relee Replace if necessary Retest s Recheck boll roperaton 30 Part Number 550 110 737 1108 12 Troubleshooting continued GW S O90 E Gas Fired Water Boiler Boiler Manual CHART 6 FLAME light flashing and POWER light on steady ALSO Troubleshooting failure to establish main flame RNING Electrical shock hazard Wherever you see TURN OFF POWER follow the instructions Failure to follow Are main manual shutoff valve and boiler gas valve open No Yes y ATURN OFF POWER A 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 instructions could result in severe personal injury death or substantial property damage e Is pilot flame visible through inspection port No P Yes e Boiler should be in normal operating sequence e Observ
80. st fans etc using the air supply The sizing given in Figure 2 is based on the National Fuel Gas Code ANSI 2223 1 allowing adequate air opening for gravity vented gas appliances The air openings recommended in Figure 2 will allow adequate ventilation and combustion air provided the boiler room is not subjected to negative pressure due to exhaust fans or other mechanical ventilation devices Refer to the National Fuel Gas Code for dealing with other conditions Louver allowance The free area of openings means the area after reduction for any installed louvers or grilles Be sure to consider this reduction when sizing the air openings Special considerations Tight construction ANSI 2223 1 defines unusually tight construction where a Walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and b Weather stripping has been added on openable windows and doors and c Caulking or sealants are applied to areas such as joints around windows and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and in other openings For buildings with such construction provide air openings into the building from outside sized per the appropriate case in Figure 2 Exhaust fans and air movers The appliance space must never be under a negative pr
81. tion 7 page 14 of this manual 5 Verify operation using procedures below Perform checkout procedure in Section 8 page 16 and fill in the Installation and service certificate If boiler doesn t start Check for Loose connections blown fuse or service switch off High limit switch 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 If none of the above corrects the problem see Troubleshoot ing page 25 of this manual E E Se GH Part Number 550 110 737 1108 GW S O90 E Gas Fired Water Boiler Boiler Manual Verify operation Check burner flame Pilot burner Proper pilot flame See Figure 10 1 Blue flame 2 Inner cone engulfing pilot flame sensor 3 Pilot flame sensor glowing cherry red Improper pilot flame 1 Overfired Large flame lifting or blowing past pilot flame sensor 2 Underfired 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 11 1 Yellow orange streaks may appear caused by dust The GWS 090E will operate at low fire for the first 60 seconds Improper main burner flame 1 Overfired Large flames 2 Underfired Small flame
82. tion 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 550 110 737 1108 5 GW S O9O0OE Gas Fired Water Boiler Boiler Manual 1 Prepare boiler location continued Air openings Using outside air direct venting Combustion air can be ducted directly from outside to the GWS O90E boiler air intake fitting This method is defined as direct vent also referred to as sealed combustion Refer to the appropriate instructions in the GWS Venting Manual and the instructions in this manual Two options are available sidewall or vertical direct vent Each requires a special vent component kit Sizing air openings Air openings provide for ventilation to prevent overheating of the boiler controls and boiler space Air is also needed for other ap pliances located in the same space Use Figure 2 page 7 selecting the appropriate installation condi tions Note that the sizing given in Figure 2 applies only to GWS O90E installations with clearances no smaller than shown in Table 1 page 3 of this manual For smaller clearances regardless of how the air openings are arranged two openings providing free area of 1 square inch per 1 000 Btuh input of all appliances in the space are required NOTICE Air openings must be sized to handle all appliances and air movers exhau
83. use only by your qualified Consider piping and installation when determining heating installer service technician boiler location Please see the User s Information Manual for your Any claims for damage or shortage in shipment reference must be filed immediately against the transporta Have the boiler serviced by a qualified service tion company by the consignee technician at least annually AWARNING 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 Norice When calling or writing about the boiler Please have e boiler model number from the boiler rating label and e 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 Part Number 550 110 737 1108 GW S O90O0E Gas Fired Water Boiler Boiler Manual Read this first AWARNING Failure to adhere to the guidelines below can result in severe personal injury death or sub stantial property damage The boiler contains ceramic fiber and fiber glass materials Use care when handling these materials per instructions on page 21 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
84. with any other appliance This will cause flue gas spillage or appliance malfunction resulting in pos sible severe personal injury death or substantial property damage GWS O90E boilers can only be direct vent vented They cannot be chimney draft vented or direct ex haust vented See GWS Venting Manual for detailed installation instructions If you are removing an existing boiler from a shared venting system the GWS 090E boiler cannot share the vent system it requires its own vent You must test each appliance remaining on the old common vent system individually to verify the vent system still operates adequately Follow guidelines below 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 Visually inspect the venting system for proper size and hori zontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition 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 spa

GWS-090E - Williamson

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