gas-fired water boilers gwa - todd's...

Part Number 670 06 1004 00

GWA

This supplement must only be used by a qualifiedheating installer/service technician. Failure tocomply could result in severe personal injury, deathor substantial property damage.

Hazard definitions

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

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

Hazards that will or can cause minor personalinjury or property damage.

Special instructions on installation, operation ormaintenance that are important but not related topersonal injury or property damage.

When calling or writing about the boiler— Please havethe boiler model number from the boiler rating labeland the CP number from the boiler jacket.

Failure to adhere to the guidelines on this page canresult in severe personal injury, death or substantialproperty damage.

This control system is not offered for retrofit or conversion from standing pilot systems. The control system and instructionsare intended only for factory-packaged boilers. Any attempt to apply the system components to a boiler shipped for use witha different control system will not be covered under boiler warranty and can cause severe personal injury, death or substantialproperty damage.

Contents Page

1 Boiler wiring ........................................................................ 2

2 Sequence of operation ........................................................ 2

3 Operating instructions ......................................................4-5

4 Troubleshooting ............................................................. 6-10

5 Parts ................................................................................ 11

INSTALLER — Read all instructions beforeinstalling. Follow all instructions in proper orderto prevent personal injury or death.

• U.S. only — GWA boilers must have dampersinstalled.

• Canada only — GWA boilers may have dampersinstalled.

USER — Please read the following. Failure tocomply could result in severe personal injury, deathor substantial property damage.

• Controls must only be installed and ControlSupplement used by your qualified heatinginstaller/service technician.

• Please see the User’s Information Manual for yourreference.

Control Supplement

Gas-Fired Water Boilers

Spark-Ignited Pilot System

GWA Gas-Fired Water Boilers – Control Supplement

12 Part Number 670 06 1004 00


2 Part Number 670 06 1004 00

2S

equence o

f opera

tion

1.S

ee T

able

1 fo

r “O

pera

ting

Inst

ruct

ions

” pa

ge n

umbe

r lo

catio

ns. R

aise

roo

mth

erm

osta

t to

call

for h

eat.

Dam

per a

ctua

tor w

ill s

low

ly o

pen

dam

per.

2.W

hen

dam

per i

s fu

lly o

pen,

igni

tion

cont

rol p

ower

s sp

ark

gene

rato

r and

ope

nspi

lot v

alve

. Dam

per m

ust b

e in

ope

n po

sitio

n w

hen

appl

ianc

e m

ain

burn

ers

are

oper

atin

g. If

dam

per

is n

ot in

ope

n po

sitio

n, fl

ue p

rodu

cts

such

as

carb

on m

onox

ide

will

esc

ape

into

the

hous

e, c

ausi

ng s

ever

e pe

rson

alin

jury

or d

eath

.

3.If

pilo

t do

es n

ot l

igh

t wit

hin

15

seco

nd

s —

Pilo

t val

ve is

clo

sed

and

spar

kge

nera

tor i

s tu

rned

off.

The

igni

tion

cont

rol i

nitia

tes

a fiv

e-m

inut

e w

ait p

erio

d. If

call

for h

eat e

xist

s af

ter f

ive

min

utes

, ign

ition

seq

uenc

e st

arts

at S

tep

2.

If p

ilot a

nd

ign

itio

n c

on

tro

l sen

ses

flam

e cu

rren

t — M

ain

valv

e op

ens

and

spar

k ge

nera

tor i

s tu

rned

off.

4.D

urin

g m

ain

burn

er o

pera

tion:

a.Ig

nitio

n co

ntro

l mon

itors

pilo

t fla

me

curr

ent.

If si

gnal

is lo

st, m

ain

valv

e is

clos

ed, s

park

gen

erat

or a

ctiv

ated

and

seq

uenc

e re

turn

s to

Ste

p 3.

b.If

pow

er is

inte

rrup

ted,

the

cont

rol s

yste

m s

huts

off

pilo

t and

mai

n ga

s va

lves

and

rest

arts

at S

tep

1 w

hen

pow

er is

rest

ored

.

5.T

herm

osta

t is

satis

fied

— p

ilot a

nd m

ain

gas

valv

es a

re c

lose

d. D

ampe

r w

illcl

ose.

6.B

oile

r is

now

in th

e of

f cyc

le.

7.R

epea

t Ste

ps 1

-6 s

ever

al ti

mes

to v

erify

ope

ratio

n.

8.R

etur

n th

erm

osta

t to

norm

al s

ettin

g.

9.S

et th

erm

osta

t hea

t ant

icip

ator

set

ting

indi

cate

d in

not

es in

wiri

ng d

iagr

am. S

eeF

igur

e 1

on p

age

3.

GW

A s

park

-ig

nited

pilo

t —

With

gas v

alv

e:

Pa

ge

Ho

ne

yw

ell

VR

82

04

/VR

83

04

4

Ro

be

rts

ha

w7

20

05

Wh

ite

-Ro

dg

ers

36

E o

r 3

6C

4

Tab

le 1

“Op

erat

ing

Inst

ruct

ions

” lo

catio

ns

1B

oiler

wir

ing

For y

our s

afet

y, tu

rn o

ff e

lect

rica

l pow

er s

uppl

y at

ser

vice

ent

ranc

ep

anel

bef

ore

mak

ing

an

y el

ectr

ical

co

nn

ectio

ns

to a

void

pos

sibl

eel

ectr

ic s

hock

haz

ard.

Fai

lure

to d

o so

can

cau

se s

ever

e pe

rson

alin

jury

or d

eath

.

Wir

ing

mu

st b

e N

.E.C

. Cla

ss 1

.

If ro

llout

ther

mal

fuse

ele

men

t wire

as

supp

lied

with

boi

ler

mus

t be

repl

aced

, typ

e 20

0 °C

wire

or e

quiv

alen

t mus

t be

used

. If o

ther

orig

inal

wiri

ng a

s su

pplie

d w

ith b

oile

r mus

t be

repl

aced

, use

onl

y ty

pe 1

05 °C

wire

or e

quiv

alen

t.

Boi

ler

mus

t be

ele

ctri

cally

gro

un

ded

as

requ

ired

by N

atio

nal

Ele

ctric

al C

ode

AN

SI/N

FPA

70-

late

st e

ditio

n.

1.B

ring

supp

ly w

iring

to b

oile

r. M

ust b

e 14

gau

ge o

r hea

vier

.

2.S

ee w

iring

dia

gram

on

page

3. A

ll w

iring

mus

t be

inst

alle

d in

acc

orda

nce

with

:

•U

.S.A

. — N

atio

nal E

lect

rical

Cod

e an

d an

y ot

her

natio

nal,

stat

e or

loca

lco

de re

quire

men

ts.

•C

anad

a —

CS

A C

22.1

Can

adia

n E

lect

rical

Cod

e P

art

1 an

d an

y ot

her

natio

nal,

prov

inci

al o

r loc

al c

ode

requ

irem

ents

.


11Part Number 670 06 1004 00

5 Parts

Itemnumber

Part descript ion Boiler models Vendor Vendor part numberInternational

Comfort Productspart number

1 Ignition Control GWA-052 to GWA-245Honeywell S8620C1003

511330097WTUnited Technologies 1003-511

2Gas valve, ½" x ½", Natural gas GWA-052 to GWA-175

Honeywell VR8204A-2001

511044381WTRobertshaw 7200ER 7AO-A1B-042

White-Rodgers 36E36-266

Gas valve, ¾" x ¾", Natural gas GWA-210 and -245 Honeywell VR8304P-4348 511044382WT

3Pilot assembly kit with orifice andaluminum pilot gas tubing

GWA-052 to GWA-245 International ComfortProducts

511330166WT

not shown Boiler wiring harness GWA-052 to GWA-245International Comfort

Products591391863WT

4 Transformer relay GWA-052 to GWA-245 510312167WT


3Part Number 670 06 1004 00

Figu

re 1

Wir

ing

dia

gram

— S

par

k-ig

nite

d p

ilot s

yste

m


10 Part Number 670 06 1004 00

Are pilot valve wiring connections CORRECT and securely fastened?

Connect securely to terminal PV on ignition control andterminal TR on main gas valve.

No Yes

Is inlet gas pressure at least 5.0" w.c. and not over14" w.c.?

Open pilot shutoff valve.

No Yes

Pilot assembly and ignition control must share common groundwith main burner. Nuisance shutdowns are often caused bypoor or erratic ground.

❏ Check for good metal-to-metal contact between pilot burnerbracket and main burner, and between main burner andburner rest.

❏ Check ground lead from GND (Burner) terminal on ignitioncontrol to ignition control mounting screw and from C ontransformer to transformer case ground. Make sureconnections are clean and tight. If wire is damaged ordeteriorated, replace with No. 18 gauge moisture-resistant,thermoplastic insulated wire with105 ˚C minimum rating.

To check ignition system grounding (instruction for continuation of Chart 3)

No YesIs pilot shutoff valve open?

No Yes

Contact gas supplier tocorrect gas pressure.

Is gas present at pilot burner assembly?

Remove MV wire from ignition control. Use amatch taped to a long screwdriver or pilotlighter rod and manually light pilot.

Make sure pilot shutoff valve is open, 24 VAC is present topilot valve and pilot line is not kinked or obstructed. Checkfor clean pilot orifice. If OK, replace pilot gas valve. Is spark gap 0.125" and located in pilot gas stream?

No Yes

Replace pilot assembly.

Block any draft aroundboiler. Check for cleanpilot orifice.

Turn OFF supply voltage.

Electrical shock hazard. Failure to turn offpower before proceeding could causesevere personal injury or death.

CHART 3: Pilot lights — Main valve will not come on — continued from previous page

CHART 4: Spark is present — Pilot will not light (boiler with or without damper)

4 Troubleshooting continued


4 Part Number 670 06 1004 00

3 Operating instructions

FOR YOUR SAFETY READ BEFORE OPERATING

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

1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to

be performed.3. Remove front panel.

4. Turn gas control knob clockwise to OFF. Do notforce. (Press down on 36C valve knob to turn.)

5. Replace front panel.

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

2. Set the thermostat to lowest setting.3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold

Damper Open position.4. Turn off all electrical power to the appliance.5. When equipped with Johnson Controls vent damper Model M35, manually rotate damper

blade in direction of arrow to Open position indicated on damper assembly.6. This appliance is equipped with an ignition device which automatically lights the pilot. Do

not try to light the pilot by hand.7. Turn gas control knob clockwise to OFF. (Press down on White-Rodgers 36C valve

knob to turn.)8. When equipped with vent damper, verify damper blade is in full open position.9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you

smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go tothe next step.

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

11. Turn on all electric power to the appliance.12. When equipped with Effikal vent damper, place service switch in Automatic Operation

position.13. Set thermostat to desired setting.14. If the appliance will not operate, follow the instructions To Turn Off Gas To The Appliance

and call your service technician or gas supplier.15. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE

OPERATING INSTRUCTIONS

• Do not try to light any appliance.• Do not touch any electric switch; do not use any phone in

your building.

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

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

WHAT TO DO IF YOU SMELL GAS

A. This appliance is equipped with an ignitiondevice which automatically lights the pilot. Donot try to light the pilot by hand.

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

C. Use only your hand to depress or move the selector arm. Never use tools.If the selector arm will not depress or move by hand, don't try to repair it, calla qualified service technician. Force or attempted repair may result in a fireor explosion.

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

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


9Part Number 670 06 1004 00


Set up microammeter to measure output current in flame sensor circuit as follows.a. Detach sense lead from ignition control. Attach negative lead from microammeter to

sense terminal on ignition control.b. Attach positive lead to sense wire from pilot assembly.c. Disconnect main valve lead from terminal MV on ignition control.d. Energize the system. Spark should ignite the pilot. As soon as pilot is burning,

microammeter should read at least 0.5 microamp for Honeywell S8620C, 0.1 microampfor U.T. 1003-510

e. Is flame current signal less than the minimum specified in d above?

Does spark stay on for more than a few seconds after pilot is established?

Is 24 VAC between terminals MV and MV/PV onignition control?

No Yes

Make sure sense wire is not wrapped around any pipe oraccessories.

No Yes

Replace ignition control.Retest.

Contact gas supplier tocorrect.

Correct wiring. Retest. Replace valve. Retest.

Is main valve wiring secure at terminals?

No Yes


No Yes

Is sense wire securely attached to sense terminaland pilot assembly?

No Yes

Correct and retest.

Is sensing probe ceramic cracked?

No Yes

Replace pilot assembly.Retest.

Is sense wire or sensing probe shorted out to metalsurface?

No Yes

Correct and retest.

Check for continuity of sense wire and condition ofinsulation.

NOT OK OK


Does system have proper flame signal?

No Yes

Check for proper gas pressure, clean pilot assembly, tight mechanical and electricalconnections. Also check for proper system grounding per following page.



Electrical shock hazard. Failure to turn offpower before proceeding could cause severepersonal injury or death.

CHART 3: Pilot lights — Main valve will not come on (boiler with or without damper)


5Part Number 670 06 1004 00

3 Operating instructions continued


Gas valve — Robertshaw 7200







your building.



1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, placeservice switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper ModelM35, manually rotate damper blade in direction of arrow toOpen position indicated on damper assembly.

6. This appliance is equipped with an ignition device whichautomatically lights the pilot. Do not try to light the pilot byhand.

7. Depress and move selector arm to OFF. Note: Selectorarm cannot be moved to OFF unless selector arm isdepressed slightly. Do not force.

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

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

10. Move selector arm to ON.

11. Turn on all electric power to the appliance.

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

13. Set thermostat to desired setting.

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



1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to be

performed.

3. Remove front panel.4. Depress and move selector arm to OFF. Do not force.5. Replace front panel.




8 Part Number 670 06 1004 00

Is damper harness securely plugged in at both ends?

Secure connections.

Is 24 VAC present across transformer terminals C & Y?

Check for open thermostat, circulator relay (where used),loose wire connections, defective spill switch or rolloutthermal fuse element, open LWCO or high limit contacts.

If LWCO, spill switch or rollout thermal fuseelement contacts are open, determine causeand correct condition. Failure to do so willcause severe personal injury, death orsubstantial property damage.

DANGER

Check for out of round stack section.Does motor rotate open?

Is 24 VAC present across terminal C and yellow wire onbetween damper connector and rollout thermal fuse

element?

Is 24 VAC present across terminals PV and MV/PV?

Open thermostat contacts for 30 seconds. Damper willrotate to closed position. Close thermostat contacts.Damper will rotate to open position.Is 24 VAC present across terminals PV and MV/PV?

Remove damper harness fromboiler wiring harness.TEMPORARILY install jumperbetween terminal 2 andterminal 5 on damper plug inboiler wiring harness. Seefigure below. Does boiler fire?

No Yes

No Yes

Check for loose wire connections or bad relay ontransformer.

No Yes

Is damper rotated open?

No Yes

No Yes

Replace actuator. Retest.

Check continuity of each wire in wiring harness to damper.Does continuity exist for each wire?

Replace damper wiringharness. Retest.

Replace ignitioncontrol. Retest.

Is spark present now?

No Yes

Retest.

No Yes

No Yes

No Yes

No Yes

1

4

2

5

3

6Replace damperactuator. Retest.

Temporaryjumper

Securely connect andturn ON supplyvoltage. Retest.

No Yes

Replace pilotassembly.Retest.

Is condition of spark wire good (notbrittle, burned or cracked)?

No Yes

Is spark electrodeceramic cracked?

No Yes

Is spark gap 0.125" andlocated in pilot gas stream?

Replace pilotassembly.



Turn ON supply voltage andoperate system several completecycles.

No Yes



CHART 2: No spark — System (boiler with vent damper) does not work

Check spark wire.Is it securely connected to

ignition control?

Remove jumper after test.Failure to remove jumpercould result in severepersonal injury or death.



6 Part Number 670 06 1004 00

4 Troubleshooting

Verify proper operation after servicing. • See ventdamper manufacturer’s instructions packed with ventdamper for additional information. Failure to complycould result in severe personal injury, death orsubstantial property damage.

Figure 2 Manually opening vent damper

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper anddangerous operation.Never jumper (bypass) rollout thermal fuse elementor any other device except for momentary testing asoutlined in “Troubleshooting” charts. Severe personalinjury, death or substantial property damage canresult.Burner access panel must be in position during boileroperation to prevent momentary flame rollout onignition of main flame. Severe personal injury orsubstantial property damage will result.

1. Move damper service switch to Hold Damper Open position.Apply call for heat to boiler. Damper blade should then rotate toopen position and boiler will fire.

2. If step 1 does not open damper, manually rotate damper bladeto open position using wrench or pliers on flat shaft betweendamper and actuator. Boiler will fire. Verify that damper serviceswitch is in Hold Damper Open position. (Figure 2)

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

Johnson Controls vent damperIf troubleshooting chart recommends replacing actuator and actuatoris not immediately available, damper blade can be fixed in an openposition to allow boiler operation. Follow these instructions only incase of no heat or damper actuator malfunction. See Figure 2.1. Turn off power to boiler.

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

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

3. Turn on power to boiler.4. Using wrench or pliers on flat shaft section, manually rotate

damper blade until green light turns on. Boiler will fire. (Figure 2)5. Do not leave vent damper permanently in this position. Replace

actuator immediately. If vent damper is left in open position,boiler will not operate at published efficiencies.

In event of vent damper failure:

Effikal vent damperIf troubleshooting chart recommends replacing actuator and actuatoris not immediately available, damper blade can be fixed in an openposition to allow boiler operation. Manually turning blade can causeactuator damage. Follow these instructions only in case of no heator damper actuator malfunction.

Before troubleshooting:1. Have the following items:

a. Voltmeter that can check 120 VAC and 24 VAC.b. Microammeter with a scale range of 0-10.c. Continuity checker.d. U-tube manometer.

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

3. Check for 24 VAC at secondary side of transformer.4. Make sure thermostat is calling for heat and contacts (including

appropriate zone controls) are closed. Check for 24 VACbetween 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 gaspressure upstream of gas valve.

b. With boiler on:• 5" w.c. minimum natural gas pressure or 11" w.c. propane

gas pressure upstream of gas valve.• 3.5" w.c. minimum natural gas pressure or 10" w.c. propane

gas pressure downstream tapping on gas valve — Can beadjusted by regulator on gas valve.


7Part Number 670 06 1004 00

VISUALLY CHECK —Is ground wire connected from GND (Burner) to ignitioncontrol mounting screw, and ground wire connected from

transformer terminal C to case ground?

Correct by making connections.

Replace ignition control. Retest.

Open thermostat contacts for 15 seconds. Closethermostat contacts.

Is 24 VAC across terminals PV & MV/PV?

Securely connect spark wire. Then turn ON supply voltage.Retest.

No Yes

Replace pilot assembly. Retest.

Is condition of spark wire good (not cut, brittle, burned orcracked)?

No Yes

Replace pilot assembly, turn ON supply voltage, operatesystem several complete heat cycles.

Replace pilot assembly, turn ONsupply voltage. Operate systemseveral complete heat cycles.

No Yes

Yes


Check for open thermostat, circulator relay(where used),loose wire connections, defective spill switch or rolloutthermal fuse element, open LWCO or limit contacts.

If LWCO, spill switch or rollout thermal fuseelement contacts are open, determinecause and correct condition. Failure to doso will cause severe personal injury, deathor substantial property damage.

DANGER

Is spark electrode ceramic cracked?

No Yes

Check spark wire.Is it securely connected to spark transformer?

No Yes



Is spark gap 0.125" and isolated in pilot gas stream?

No Yes

Is 24 VAC present across terminals 24V and 24V(GND)?

No Yes

CHART 1: No spark — System (boiler without vent damper) does not work



5Part Number 670 06 1004 00

3 Operating instructions continued


Gas valve — Robertshaw 7200







your building.



1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, placeservice switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper ModelM35, manually rotate damper blade in direction of arrow toOpen position indicated on damper assembly.

6. This appliance is equipped with an ignition device whichautomatically lights the pilot. Do not try to light the pilot byhand.

7. Depress and move selector arm to OFF. Note: Selectorarm cannot be moved to OFF unless selector arm isdepressed slightly. Do not force.

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

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

10. Move selector arm to ON.

11. Turn on all electric power to the appliance.

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

13. Set thermostat to desired setting.

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



1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to be

performed.

3. Remove front panel.4. Depress and move selector arm to OFF. Do not force.5. Replace front panel.




8 Part Number 670 06 1004 00

Is damper harness securely plugged in at both ends?

Secure connections.

Is 24 VAC present across transformer terminals C & Y?

Check for open thermostat, circulator relay (where used),loose wire connections, defective spill switch or rolloutthermal fuse element, open LWCO or high limit contacts.

If LWCO, spill switch or rollout thermal fuseelement contacts are open, determine causeand correct condition. Failure to do so willcause severe personal injury, death orsubstantial property damage.

DANGER

Check for out of round stack section.Does motor rotate open?

Is 24 VAC present across terminal C and yellow wire onbetween damper connector and rollout thermal fuse

element?

Is 24 VAC present across terminals PV and MV/PV?

Open thermostat contacts for 30 seconds. Damper willrotate to closed position. Close thermostat contacts.Damper will rotate to open position.Is 24 VAC present across terminals PV and MV/PV?

Remove damper harness fromboiler wiring harness.TEMPORARILY install jumperbetween terminal 2 andterminal 5 on damper plug inboiler wiring harness. Seefigure below. Does boiler fire?

No Yes

No Yes

Check for loose wire connections or bad relay ontransformer.

No Yes

Is damper rotated open?

No Yes

No Yes

Replace actuator. Retest.

Check continuity of each wire in wiring harness to damper.Does continuity exist for each wire?

Replace damper wiringharness. Retest.


Is spark present now?

No Yes

Retest.

No Yes

No Yes

No Yes

No Yes

1

4

2

5

3

6Replace damperactuator. Retest.

Temporaryjumper

Securely connect andturn ON supplyvoltage. Retest.

No Yes

Replace pilotassembly.Retest.

Is condition of spark wire good (notbrittle, burned or cracked)?

No Yes

Is spark electrodeceramic cracked?

No Yes

Is spark gap 0.125" andlocated in pilot gas stream?




Turn ON supply voltage andoperate system several completecycles.

No Yes



CHART 2: No spark — System (boiler with vent damper) does not work

Check spark wire.Is it securely connected to

ignition control?

Remove jumper after test.Failure to remove jumpercould result in severepersonal injury or death.



4 Part Number 670 06 1004 00

3 Operating instructions


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

1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to

be performed.3. Remove front panel.

4. Turn gas control knob clockwise to OFF. Do notforce. (Press down on 36C valve knob to turn.)


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

2. Set the thermostat to lowest setting.3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold

Damper Open position.4. Turn off all electrical power to the appliance.5. When equipped with Johnson Controls vent damper Model M35, manually rotate damper

blade in direction of arrow to Open position indicated on damper assembly.6. This appliance is equipped with an ignition device which automatically lights the pilot. Do

not try to light the pilot by hand.7. Turn gas control knob clockwise to OFF. (Press down on White-Rodgers 36C valve

knob to turn.)8. When equipped with vent damper, verify damper blade is in full open position.9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you

smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go tothe next step.

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

11. Turn on all electric power to the appliance.12. When equipped with Effikal vent damper, place service switch in Automatic Operation

position.13. Set thermostat to desired setting.14. If the appliance will not operate, follow the instructions To Turn Off Gas To The Appliance

and call your service technician or gas supplier.15. Replace front panel.




your building.










9Part Number 670 06 1004 00


Set up microammeter to measure output current in flame sensor circuit as follows.a. Detach sense lead from ignition control. Attach negative lead from microammeter to

sense terminal on ignition control.b. Attach positive lead to sense wire from pilot assembly.c. Disconnect main valve lead from terminal MV on ignition control.d. Energize the system. Spark should ignite the pilot. As soon as pilot is burning,

microammeter should read at least 0.5 microamp for Honeywell S8620C, 0.1 microampfor U.T. 1003-510

e. Is flame current signal less than the minimum specified in d above?

Does spark stay on for more than a few seconds after pilot is established?

Is 24 VAC between terminals MV and MV/PV onignition control?

No Yes

Make sure sense wire is not wrapped around any pipe oraccessories.

No Yes


Contact gas supplier tocorrect.

Correct wiring. Retest. Replace valve. Retest.

Is main valve wiring secure at terminals?

No Yes


No Yes

Is sense wire securely attached to sense terminaland pilot assembly?

No Yes

Correct and retest.

Is sensing probe ceramic cracked?

No Yes


Is sense wire or sensing probe shorted out to metalsurface?

No Yes

Correct and retest.

Check for continuity of sense wire and condition ofinsulation.

NOT OK OK


Does system have proper flame signal?

No Yes

Check for proper gas pressure, clean pilot assembly, tight mechanical and electricalconnections. Also check for proper system grounding per following page.



Electrical shock hazard. Failure to turn offpower before proceeding could cause severepersonal injury or death.

CHART 3: Pilot lights — Main valve will not come on (boiler with or without damper)


3Part Number 670 06 1004 00

Figu

re 1

Wir

ing

dia

gram

— S

par

k-ig

nite

d p

ilot s

yste

m


10 Part Number 670 06 1004 00

Are pilot valve wiring connections CORRECT and securely fastened?

Connect securely to terminal PV on ignition control andterminal TR on main gas valve.

No Yes


Open pilot shutoff valve.

No Yes

Pilot assembly and ignition control must share common groundwith main burner. Nuisance shutdowns are often caused bypoor or erratic ground.

❏ Check for good metal-to-metal contact between pilot burnerbracket and main burner, and between main burner andburner rest.

❏ Check ground lead from GND (Burner) terminal on ignitioncontrol to ignition control mounting screw and from C ontransformer to transformer case ground. Make sureconnections are clean and tight. If wire is damaged ordeteriorated, replace with No. 18 gauge moisture-resistant,thermoplastic insulated wire with105 ˚C minimum rating.

To check ignition system grounding (instruction for continuation of Chart 3)

No YesIs pilot shutoff valve open?

No Yes

Contact gas supplier tocorrect gas pressure.

Is gas present at pilot burner assembly?

Remove MV wire from ignition control. Use amatch taped to a long screwdriver or pilotlighter rod and manually light pilot.

Make sure pilot shutoff valve is open, 24 VAC is present topilot valve and pilot line is not kinked or obstructed. Checkfor clean pilot orifice. If OK, replace pilot gas valve. Is spark gap 0.125" and located in pilot gas stream?

No Yes

Replace pilot assembly.

Block any draft aroundboiler. Check for cleanpilot orifice.



CHART 3: Pilot lights — Main valve will not come on — continued from previous page

CHART 4: Spark is present — Pilot will not light (boiler with or without damper)



2 Part Number 670 06 1004 00

2S

equence o

f opera

tion

1.S

ee T

able

1 fo

r “O

pera

ting

Inst

ruct

ions

” pa

ge n

umbe

r lo

catio

ns. R

aise

roo

mth

erm

osta

t to

call

for h

eat.

Dam

per a

ctua

tor w

ill s

low

ly o

pen

dam

per.

2.W

hen

dam

per i

s fu

lly o

pen,

igni

tion

cont

rol p

ower

s sp

ark

gene

rato

r and

ope

nspi

lot v

alve

. Dam

per m

ust b

e in

ope

n po

sitio

n w

hen

appl

ianc

e m

ain

burn

ers

are

oper

atin

g. If

dam

per

is n

ot in

ope

n po

sitio

n, fl

ue p

rodu

cts

such

as

carb

on m

onox

ide

will

esc

ape

into

the

hous

e, c

ausi

ng s

ever

e pe

rson

alin

jury

or d

eath

.

3.If

pilo

t do

es n

ot l

igh

t wit

hin

15

seco

nd

s —

Pilo

t val

ve is

clo

sed

and

spar

kge

nera

tor i

s tu

rned

off.

The

igni

tion

cont

rol i

nitia

tes

a fiv

e-m

inut

e w

ait p

erio

d. If

call

for h

eat e

xist

s af

ter f

ive

min

utes

, ign

ition

seq

uenc

e st

arts

at S

tep

2.

If p

ilot a

nd

ign

itio

n c

on

tro

l sen

ses

flam

e cu

rren

t — M

ain

valv

e op

ens

and

spar

k ge

nera

tor i

s tu

rned

off.

4.D

urin

g m

ain

burn

er o

pera

tion:

a.Ig

nitio

n co

ntro

l mon

itors

pilo

t fla

me

curr

ent.

If si

gnal

is lo

st, m

ain

valv

e is

clos

ed, s

park

gen

erat

or a

ctiv

ated

and

seq

uenc

e re

turn

s to

Ste

p 3.

b.If

pow

er is

inte

rrup

ted,

the

cont

rol s

yste

m s

huts

off

pilo

t and

mai

n ga

s va

lves

and

rest

arts

at S

tep

1 w

hen

pow

er is

rest

ored

.

5.T

herm

osta

t is

satis

fied

— p

ilot a

nd m

ain

gas

valv

es a

re c

lose

d. D

ampe

r w

illcl

ose.

6.B

oile

r is

now

in th

e of

f cyc

le.

7.R

epea

t Ste

ps 1

-6 s

ever

al ti

mes

to v

erify

ope

ratio

n.

8.R

etur

n th

erm

osta

t to

norm

al s

ettin

g.

9.S

et th

erm

osta

t hea

t ant

icip

ator

set

ting

indi

cate

d in

not

es in

wiri

ng d

iagr

am. S

eeF

igur

e 1

on p

age

3.

GW

A s

park

-ig

nited

pilo

t —

With

gas v

alv

e:

Pa

ge

Ho

ne

yw

ell

VR

82

04

/VR

83

04

4

Ro

be

rts

ha

w7

20

05

Wh

ite

-Ro

dg

ers

36

E o

r 3

6C

4

Tab

le 1

“Op

erat

ing

Inst

ruct

ions

” lo

catio

ns

1B

oiler

wir

ing

For y

our s

afet

y, tu

rn o

ff e

lect

rica

l pow

er s

uppl

y at

ser

vice

ent

ranc

ep

anel

bef

ore

mak

ing

an

y el

ectr

ical

co

nn

ectio

ns

to a

void

pos

sibl

eel

ectr

ic s

hock

haz

ard.

Fai

lure

to d

o so

can

cau

se s

ever

e pe

rson

alin

jury

or d

eath

.

Wir

ing

mu

st b

e N

.E.C

. Cla

ss 1

.

If ro

llout

ther

mal

fuse

ele

men

t wire

as

supp

lied

with

boi

ler

mus

t be

repl

aced

, typ

e 20

0 °C

wire

or e

quiv

alen

t mus

t be

used

. If o

ther

orig

inal

wiri

ng a

s su

pplie

d w

ith b

oile

r mus

t be

repl

aced

, use

onl

y ty

pe 1

05 °C

wire

or e

quiv

alen

t.

Boi

ler

mus

t be

ele

ctri

cally

gro

un

ded

as

requ

ired

by N

atio

nal

Ele

ctric

al C

ode

AN

SI/N

FPA

70-

late

st e

ditio

n.

1.B

ring

supp

ly w

iring

to b

oile

r. M

ust b

e 14

gau

ge o

r hea

vier

.

2.S

ee w

iring

dia

gram

on

page

3. A

ll w

iring

mus

t be

inst

alle

d in

acc

orda

nce

with

:

•U

.S.A

. — N

atio

nal E

lect

rical

Cod

e an

d an

y ot

her

natio

nal,

stat

e or

loca

lco

de re

quire

men

ts.

•C

anad

a —

CS

A C

22.1

Can

adia

n E

lect

rical

Cod

e P

art

1 an

d an

y ot

her

natio

nal,

prov

inci

al o

r loc

al c

ode

requ

irem

ents

.


11Part Number 670 06 1004 00

5 Parts

Itemnumber

Part descript ion Boiler models Vendor Vendor part numberInternational

Comfort Productspart number

1 Ignition Control GWA-052 to GWA-245Honeywell S8620C1003

511330097WTUnited Technologies 1003-511

2Gas valve, ½" x ½", Natural gas GWA-052 to GWA-175

Honeywell VR8204A-2001

511044381WTRobertshaw 7200ER 7AO-A1B-042

White-Rodgers 36E36-266

Gas valve, ¾" x ¾", Natural gas GWA-210 and -245 Honeywell VR8304P-4348 511044382WT

3Pilot assembly kit with orifice andaluminum pilot gas tubing

GWA-052 to GWA-245 International ComfortProducts

511330166WT

not shown Boiler wiring harness GWA-052 to GWA-245International Comfort

Products591391863WT

4 Transformer relay GWA-052 to GWA-245 510312167WT

Part Number 670 06 1004 00

GWA

This supplement must only be used by a qualifiedheating installer/service technician. Failure tocomply could result in severe personal injury, deathor substantial property damage.

Hazard definitions

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

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

Hazards that will or can cause minor personalinjury or property damage.

Special instructions on installation, operation ormaintenance that are important but not related topersonal injury or property damage.

When calling or writing about the boiler— Please havethe boiler model number from the boiler rating labeland the CP number from the boiler jacket.

Failure to adhere to the guidelines on this page canresult in severe personal injury, death or substantialproperty damage.

This control system is not offered for retrofit or conversion from standing pilot systems. The control system and instructionsare intended only for factory-packaged boilers. Any attempt to apply the system components to a boiler shipped for use witha different control system will not be covered under boiler warranty and can cause severe personal injury, death or substantialproperty damage.

Contents Page

1 Boiler wiring ........................................................................ 2

2 Sequence of operation ........................................................ 2

3 Operating instructions ......................................................4-5

4 Troubleshooting ............................................................. 6-10

5 Parts ................................................................................ 11

INSTALLER — Read all instructions beforeinstalling. Follow all instructions in proper orderto prevent personal injury or death.

• U.S. only — GWA boilers must have dampersinstalled.

• Canada only — GWA boilers may have dampersinstalled.

USER — Please read the following. Failure tocomply could result in severe personal injury, deathor substantial property damage.

• Controls must only be installed and ControlSupplement used by your qualified heatinginstaller/service technician.

• Please see the User’s Information Manual for yourreference.

Control Supplement

Gas-Fired Water Boilers

Spark-Ignited Pilot System


12 Part Number 670 06 1004 00

gas-fired water boilers gwa - todd's...

Documents