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GW IBoiler Manual

Series 2 Gas-Fired Water Boilers

Part Number 550-142-785/1215

This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in severe personal injury, death or substantial property damage.

When calling or writing about the boiler— Please have: • boiler model number from the boiler rating label and•CPnumberfromtheboilerjacket.YoumaylisttheCPnumberinthespaceprovidedonthe“Installationandservicecertificate”foundonpage 21.

Hazards that will or can cause minor personal injury or property damage.

Special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

INSTALLER —Readallinstructionsbeforein-stalling. Read page 2 first. Follow all instructions in proper order to prevent personal injury or death.

• Considerpipingandinstallationwhendeterminingboiler location.

• Anyclaimsfordamageorshortageinshipmentmust be filed immediately against the transporta-tion company by the consignee.

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

• This manual is for use only by your qualified heating installer/service technician.

• PleaseseetheUser’sInformationManualforyourreference.

• Have theboilerservicedbyaqualifiedservicetechnician, at least annually.

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

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

Hazard definitions

Contents Page

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

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

3 Vent installation ..................................................................7

4 Installwaterpiping ............................................................13

5 Installgaspiping ...............................................................16

6 Field wiring .......................................................................17

7 Start-up ............................................................................18

8 Checkoutprocedure .........................................................20

9 DepartmentofEnergyCompliance ..................................21

9a Sequenceofoperation .....................................................22

10 Operating instructions ......................................................26

11 Service and maintenance .................................................27

12 Troubleshooting ................................................................31

13 Replacement parts ...........................................................41

14 Dimensions .......................................................................46

15 Ratings .............................................................................47

2 Part Number 550-142-785/1215

GWI Series 2 Gas-Fired Water Boilers – Boiler Manual

Installations must follow these codes:• Local,state,provincial,andnationalcodes,laws,regulations

and ordinances.• NationalFuelGasCode,ANSIZ223.1/NFPA54–latestedition.• StandardforControlsandSafetyDevicesforAutomatically

FiredBoilers,ANSI/ASMECSD-1,whenrequired.• NationalElectricalCode.• ForCanadaonly:B149.1orB149.2InstallationCode,CSA

C22.1CanadianElectricalCodePart1andanylocalcodes.

Certification

TheGWIboilergasmanifoldandcontrolsmetsafelightingandotherperformancecriteriawhenboilerunderwent tests specified in ANSI Z21.13/NFPA54–latestedition.

Before locating the boiler:❏ Checkfornearbyconnectionto:

• Systemwaterpiping• Ventingconnections• Gassupplypiping• Electricalpower

❏ Checkareaaroundboiler.Removeanycombustiblematerials,gasolineandotherflammableliquids.

Failuretokeepboilerareaclearandfreeofcom-bustible materials, gasoline and other flammable liquids and vapors can result in severe personalinjury, death or substantial property damage.

❏ The boiler must be installed such that the gas ignition and controlsystemcomponentsareprotectedfromwater(dripping,spraying, rain, etc.) during appliance operation and service (circulatorreplacement,condensatetrap,controlreplacement,etc.).

❏ Ifnewboilerwillreplaceexistingboiler,checkforandcorrectsystem problems, such as:1. Systemleakscausingoxygencorrosionorsectioncracks

fromhardwaterdeposits.2. Incorrectly-sizedexpansiontank.3. Lackofantifreeze(whenrequired)inboilerwatercausing

systemandboilertofreezeandleak.

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

When servicing boiler —1. To avoid electric shock, disconnect electrical supply

beforeperformingmaintenance.2. Toavoidsevereburns,allowboilertocoolbeforeper-

formingmaintenance.

Boiler operation —3. Donotblockflowofcombustionorventilationairtoboiler.4. Shouldoverheatingoccurorgassupplyfailtoshutoff,do

notturnoffordisconnectelectricalsupplytocirculator.Instead,shutoffthegassupplyatalocationexternaltothe appliance.

5. Donotusethisboilerifanyparthasbeenunderwater.Immediatelycallaqualifiedservicetechniciantoinspecttheboilerandtoreplaceanypartofthecontrolsystemand any gas control that has been under water.

Boiler water —6. DO NOT use petroleum-based cleaning or sealing com-

pounds in boiler system. Water seal deterioration will oc-cur,causingleakagebetweenboilersections,circulatorflanges,diaphragmtanksorothersystemcomponents.This can result in substantial property damage.

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

8. Continualfreshmakeupwaterwillreduceboilerlife.Min-eralbuildupinsectionsreducesheattransfer,overheatscastiron,andcausessectionfailure.Additionofoxygenandother gases can cause internal corrosion. Leaksin boiler or piping must be repaired at once to prevent makeupwater.

9. Donotaddcoldwatertohotboiler.Thermalshockcancausesectionstocrack.

Glycol — potential fire hazard —Allglycolisflammablewhenexposedtohightemperatures.Ifglycol is allowed to accumulate in or around the boiler or any otherpotentialignitionsource,afirecandevelop.Inordertoprevent potential severe personal injury, death or substantial propertydamagefromfireand/orstructuraldamage:• Never storeglycol of any kindnear theboiler or any

potential ignition source.• Monitorandinspectthesystemandboilerregularlyfor

leakage.Repairanyleaksimmediatelytopreventpos-sibleaccumulationofglycol.

• Neveruseautomotiveantifreezeorethyleneglycol inthesystem.Usingtheseglycolscanleadtohazardousleakageofglycolintheboilersystem.

1 Prepare boiler locationRead this first!

Codes & checklist

The boiler contains ceramic fiber and fiber-glassmaterials.Usecarewhenhandlingthesematerials per instructions on page 48ofthismanual. Failure to comply could result in severe personal injury.

3Part Number 550-142-785/1215

Service clearances1. Provideminimumclearancesforcleaningandservicingthe

boilerandforaccesstocontrolsandcomponentsaslistedinthe table below:

2. Provideat leastscrewdriverclearanceto jacketfrontpanelscrews for removalof frontpanel for inspectionandminorservice.Ifunabletoprovideatleastscrewdriverclearance,installunionsandshutoffvalvesinsystemsoboilercanbemovedforservicing.

Small space installations1. When the boiler is located in a closet or small space, provide

clearances no less than those shown in Figure 1. The clear-ancesarerequired toanysurface,whethercombustibleornon-combustible.

Table 1 Minimum foundation size


Service clearances: Minimum

Top (for cleaning flueways) 35”

Front (for access to controls and components) 18”

Back 7”

Left side (for cleaning and servicing) 24”

Right side 7”

Boiler model

Minimum foundation

length

Minimum foundation

width

GWI-047 25” 12”

GWI-063 25” 12”

GWI-095 25” 15”

GWI-127 25” 18”

GWI-158 25” 21”

GWI-190 25” 24”

Minimum clearance to combustible materials1. Hotwaterpipesmustbeatleast½”fromcombustiblematerial.2. Single-wallventpipemustbeatleast2inchesfromcombus-

tible material.3. TypeBdouble-wallmetalventpipe—seeventmanufacturer’s

recommendationforclearancestocombustiblematerial.

Figure 1 Minimum clearances

Flooring and foundation

FlooringTheGWIboilerisapprovedforinstallationoncombustibleflooring,but must never be installed on carpeting.

Donotinstallboileroncarpetingeveniffoundationis used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation1. Provideasolidbrickorminimum2-inchthickconcretefounda-

tionpadifanyofthefollowingistrue:• floorcanbecomeflooded.• theboilermountingareaisnotlevel.

2. See Table 1forminimumfoundationdimensions.

Residential garage installationsTakethefollowingspecialprecautionswheninstallingtheboilerinaresidentialgarage,perANSIZ223.1/NFPA54,paragraph5.1.9:

• Mounttheboileraminimumof18 inches above the floorofthe garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

• Locateorprotect the boiler so it cannot be damaged by a moving vehicle.

1 Prepare boiler location continued

Clearances

4 Part Number 550-142-785/1215



Failuretofollowallinstructionscanresultinfluegasspillageandcarbonmonoxideemissions,causingsevere personal injury or death.

When removing boiler from existing common vent system:Atthetimeofremovalofanexistingboiler, thefollowingstepsshall be followed with each appliance remaining connected tothe common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

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

b. Visuallyinspecttheventingsystemforpropersizeandhori-zontalpitchanddeterminethereisnoblockageorrestriction,leakage,corrosionorotherdeficiencieswhichcouldcauseanunsafecondition.

c. Testventsystem—Insofarasispractical,closeallbuildingdoors and windows and all doors between the space in which the appliances remaining connected to the common venting systemare locatedand other spacesof the building.Turnon clothes dryers and any appliance not connected to the commonventingsystem.Turnonanyexhaustfans,suchasrangehoodsandbathroomexhausts,sotheywilloperateatmaximumspeed.Donotoperateasummerexhaustfan.Closefireplace dampers.

d. Place in operation the appliance being inspected. Follow the lighting/operatinginstructions.Adjustthermostatsoappliancewill operate continuously.

e. Testforspillageatdrafthoodreliefopeningafter5minutesofmainburneroperation.Usetheflameofamatchorcandle.

f. Afterithasbeendeterminedthateachapplianceremainingconnected to the common venting system properly vents when testedasoutlinedabove,returndoors,windows,exhaustfans,fireplace dampers, and any other gas-burning appliance to theirpreviousconditionsofuse.

Any improperoperationof commonventing systemshouldbecorrectedsotheinstallationconformswiththeNationalFuelGasCode,ANSIZ223.1/NFPA54–latestedition.Correctbyresizingtoapproach the minimum size as determined using the appropriate tablesinPart11ofthatcode.CanadianinstallationsmustcomplywithB149.1orB149.2InstallationCode.

Chimney draft vent requirements1. Venting must be installed according to Part 7,Venting of

Equipment,ofNationalFuelGasCode,ANSIZ223.1/NFPA54 -latest edition and applicable building codes. CanadianinstallationsmustcomplywithB149.1orB149.2InstallationCodes.

2. Chimneyorventtermination:• Achimney,oranyventotherthanaTypeBventwithlisted

ventcap,mustextendatleast3feetabovethehighestpointwhereitpassesthrougharoofofabuilding,andatleast2feethigherthananyportionofabuildingwithinahorizontaldistanceof10feet.

• TypeBventswithlistedcapsmayterminateasinFigure2ifnocloserthan8feetfromaverticalwallorsimilarob-struction.

• Otherwise,TypeBventsmust terminateat least2 feetabovetheroofpenetrationandatleast2feethigherthananyportionofabuildingwithin10feet.

3. Alinedchimneyispreferredandmustbeusedwhenrequiredby local, state, provincial and national codes, laws, regulations and ordinances. Vitreous tile linings with joints that prevent retentionofmoistureandliningsmadeofnoncorrosivemateri-alsarebest.Adviceforflueconnectionsandchimneyliningscanbeobtainedfromlocalgasutility.TypeBdouble-wallmetalvent pipe or single-wall vent pipe may be used as a liner.

4. Coldmasonrychimneys,alsoknownasoutsidechimneys,typicallyhaveoneormorewallsexposedtooutsideair.When any atmospheric gas-fired boiler with automatic vent damperisventedthroughthistypeofchimney,thepotentialexistsforcondensationtooccur.Condensationcandamageamasonrychimney.Manufacturerrecommendsthefollowingto prevent possible damage.a. Linechimneywithcorrosion-resistantmetallinersuchas

AL29-4C®single-wallstainlesssteelorB-vent.SizelinerperNationalFuelGasCodeANSIZ223.1/NFPA54–latestedition.

b. Provide drain trap to remove any condensate.5. Where two or more gas appliances vent into a common chim-

neyorvent,equivalentareashouldbeatleastequaltoareaofventoutletonlargestapplianceplus50percentofventoutletareaofadditionalappliance.

Direct exhaust venting (Category III) — DO NOT COMMON venttheGWIinadirectexhaustsystem(CategoryIII).Connectingmorethanoneappliancetoadirectexhaustsystemwillcausefluegasspill-ageorappliancemalfunction,resultinginpossiblesevere personal injury, death or substantial property damage.

Inspect existing chimney before installing boiler.Failure tocleanor replaceperforatedpipeor tilelining will cause severe personal injury or death.

Vent system

GWI boilers can be either chimney draft ventedor direct-exhaust vented. See pages 7 to 12 fordetailed installation instructions.

IfyouareremovinganexistingboilerfromasharedventingsystemandthenewGWIboilerwillnotsharetheventsystem(allowedonlywhenchimneydraftventing), you must test each remaining appliance individuallytoverifytheventsystemstilloperatesadequately.Followguidelinesbelow.

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

5Part Number 550-142-785/1215


Products to avoid

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinatedwaxes/cleaners

Chlorine-basedswimmingpoolchemicals

Calciumchlorideusedforthawing

Sodiumchlorideusedforwatersoftening

Refrigerantleaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cementsandglues

Antistaticfabricsoftenersusedinclothesdryers

Chlorine-typebleaches,detergents,andcleaningsolventsfoundinhouseholdlaundryrooms

Adhesivesusedtofastenbuildingproductsandothersimilarproducts

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metalfabricationplants

Beauty shops

Refrigerationrepairshops

Photo processing plants

Autobodyshops

Plasticmanufacturingplants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garageswithworkshops

Table 2 Corrosive contaminants and likely locations

To prevent potential of severe personal injury ordeath, check for products or areas listed belowbeforeinstallingboiler.Ifanyofthesecontaminantsarefound:

• removecontaminantspermanently. — OR —• isolateboilerandprovideoutsidecombustionair.

Seenational,provincialor localcodes for furtherinformation.

Pleasereviewthefollowinginformationonpotentialcombustionair contamination problems.See Table 2forproductsandareaswhichmaycausecontami-nated combustion air.

Air contamination Air openings


CombustionairandventilationopeningsmustcomplywithSection5.3,“Air forCombustionandVentilation”,ofNationalFuelGasCodeANSIZ223.1/NFPA54–latestedition,orapplicable localbuildingcodes.CanadianinstallationsmustcomplywithB149.1orB149.2InstallationCodes.Seetablebelowforminimumcombustion/ventilationairopeningsizes.Whereopeningsarerequired,providetwo(2)openings—onewithin12inchesoftheceiling,theotherwithin12inchesofthe floor, as shown in the table illustrations.

Provideadequatecombustionandventilationairtoassurepropercombustionandreduce theriskofsevere personal injury, death or substantial property damage caused by flue gas spillage and carbon monoxideemissions.

6 Part Number 550-142-785/1215


Location Natural gas Propane gas

U. S.

Sea level – 2,000 ft.

over 2,000 ft.

Sea level – 2,000 ft.

over 2,000 ft.

Sz 48 (Note1) Sz 56 (Note1)

Note1: ForU.S.elevationsabove2,000feet,contactyourlocalsupplierfordetails.


Exhaust fans and air moversThe appliance space must never be under a negative pressure. Always provide air openings sized not only to the dimensionsrequired for thefiringrateofallappliances,butalso tohandletheairmovementrateoftheexhaustfansorairmoversusingairfromthebuildingorspace.

Air openings continued

2 Prepare boiler

Place boiler/crate near position1. Leaveboilerincrateandonpalletuntilinstallationsiteisready.2. Moveentirecrateandpalletnexttoselectedlocation.3. Removecrate.Leaveboileronpallet.4. Removeboilerfrompalletasfollows:

a. Tiltleftsideofboilerupandplaceaboardunderleftlegs.

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

c. Slideboilerbackwardsoffpalletandintoposition.

Donotdropboilerorbumpjacketonfloororpallet.Damage to boiler can result.

5. Checklevel.a. Shimlegs,ifnecessary.b. Do not alter legs.

Placement and setup

Motorized air dampersIftheairopeningsarefittedwithmotorizeddampers,electricallyinterlockthedamperto:• Preventtheboilerfromfiringifthedamperisnotfullyopen.• Shuttheboilerdownshouldthedampercloseduringboiler

operation.Toaccomplishthisinterlock,wireanisolated contact(provingthedamper open) in series with the thermostat input to the boiler. Theboilerwillnotstartifthiscontactisopen,andwillshutdownshould it open during operation.

The boiler contains ceramic fiber and fiberglass materials.Usecarewhenhandlingthesematerialsper instructions on page 48ofthismanual.Failureto comply could result in severe personal injury.

Inspect orifices and burners1. Removefrontjacketdoor.Removebaseaccesspanel(See

Figure 25, item 4, page 42).

2. Checkforcorrectly-sizedmanifoldorifices.SeeTable 3 forsizing.(Theorificesizeisstampedontheorificespudbarrel.)

Correctly-sized manifold orifices must be used.Failure to do so will result in severe personal injury, death or substantial property damage.

3. Levelandstraightenburners.

Burners must be properly seated in slots in burner restwiththeiropeningsfacingup.Mainburnerori-ficesmustinjectdowncenterofburner.Failuretoproperly seat burners will result in severe personal injury, death or substantial property damage.

4. Reinstall access panel.

Do not operate boiler without access panel secured in place. Failure to comply could cause momentary flamerolloutonignitionofmainflame,resultinginpossible fire or personal injury hazard.

Table 3 Manifold orifice sizing

7Part Number 550-142-785/1215


Perform hydrostatic pressure testPressure test boiler before attaching water or gas piping or electricalsupply(exceptasnotedbelow).

Prepare boiler for test1. Removetheshippingnipple(fromGWIsupplytapping)and

removetheboilerreliefvalve.Temporarilyplugthereliefvalvetapping with a ¾” NPT pipe plug.

2. Remove1¼”nipple, reducing teeanddrainvalve fromac-cessorybag.Installinboilerreturnconnectionasshownonin Figure 27, item 3, page 44.Installcirculatoroneitherthereturn or supply.

3. Remove 1¼” nipple, 1¼” tee, bushing and pressure/tempera-turegaugefromaccessorybag.Pipetoboilersupplyconnec-tion as shown in Figure 27, item 2, page 44.(Usepipedopesparingly.)

4. Connectahosetoboilerdrainvalve,theotherendconnectedtoafreshwatersupply.Makesurehosecanalsobeusedtodrainboileraftertest.

5. Connectanippleandshutoffvalvetosystemsupplyconnec-tion on the 1¼” tee. This valve will be used to bleed air during thefill.(Valveandnipplearenotincludedwithboiler.)

6. Connectanippleandshutoffvalvetosystemreturnconnec-tion(atcirculatorflangeifcirculatorinstalledonreturn).Thisvalvewillbeusedtobleedairduringthefill.(Valveandnippleare not included with boiler.)

Fill and pressure test1. Opentheshutoffvalvesyou installedonsupplyandreturn

connections.

Pressure test2. Slowlyopenboilerdrainvalveandfreshwatersupplytofill

boiler with water.

3. Whenwaterflowsfromshutoffvalves,closeboilerdrainvalve.

4. Closeshutoffvalves.

5. Slowlyreopenboilerdrainvalveuntiltestpressureofnotmorethan 45 psi is reached on the pressure/temperature gauge.

6. Testatnomorethan45psifornomorethan10minutes. Donotleaveboilerunattended.Acoldwaterfillcould

expandandcauseexcessivepressure,resultinginsevere personal injury, death or substantial property damage.

7. Make sure constant gauge pressure has been maintainedthroughouttest.Checkforleaks.Repairiffound.

Leaksmustberepairedatonce.Failure todosocan 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 fittings1. Disconnectfillwaterhosefromwatersource.

2. Drain boiler at drain valve or out hose, whichever provides bestaccesstodrain.Removehoseafterdrainingifusedtodrain boiler.

3. Removenipplesandvalvesunlesstheywillremainforuseinthe system piping.

4. Removeplugfromreliefvalvetapping.Seepage13toreplacereliefvalve.

3 Vent installation

TheGWIboilercanbeventedusingoneofthefollowingmethods:

Useonlytheventmaterialsandmethodsoutlinedinthismanual.Useofanyothermaterialsormeth-odscouldresultinventfailureorfluegasleakage,causing severe personal injury, death or substantial property damage.

Chimney draft venting—Usesthenaturaldraftprovidedbyaverticalventorchimney.Whenventedusingchimneydraftventing,GWIboilersareratedasCategoryIappliances(nopressureinventandfluegastem-peraturehotenoughtoavoidexcessiveventcondensation).Seefollowingsectionforinstallationprocedures.Chimneydraftinstallationsuse:a. Ventconnector(singleordoublewall)sizedtoeliminatepositive

pressure in vent system. Diameter increases immediately at boiler. See Figure 3, page 8forconnectorsizing.

b. Double-wallmetalvent(B-vent)orchimneywithlinerapprovedbytheNationalFuelGasCode,ANSIZ223.1/NFPA54–latestedition,orinCanadaB149.1orB149.2InstallationCode.

Direct exhaust — vertical or sidewall— Vent pipe is pressurized and terminated vertically through the rooforthroughasidewall.Whenventedasdirectexhaust,GWIboilersareratedasCategoryIIIappliance(positivepressureintheventandfluegastemperaturehotenoughtoavoidexcessivevent condensation).Youmustuseonlytheventmaterialslistedinthismanual.Seepages 8 through 12 forinstallationprocedures.Directexhaustinstallationsuse:a. Vent materials specified in this manual.b. Ventterminationthroughoutsidewall,rooforunusedchimney.

(Tightchimneyareaswillmakevent jointconstructionverydifficult.)

GWI venting options

2 Prepare boiler continued

8 Part Number 550-142-785/1215


3 Vent installation continued

Chimney draft venting Inspect existing chimney before installing boiler.

Failuretocleanorreplaceperforatepipeorliningwill cause severe personal injury or death.

Vent sizing given in Figure 3 is only a general guideline. The vent connector and chimney must be designed, sized and constructed in compliance with all applicable codes. Failure to correctly size and install the vent system could result in severe personal injury, death or substantial property dam-age.

See page 4foradditionalrequirementswhenchim-neydraftventing.

1. Usedoublewallmetalvent(B-vent)orchimneywithlinerasrequiredbytheNationalFuelGasCode,ANSIZ223.1/NFPA54–latestedition,orinCanada,B149.1orB149.2InstallationCode.

2. Topreventdowndrafts,chimneyshouldextendatleast3feetabovethehighestpointwhereitpassesthrougharoofandatleast2feethigherthananyportionofabuildingwithinahorizontaldistanceof10feet.

3. Toventwithanotherappliance,seeNationalFuelGasCode,ANSIZ223.1/NFPA54–latesteditionorinCanadaB149.2orB149.2InstallationCode

4. Donotconnectbreechingtoanyportionofamechanicaldraftsystem that can operate under positive pressure.

5. Maintainminimum2”clearancefromcombustiblematerialsto vent pipe.

6. Do not use chimney with an open fireplace.

7. Makehorizontal runsas short aspossible. Long runs cancause condensation.

8. When longer runs are used, support pipe with appropriate hangers.

9. Topreventblockage,donotventintobottomofchimney.

10.Ventpipemustnotgobeyondinsidewallofchimney.

11. Vent passing through floors or ceilings must be firestopped.

12. See Figure 3 to connect boiler to venting system.

Figure 3 Chimney draft venting installation

9Part Number 550-142-785/1215

Table 4 Maximum vent length


Direct exhaust ventingObtain vent system components1. ThefollowingspecialgasventsystemscomplywithUL-1738

andULC-S636standardsandarecertifiedbyCSAastheonlysystemssuitableforusewithGWIboilers(all3”diameter):

• Heat-Fab,Inc.Saf-TVent®

• Flex-LInternational,Inc.StaR-34

• Z-Flex®,Inc.Z-VentII

• ProTechSystemsFasNSeal™

Useonlytheventstarterofthesamemanufacturerastheventcomponents.Donotmixcomponentsfromdifferentsystems.Theventsystemcouldfail,causing flue gas spillage, resulting in severe per-sonal injury or death.

2. Selectverticalorsidewallventingdependingonjobrequire-ments.

3. RefertoTable4formaximumventrunlengthsandnumberofelbows.DonotexceeddatainTable 4.

4. SelectventcomponentsfromseparateGWI Vent Component Supplement.Allcomponents,includingtheventstarter,mustbeofthesameventmanufacturer.Donotmixcomponents.

1. Select a vent pipe manufacturer from separate GWI Vent Component Supplement and obtain all vent components needed, based on boiler location and venting method.

2. Youmustusetheventstarter(seebelow)madebytheventpipemanufacturer.SeeGWI Vent Component Supplementforpartnumberofeachcomponent,listedbyventmanufacturer.


3. Follow all applicable national, state, local or provincial codes whenventingtheGWIboiler.

4. Connectventstartertoblowerhousingoutletasshownbelow.a. Donotmixcomponentsfromdifferentventmanufacturers.b. Maintainminimum2”clearancefromcombustiblematerials

to vent pipe.c. Seal with sealant specified by vent pipe manufacturer,

using 3/8”bead(notrequiredforFasNSeal™).d. Tighten strap at band clamp screw until strap is snug

around blower housing.


Max.vent length (feet)

Total number of 90° elbows(Notes 1 & 2)

1 2 3 4 5 6

GWI-047 to GWI-158 55 48 41 34 27 20

GWI-190 35 28 21 14 7 --

Notes:1. Do not include termination fitting when counting total number of elbows.2. One (1) 90° elbow is equivalent to two (2) 45° elbows.

10 Part Number 550-142-785/1215


Direct exhaust venting continued

1. LocatetheboilerandventpenetrationthroughthewallsoallrequirementsonthispageandinFigures 4 and 5 will be met. Alsofollowventmanufacturer’sinstructions.

2. Gaseswillformwhiteplumeinwinter.Plumecouldobstructwindow view.

3. Prevailing winds could cause freezing of condensate andwater/icebuilduponventtermination,building,plantsorroof.Icebuilduponvent terminationcancauseboilershutdownandbuildingfreeze-up.

4. Windsover31mphcancausenuisanceboilershutdownifboilerissidewallvented.Thiscouldresultinlossofheattobuilding,causingfreeze-up.

5. Locateorguardventterminationtopreventcondensatefromdamagingexteriorsurfaces.

6. Locatetheventterminationwellawayfromtrees,shrubs,anddecorative items.

7. Locateorguardventtopreventaccidentalcontactbypeopleor pets.

8. Do not terminate vent in window well, stairwell, alcove, court-yard, or other recessed areas.

9. Do not wrap or insulate vent pipe or fittings.10.Donotterminateventaboveanydoororwindow.Condensate

canfreeze,causingiceformations.11. Do not connect:

• Anyotherappliancetoventpipe.• Multipleboilerstoacommonventpipe.

12.Canadianinstallations—SeeB149.1orB149.2InstallationCode.Terminateventnolessthan6feetfromanothercom-bustionairinlet,3feetfromanyotherbuildingopening,and3feetfromanygasserviceregulator.

13. See Figures 4 and 5, showing that the vent must terminate:• atleast7feetabovepublicwalkway.• 3feetaboveanyforcedairintakewithin10feet.• morethan4feetbelowortosideofalldoorsorwindows.• morethan1footabovegradeoranticipatedsnowline.

14. Vent must also terminate:• atleast6feetawayfromadjacentwalls.• nocloserthan5feetbelowroofoverhang.• minimum4feet(1.22m)horizontally(andinnocaseabove

orbelowunlessa4foot(1.22m)horizontaldistanceismaintained)fromelectricmeters,gasmeters,regulators,reliefvalves,andotherequipment.

15. Site conditions may dictate greater clearances.16.Donotextendexposedventpipeoutsideofbuilding.Conden-

satecouldfreezeandblockventpipe.17. Ensureproperclearanceabovegradeorsnowline.Keepvents/

airintakeareaclearofaccumulatingsnow.

Agasventextendingthroughanexteriorwallshallnot terminate adjacent to the wall or below building extensionssuchaseaves,overhangs,balconiesordecks.Failuretocomplycouldresultinsevereper-sonal injury, death or substantial property damage.

Vent termination location Follow instructions on this page when determining

ventlocationtoavoidpossibilityofseverepersonalinjury, death or substantial property damage.

Figure 4 Maintain minimum clearances from public walkways and building air openings

Figure 5 Maintain minimum clearances from doors, windows and snow line


11Part Number 550-142-785/1215



1. Donotmixtypesormanufacturersofventmaterials.


2. Cleanall jointsbeforesealing.Seeventmanufacturer’s in-structionsforcleaningandsealingjoints.Usetheirspecifiedsealant. Do not use screws.

3. Installventpipewithseamsontopofventhorizontalruns.Followrequirementsonpage 10forventterminationlocation.

4. Maintainminimum2”clearancefromcombustiblematerialsto vent pipe.

5. Vertical venting — See Figure 6.Followventmanufacturer’sinstructionsforventingthroughroof.• Vent pipe must extend through roof flashing, jacket or

thimble.• Vent may pass through floor, inside wall or concealed

spacewhen installedaccording to ventmanufacturer’sinstructions.

Sidewall venting — See Figures 7 and 8. Vent must terminate at leastone footaboveanticipatedsnowline.Ventmustbeterminated only with:• Elbowwithintegralscreen.

• Elbowandterminationcouplingwithscreen(notavailableforStaR-34).

6. Donotsealventpipe(slipconnectorforSaf-TVent)toinsideor outside plate.

7. Ifpassingthroughnoncombustiblewall,provideholediam-eterlargeenoughtoinserttheventpipe(slipconnectorforSaf-TVent).

8. Installhorizontaldrainteeascloseaspossibletoboiler, infirst horizontal run. See Figure 7.

9. Do not exceed the maximum vent system length given inTable 4, page 9.

Condensatedrainline—useonlysiliconetubingratedforatleast400°Fforthefirst18”ofconden-sate drain line, then other non-metallic tubing may beused.Usinganyothermaterialcouldcausefluegasleakage,potentiallyresultinginseverepersonalinjury, death or substantial property damage.

On some installations, the condensate drain fitting may be omitted, provided:

• Ventmanufacturershowsthisoptionintheirinstruc-tions.

• Ventisslopedtowardterminationasshownindottedlines in Figure 7.

• Theventisinstalledperboilermanufacturer’sandventmanufacturer’sinstructions.

Condensatedrippagefromsuchventsmayaccumulateonthegroundbelow.Considertrafficintheareatoavoidhazardduetoice accumulation.

Installing direct exhaust vent and termination


Figure 6 Vertical direct exhaust installation Figure 7 Direct exhaust through side wall

12 Part Number 550-142-785/1215


Usinganyterminationotherthanoneofthoseshowncould cause nuisance outages and loss of heat,resulting in substantial property damage.


Figure 8 Sidewall vent termination options and installation requirements


13Part Number 550-142-785/1215

Table 6 Water pipe size (based on 20 °F rise)GeneralBoilermodel

number

Tosystem

Fromsystem

GWI-047 ¾” ¾”

GWI-063 1” 1”

GWI-095 1” 1”

GWI-127 1” 1”

GWI-158 1 ¼” 1 ¼”

GWI-190 1 ¼” 1 ¼”


IfinstallationistocomplywithASMEorCanadianrequirements,anadditionalhightemperaturelimitisneeded.Installcontrolinsupply piping between boiler and isolation valve. Set second controltominimum20°Fabovesetpointoffirstcontrol.Maximumallowablesetpointis240°F.Seepage 24 and 25forwiring.

Alowwatercutoffdeviceisrequiredwhenboilerisinstalledaboveradiation level or by certain state or local codes or insurance companies.Uselowwatercutoffdesignedforwaterinstallations.Electrodeprobe-type isrecommended.Purchaseand install intee in supply piping above boiler.

Usebackflowcheckvalveincoldwatersupplyifrequiredbylocal codes.

See Figure 9(diaphragm-typeorbladder-typeexpansiontank)orFigure10(closed-typeexpansiontank)onpage 14, and Table 6, fornear-boilerandsingle-zonesystemsdesigned for returnwateratleast130°F.See page 13formultiple-zonepiping.See page 14forboilersusedwithrefrigerationsystems.

Near-boiler piping

Relief valveInstallreliefvalveverticallyin¾”NPTtappingonsideofboiler.Seethetagattachedtothereliefvalveformanufacturer’sinstructions.

To avoid water damage or scalding due to valve operation, discharge line must be connected to re-liefvalveoutletandruntoasafeplaceofdisposal.Terminate the discharge line to eliminate possibility ofsevereburnsshouldthevalvedischarge.

• Dischargelinemustbeasshortaspossibleandbethe same size as the valve discharge connection throughout its entire length.

• Dischargelinemustpitchdownwardfromthevalveand terminate at least 6” above the floor drain where any discharge will be clearly visible.

• Thedischargelineshallterminateplain,notthread-ed,withamaterialserviceablefortemperaturesof375°Forgreater.

• Donotpipethedischargetoanyplacewherefreez-ing could occur.

• Noshutoffvalveshallbeinstalledbetweenthereliefvalve and boiler, or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Failuretocomplywiththeaboveguidelinescouldresultinfailureofthereliefvalvetooperate,result-inginpossibilityofseverepersonalinjury,deathorsubstantial property damage.

• Testtheoperationofthevalveafterfillingandpres-surizingsystembyliftingthelever.Makesurethevalvedischargesfreely.Ifthevalvefailstooperatecorrectly,replaceitwithanewreliefvalve.

CirculatorThe circulator is shipped loose (wiring pre-attached to boiler)to allow you to locate it either in the return or supply piping, as desired. See page 14foratypicalinstallation.Pipetheexpansiontanktothesuctionsideofthecirculatorwheneverpossible.Installanairseparatorinthesupplypiping.Connecttheexpansiontanktotheairseparatoronlyiftheseparatorisonthesuctionsideofthecirculator.Alwaysinstallthesystemfillconnectionatthesamepointastheexpansiontankconnectiontothesystem.Figures 4 and 5 show typical near-boiler piping connections.

Expansion tank

Diaphragm- or bladder-type expansion tank — Figure 9, page 141. Ensure expansion tank size will handle boiler and system

watervolumeandtemperature.Tankmustbelocatedinboilerreturnpipingasclosetoboileraspossible,beforeinletsideofcirculator.Seetankmanufacturer’sinstructionsfordetails.

2. Installanautomaticairventasshown.

Closed-type expansion tank — Figure 10, page 141. Ensureexpansiontanksizewillhandleboilerandsystemwater

volumeandtemperature.Seetankmanufacturer’sinstructionsfordetails.

2. Connecttankto½”NPTtappinglocatedbehindsupplyoutlet,using ½” NPT piping. Pitch any horizontal piping up towards tank1inchper5feetofpiping.

Undersizedexpansion tankscausesystemwatertobelostfromreliefvalveandmakeupwatertobeaddedthroughfillvalve.Eventualsectionfailurecanresult.

Water piping — multiple zone systemsInstallsystempipingusingeithercirculatorzoningorzonevalvezoning.Installexpansiontankonsuctionsideofsystempump.Alwaysconnectfill lineonlyat theexpansion tank—neveratanother point in the system.

DO NOT connect directly from 3-wire zone valves to the T-T terminals on the boiler. When using 3-wire zone valves, install an isolation relay.Connectthezonevalveendswitchwirestotheisolationrelaycoil.Connecttheisolationrelaycontact across the boiler T-T terminals. Failure to comply can result in damage to boiler components or cause unreliable operation, resulting in severe property damage.

4 Install water piping4 Install water piping

14 Part Number 550-142-785/1215


Water piping — refrigeration systems

Prevent chilled water from entering boilerInstallboilersothatchilledmediumispipedinparallelwiththeheatingboiler.Useappropriatevalvestopreventchilledmediumfrom entering boiler. See Figure 11 for typical installation ofbalancingvalveandcheckvalve.

Figure 9 Diaphragm- or bladder-type expansion tank: Piping to single-zone system using diaphragm-type or bladder-type expansion tank. See Table 6, page 13, for piping sizes.

Figure 10 Closed-type expansion tank: Piping to single-zone system using closed-type expansion tank. See Table 6, page 13, for piping sizes.

Figure 11 Piping refrigeration systems

Installboilersothatchilledmediumispipedinpar-allelwithheatingboiler.Useappropriatevalvestopreventchilledmediumfromenteringboiler.ConsultAHRIInstallationandPipingGuides.

If boiler is connected to heating coils located inair handlingunitswhere they canbeexposed torefrigeratedair,useflowcontrolvalvesorotherau-tomatic means to prevent gravity circulation during coolingcycle.Circulationofcoldwaterthroughtheboilercouldresultindamagetotheheatexchanger,causing possible severe personal injury, death or substantial property damage.

Ifsystemincludesradiantheatingcircuits,providepiping and controls to regulate the temperature sup-plying the radiant circuits. Failure to comply could result in substantial property damage.

UseFigure9orFigure10onlyforsystemsdesignedforreturnwaterat least130°F.Forsystemswithlow return water temperature, such as converted gravity systems and radiant heating systems, install bypasspiping(seepage 15) to protect boiler against condensation. Failure to prevent low return water temperaturetotheboilercouldcausecorrosionofthe boiler sections or burners, resulting in severe personal injury, death or substantial property dam-age.

4 Install water piping continued

15Part Number 550-142-785/1215

4 Install water piping continued


Figure 12 System bypass piping in boiler loop with separate system circulator, using primary/secondary piping

Figure 13 Boiler bypass piping — use only for high water content systems — DO NOT use for radiant panel systems

Near-boiler piping continued

Installallcomponentsspecifiedaboveandadjustvalvesasdescribedtopreventlowtemperatureintheboiler.Failuretopreventlowwatertemperatureintheboilercouldcausecorrosionoftheboilersectionsorburners,resultinginseverepersonal injury, death or substantial property damage.

System bypass method1. Apply bypass piping of Figure 12 to high water content

systems,radiantpanelsystemsoranysystemthatislikelyto operatewith low returnwater temperature for extendedperiods.

2. Thebypassarrangementshownprotectstheboilerfromdam-age caused by condensate corrosion due to low return water temperatureandprotectslowtemperaturesystemsfromtoohigh a supply temperature.

3. Adjustthebypassvalvesasindicatedbelow.

Adjust Bypass valves 1 and 2 as follows:1. Startwithvalve2fullyclosed,valve1fullyopen.2. Slowlyopenvalve2whileclosingvalve1.Adjustthevalves

untiltheboilerpressure/temperaturegaugereads160°Forhigher.Asyouopenthevalves,pauselongenoughtoallowtemperaturestoleveloff.Ittakesawhilefortheboilerwatertemperature 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. Thepurposeofthispipingistoraisethereturnwatertem-peraturetotheboilerenoughtopreventcondensationoffluegases.

Boiler bypass method1. ApplybypasspipingofFigure 13 to high water content sys-

tems, such as converted gravity systems.2. Thebypassarrangementshownprotectstheboilerfromdam-

age caused by condensate corrosion due to low return water temperature.Thismethoddoesnotprovideprotectionfromhigh temperature water being supplied to the system.

3. DO NOT apply this piping to radiant panel systems.4. Adjustthebypassvalvesasindicatedbelow.

Adjust Bypass valves 1 and 2 as follows:1. Startwithvalve1fullyclosed,valve2fullyopen.2. Slowlyopenvalve1whileclosingvalve2.Adjustthevalves

until theboilerpressure/temperaturegauge readsapproxi-mately60°Fhigherthanthesystemtemperaturegauge.Asyou open the valves, pause long enough to allow temperatures toleveloff.Ittakesawhilefortheboilerwatertemperaturetorise as the flow changes.

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

4. Thepurposeof thispiping is tocauseahighenoughtem-perature rise in the boiler that the average temperature will bewarmenoughtopreventcondensationoffluegases.

16 Part Number 550-142-785/1215


Figure 14 Gas supply pipingTable 7 Pipe capacity for 0.60 specific gravity natural gas

Connecting gas supply piping to boiler1. RemovejacketfrontpanelandseeFigure 14 to pipe gas to

boiler.a. Installdriplegatinletofgasconnectiontoboiler.Where

localutilityrequiresdriplegtobeextendedtothefloor,useappropriatelengthofnipplebetweencapandtee.

b. Installgroundjointunionforservicing,whenrequired.c. Installmanualshutoffvalveingassupplypipingoutside

boilerjacketwhenrequiredbylocalcodesorutilityrequire-ments.

d. InCanada—Whenusingmanualmainshutoffvalve,itmust be identified by the installer.

2. Support piping with hangers, not by boiler or its accessories.3. Purgeallairfromgassupplypiping.4. Beforeplacingboiler inoperation,checkboilerand itsgas

connectionforleaks.a. Close manual main shutoff valve during any pressure

testing at less than 13” w.c.b. Disconnectboilerandgasvalvefromgassupplypiping

during any pressure testing greater than 13” w.c.

Donotcheckforgasleakswithanopenflame—Usebubbletest.Failuretousebubbletestorcheckforgasleakscancauseseverepersonalinjury,deathor substantial property damage.

5. Usepipedopecompatiblewithpropanegases.Applysparinglyonlytomalethreadsofpipejointssothatpipedopedoesnotblockgasflow.

5 Install gas piping Failure to apply pipe dope as described in this

manual can result in severe personal injury, death or substantial property damage.

Natural Gas:1. SeeTable7forpipelengthanddiameter.Baseonratedboiler

input(divideby1,000toobtaincubicfeetperhour).Table 7 isonlyforgaswithspecificgravity0.60,withapressuredropthroughthegaspipingof0.30”w.c.Foradditionalgaspipesizing information,seeANSIZ223.1(B149.1orB149.2forCanadianinstallations).

2. Inletpressurerequiredatgasvalveinlet:• Maximum:13”w.c.• Minimum:5”w.c.• Manifoldgaspressure:3.5”w.c.

3. Install100%lockupgaspressureregulator insupply line ifinletpressureexceeds13”w.c.Adjustfor13”w.c.maximum.

Propane Gas:1. Contactgassuppliertosizepipes,tanksand100%lockup

gas pressure regulator.2. Adjustpropanesupplyregulatorprovidedbygassupplierfor

13”w.c.maximumpressure.3. Inletpressurerequiredatgasvalveinlet:

• Maximum:13”w.c.• Minimum:11”w.c.• Manifoldgaspressure:10”w.c.

Gas pipe length (feet)

Capacity of pipe for pipe size of:(Capacity in cubic feet gas per hour)

½” ¾” 1” 1¼” 1½”

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 860

40 63 130 245 500 760

50 56 115 215 440 670

75 45 93 175 360 545

100 38 79 150 305 460

150 31 64 120 250 380

17Part Number 550-142-785/1215


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

WiringmustbeN.E.C.Class1. If rollout thermal fuse element wire as supplied

withboilermustbereplaced,type200°Cwireorequivalentmustbeused.Ifotheroriginalwiringassupplied with boiler must be replaced, use only type 105°Cwireorequivalent.

BoilermustbeelectricallygroundedasrequiredbyNationalElectricalCodeANSI/NFPA70-latestedition.

Electrical installation must comply with:1. NationalElectricalCodeandanyothernational,state,provin-

cial or local codes or regulations.2. InCanada,CSAC22.1CanadianElectricalCodePart1,and

any local codes.

Wiring connectionsBoiler is shipped with controls completely wired. See wiring dia-gram on page 24 and 25fordetails.Circulatorisshippedloose,butwiringharnessispre-attachedtotheboiler.Connectwiresincirculatorjunctionbox.

Thermostat1. Connectthermostatasshownonwiringdiagramonboiler.2. Installoninsidewallawayfrominfluencesofdrafts,hotorcold

waterpipes,lightingfixtures,television,sunraysorfireplaces.3. If thermostathasaheatanticipator, setheatanticipator in

thermostattomatchpowerrequirementsofequipmentcon-nectedtoit.Ifconnecteddirectlytoboiler,seeWiringdiagrams,

6 Field wiringpage 24 and 25,foranticipatorsetting.Forotherdevices,seemanufacturer’sspecifications.Wiringdiagramonboilergivessettingforcontrolmoduleandgasvalve.Alsoseeinstructionswith thermostat.

DHW (if used)ConnectDHWaquastatasshowninwiringbelow.Economyfunctionisn’tutilizedwithDHWinput.

R & C Connections (if used)

24Vacleadsshouldbeusedforpowerstealingthermostatsonly!

Junction box (furnished)1. Connect120VACpowerwiring(Figure 15).2. Fuseddisconnectorserviceswitch(15amp.recommended)

maybemountedonthisbox.Forthoseinstallationswithlocalcodeswhichprohibitinstallationoffuseddisconnectorserviceswitchonboiler,installa2x4coverplateontheboilerjunctionboxandmounttheserviceswitchremotelyasrequiredbythecode.

Wiring multiple zonesSeezonevalvemanufacturer’sliteratureforwiringandapplication.Aseparatetransformerisrequiredtopowerzonevalves.Zoningwithcirculatorsrequiresarelayforeachcirculator.

DO NOT connect directly from 3-wire zone valves to the T-T terminals on the boiler. When using 3-wire zone valves, install an isolation relay.Connectthezonevalveendswitchwirestotheisolationrelaycoil.Connecttheisolationrelaycontact across the boiler T-T terminals. Failure to comply can result in damage to boiler components or cause unreliable operation, resulting in severe property damage.

Figure 15 Field wiring connections — service switch, DHW (if used) and thermostat (or end switch) provided by installer

18 Part Number 550-142-785/1215


Check for gas leaks Beforestartingtheboiler,andduringinitialopera-

tion,smellnearthefloorandaroundtheboilerforgas odorant or any unusual odor. Do not proceed withstart-upifthereisanyindicationofagasleak.Repairanyleakatonce.

Propaneboilersonly—Yourpropanesuppliermixesanodorantwiththepropanetomakeitspresencedetectable.Insomeinstances,theodorantcanfadeand the gas may no longer have an odor.

• Propanegascanaccumulateatfloor level.Smellnear thefloor for thegasodorantoranyunusualodor.Ifyoususpectaleak,donotattempttolightthe pilot.

• Usecautionwhenattemptingtolightthepropanepilot.This should be done by a qualified servicetechnician,particularlyifpilotoutagesarecommon.

• Periodicallychecktheodorantlevelofyourgas.• Inspectboilerandsystematleastyearlytomake

sureallgaspipingisleak-tight.• Consultyourpropanesupplierregardinginstallation

ofagasleakdetector.Therearesomeproductsonthemarketintendedforthispurpose.Yoursuppliermay be able to suggest an appropriate device.

Determine if water treatment is needed Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Eliminateallsystemleaks.Continualfreshmakeupwaterwillreduceboilerlife.Mineralscanbuildupinsections,reducingheattransfer,overheatingcastiron,andcausingsectionfailure.

Verify water chemistryConsultlocalwatertreatmentcompaniesforunusuallyhardwaterareas(above7grainshardness)orlowpHwaterconditions(below7.0).BoilerwaterpHof7.0to8.5isrecommended.

Freeze protection (when used)Useantifreezemadeespecially forhydronicsystems. Inhibitedpropylene glycol is recommended.

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

1. Determine antifreeze quantity according to system watercontent. Boiler water content is listed on page 47. Remember toincludeexpansiontankwatercontent.

2. Followantifreezemanufacturer’sinstructions.

3. A50%solutionofpropyleneglycol/waterprovidesmaximumprotectiontoabout-30°F.

4. Localcodesmayrequirebackflowpreventeroractualdiscon-nectfromcitywatersupply.

5. Whenusingantifreezeinasystemwithautomaticfill,installawatermetertomonitorwatermakeup.Glycolwillleakbeforethewaterbeginstoleak,causingglycolleveltodrop.Addedwaterwilldilutetheantifreeze,reducingthefreezeprotectionlevel.

PreparationFill the system with water1. Closemanualandautomaticairventsandboilerdraincock.2. Fill to correct system pressure. Correct pressure will vary

with eachapplication.Typical coldwater fill pressure for aresidential system is 12 psi.

3. Purgeairfromsystem:a. Connectahosetopurgevalveorvalves,ifinstalled.Route

hose to an area where water can drain and be seen.b. Close theboiler or system isolation valvebetween the

purge valve and fill connection to the system.c. Closezoneisolationvalves.d. Openquick-fillvalveoncoldwatermakeupline.e. Open purge valve.f. Onezoneatatime,opentheisolationvalves.Allowwater

to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolationvalvesandproceedwiththenextzone.Followthisproce-dure until all zones are purged.

g. Closethequick-fillwatervalveandpurgevalveandremovethe hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h. Afterthesystemhasoperatedforawhile,eliminateanyresidual air by using the manual air vents located through-out the system.

i. Ifpurgevalvesarenotinstalledinsystem,openmanualairvents in system one at a time, beginning with lowest floor. Closeventwhenwatersquirtsout.Repeatwithremainingvents.

4. Open automatic air vent (diaphragm-type or bladder-typeexpansiontanksystemsonly)oneturn.

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

untilwatersquirtsout.b. Repeat with remaining vents.

6. Refill to correct pressure.

Inspect system water pipingAfterfilling theboilerandsystemwithwater, inspectallpipingthroughout the system for leaks. If found, repair immediately.Repeatthisinspectionaftertheboilerhasbeenstartedandthesystem has heated up.

Leaksmustberepairedatonce.Failuretodosocandamage the boiler, resulting in substantial property damage.


Inspect base insulationChecktomakesureinsulationissecureagainstallfoursidesofthebase.Ifinsulationisdamagedordisplaced,donotoperateboiler. 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.

The boiler contains ceramic fiber and fiberglass materials.Usecarewhenhandlingthesematerialsperinstructionsonpage48ofthismanual.Failureto comply could result in severe personal injury.

7 Start-up

19Part Number 550-142-785/1215


Operate boiler DO NOT proceed with boiler operation unless boiler

and system have been filled with water and all in-structionsandproceduresofpreviousmanualsec-tions have been completed. Failure to do so could result in severe personal injury, death or substantial propertydamage.Beforestartingtheboiler...

• ReadmanualSections 9 and 10andthe“Operatinginstructions”, page 26.

• Verifytheboilerandsystemarefullofwater.• VerifytheStart-up“Preparation”proceduresofthis

section have been completed.

Adjust boiler control settingsBOILER OPERATING TEMPERATUREWithpowerturnedon,controlmodulereceivesasignalfromthetemperature sensor and displays boiler temperature. The control knob labeled BOILER TEMP is used to adjust the operating temperaturesetpoint,turningclockwisetoincreasetemperaturesetting and counterclockwise to decrease. When the knob isturned to adjust temperature the display will brighten to indicate adjustmentmode.Aftertemperatureissettodesiredvalue,displaywilldimafterapproximately5secondstoindicatemeasurementmode.

ADJUST BOILER OPERATING TEMPERATURE TO DESIRED SETPOINT

BOILER ECONOMY SETTINGTo comply with Department of Energy regulations, the controlmodule circulates available hot water before turning on theboiler toattempt tosatisfyacall forheat. Whileattempting tosatisfy theheatdemand, thecontrolmodulealsomonitors theboiler temperature changes via the temperature sensor and determines whether or not the available hot water will satisfythe demand, adjusting the time delay to turn on the boiler until it determines that additional heat will be needed. The knoblabeledECONOMYADJUSTprovidesanadjustmentbetweenmaximize(MAX)andminimize(MIN)thedelay.Themaximum(MAX)adjustmentpositionshouldbeusedtomaximizeenergysavings.Turningtheknobcounterclockwisedecreasesthedelaytime and should only be used in the event that the heated space becomesuncomfortable.

ADJUST ECONOMY TO DESIRED POSITION (MAX IS THE PREFERRED SETTING)

IMPORTANTInaccordancewithSection325(f)(3)oftheEnergyPolicyandConservationAct,thisboilerisequippedwithafeaturethatsavesenergy by reducing the boiler water temperature as the heating loaddecreases.Thisfeatureisequippedwithanoverridewhichis provided primarily to permit the use of an external energy

managementsystemthatservesthesamefunction.

7 Start-up continued

THISOVERRIDEMUSTNOTBEUSEDUNLESSATLEASTONEOFTHEFOLLOWINGCONDITIONSISTRUE:

• Anexternalenergymanagementsystemisinstalledthatreducestheboilerwatertemperatureastheheatingloaddecreases.

• Thisboilerispartofamodularormultipleboilersystemhavingatotalinputof300,000BTU/hrorgreater.

• Thisboilerisequippedwithatanklesscoil.

Start the boilerFollowthe“Operatinginstructions”,page 26.Ifboilerfailstostart,see“Ifboilerdoesn’tstart...Checkfor:”on this page.

Check system and boiler Eliminateallsystemleaks.Continualfreshmakeup

waterwillreduceboilerlife.Mineralscanbuildupinsections,reducingheattransfer,overheatingcastiron,andcausingsectionfailure.

Ifyoudiscoverevidenceofanygasleak,shutdowntheboileratonce.Findtheleaksourcewithbubbletest 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.


1. Checksystempipingforleaks.Iffound,shutdownboilerandrepair immediately.

2. Ventairfromsystemusingmanualvents.Airinthesystemwillinterferewithcirculationandcauseheatdistributionproblemsand noise.

3. Inspectventsystemthoroughlyforsignsofdeteriorationfromcorrosion,physicaldamageorsagging.Verifythatmasonrychimney liners are in good condition, with no obstructions, and there are no openings into the chimney.

4. Checkaroundtheboilerforgasodorfollowingtheprocedureofpage 16ofthismanual.

5. Verifyoperationusingproceduresbelow.Perform“Checkoutprocedure” on pages 20 and 21andfillinthe“Installationandservice certificate”.

If boiler doesn’t start . . . Check for:1. Looseconnections,blownfuseorserviceswitchoff?2. Highlimitswitchsetbelowboilerwatertemperature?3. Thermostatsetbelowroomtemperature?4. Gasnotturnedonatmeterorboiler?5. Incominggaspressurelessthan: 5”w.c.fornaturalgas?11”w.c.forpropanegas?6. Ifnoneoftheabovecorrectstheproblem,see“Troubleshoot-

ing”, page 31ofthismanual.

20 Part Number 550-142-785/1215


❏ Boilerandheatdistributionunitsfilledwithwater?❏ Automaticairvent,ifused,openonefullturn?❏ Airpurgedfromsystem?❏ Airpurgedfromgaspiping?Pipingcheckedforleaks?❏ Correctly-sized manifold orifices installed? See Table 3,

page 6tochecksizeandfueltype.

Correctly sized manifold orifices must be used.Failure to do so will cause severe personal injury, death or substantial property damage.

❏ Followed“Operatinginstructions”onboilerorinmanual,page 26forproperstart-up?

❏ Properburnerflameobserved?See“Verifyoperation”,manualSection 7.

❏ Test temperature limit — While burners are operating, turn BoilerTempadjustmentknobcounterclockwiseuntildisplayreading is below actual boiler water temperature. Burners should go off while circulator continues to operate.TurnBoilerTempadjustmentknobclockwiseuntildisplayread-ingisaboveboilerwatertemperatureandignitionsequenceshould resume.

❏ Testadditionalfield-installedcontrols—Ifboilerhasa lowwater cutoff, additional high limit or other controls, test foroperation as outlined by manufacturer. Burners should beoperatingandshouldgooffwhencontrolsaretested.Whencontrols are restored, burners should reignite.

❏ Testignitionsystemsafetydevice:a. Connectmanometertooutletsideofgasvalve.Startboiler,

allowingfornormalstart-upcycletooccurandmainburn-erstoignite.Withmainburnerson,manuallyshutoffgassupplyatmanualmainshutoffgasvalve.Burnersshouldgooff.Openmanualmainshutoffgasvalve.Manometershould confirm there is no gas flow. Pilot will relight, flame sensing element will sense pilot flame and main burners reignite.

❏ Setlimitcontrol(s)tosystemtemperaturerequirements.Adjustbalancing valves and controls to provide design temperature to system.

❏ SetEconomymode,fullyclockwise.❏ For multiple zones, adjust flow so it is about the same in each zone.❏ Verifythermostatheatanticipator(ifavailable)setproperly?

See wiring diagram label on boiler or in manual, page 24 and 25.

❏ Cycleboilerwiththermostat—Raisetohighestsettingandverify boiler goes through normal start-up cycle. Lower tolowestsettingandverifyboilergoesoff.

❏ CycleDHWAquastatifused.

❏ Measurenaturalgasinput:a. Operate boiler 10 minutes.b. Turnoffotherappliances.c. Atnaturalgasmeter,measuretime(inseconds)required

touseonecubicfootofgas.d. Calculategasinput:

3600 x 1000

number of seconds from step c= Btuh

e. Btuhcalculatedshouldapproximateinputratingonboilerrating label.

8 Checkout procedure

Check burner flame — Pilot burner

Proper pilot flame (see Figure 16):1. Blue flame.2. Innerconeengulfingpilotflamesensor.3. Pilot flame sensor glowing cherry red.

Improper pilot flame:1. Overfired—Largeflame liftingorblowingpastpilot flame

sensor.2. Underfired—Smallflame.Innerconenotengulfingpilotflame

sensor.3. Lackofprimaryair—Yellowflametip.

Figure 17 Typical main burner flame

Verify operation

Figure 16 Typical pilot burner flame

4. Incorrectlyheatedpilotflamesensor.

Check burner flames — Main burner

Proper main burner flame (see Figure 17):1. Yellow-orangestreaksmayappear(causedbydust).

Improper main burner flame:1. Overfired—Largeflames.2. Underfired—Smallflames.3. Lackofprimaryair—Yellowtippingonflames(sootingwill

occur).

7 Start-up continued

21Part Number 550-142-785/1215

Boiler model_______________________________________________________________Series ____________

CP number_______________________________________Date installed_________________________________

Measured Btuh input____________

Installer_________________________________________________________________________________(company) (address) (phone)

_____________________________________

(installer’s signature)

Installation instructions have been followed.

Checkout sequence has been performed.

Above information is certified to be correct.

Information received and left with owner/maintenance person.

Installation and service certificate

Thisboilerisequippedwithacontrolsystemthatautomaticallyadjustsatimedelayperiodtoturnontheboilerduringacallforheat.Thisisaccomplishedbycirculatingavailablehotwaterinthesystemwhilemeasur-ingwaterboilerwatertemperaturechanges.Thecontrolcalculatesasuitabledelaybasedontemperaturemeasurementsandturnstheboilerononlyafteritdeterminesthatthedemandforheatcannotbesatis-fiedwiththeavailablehotwater.

Duetothewidevarietyofcontrolsusedinboilerinstallations,thiscontrolisalsoequippedwithanadjustmentforthecalculatedtimedelayperiod(ECONOMYADJUST).IntheMINposition,thetimedelayiszeroandtheIMPORTANTnoticebelowmustbeobserved:

IMPORTANT

InaccordancewithSection325(f)(3)oftheEnergyPolicyandConservationAct,thisboilerisequippedwithafeaturethatsavesenergybyreducingtheboilerwatertemperatureastheheatingloaddecreases.This

featureisequippedwithanoverridewhichisprovidedprimarilytopermittheuseofanexternalenergymanagementsystemthatservesthesamefunction.

THISOVERRIDEMUSTNOTBEUSEDUNLESSATLEASTONEOFTHEFOLLOWINGCONDITIONSISTRUE:

• Anexternalenergymanagementsystemisinstalledthatreducestheboilerwatertemperatureastheheatingloaddecreases.

• Thisboilerispartofamodularormultipleboilersystemhavingatotalinputof300,000BTU/hrorgreater.

• Thisboilerisequippedwithatanklesscoil.


❏ Checkmanifoldgaspressurebyconnectingmanometer todownstreamtesttappingonmaingasvalve.Manifoldpressurefornaturalgasshouldbe3.5”w.c.andforpropanegasshouldbe 10” w.c.

❏ Observeseveraloperatingcyclesforproperoperation.❏ Set room thermostat to desired room temperature.

❏ Fillin“Installationandservicecertificate”below?❏ Review all instructions shipped with this boiler with owner or

maintenance person. Return instructions to envelope and give toownerorplaceinpocketinsidefrontpanelinboiler.

9 Department of Energy – Compliance

8 Checkout procedure continued

22 Part Number 550-142-785/1215


Follow all procedures given in this manual and “OperatingInstructions”whenoperatingtheboiler.Failure to do so could result in severe personal injury, death or substantial property damage.

1. See page 26 (or boiler “Operating Instructions” label) for“OperatingInstructions.”

2. Raiseroomthermostattocallforheat.

a. Whileattemptingtosatisfytheheatdemand,thecontrolmodule monitors the boiler temperature changes via the temperature sensor and determines whether or not the availablehotwaterwillsatisfythedemand,onlyrunningthecirculator.Ifadditionalheatisneeded,thesequencecontinues.WhenDHW(ifused)callsforheat,sequenceabove is bypassed.

3 Blowerandcirculatorenergize.Afterpressureswitchprovesairflow, ignition control starts a 30-second prepurge.

4. Control module sparks the pilot and opens pilot valve in main gas valve.

a. Ifpilotdoes not light within 15 seconds, pilot valve is closedandsparkgeneratoristurnedoff.Controlmoduleiniti-ates a 15-second postpurge, then starts a new cycle.

b. Ifpilotdoes light and control module senses flame cur-rent,sparkgeneratoristurnedoffandmainvalveopens.

c. Natural Gas - Ifpilotdoesnotlightwithin15seconds,pilotvalveisclosedandsparkgeneratoristurnedoff.Controlmodule waits 5 minutes, then attempts to ignite pilot again. Thiscyclewillcontinueindefinitelyifpilotignitioncontroldoesnot sense pilot flame.

5. During main burner operation:

a. Ignitioncontrolmonitorspilotflame.Ifsignalislost,maingasvalveclosesandsparkstarts.Ignitioncontrolsstartsa flame-proving cycle as in step 5, above.

b. Ifpowerisinterrupted,mainandpilotgasvalvesclose.Ignitioncontrolwillstartagainatstep3,left,whenpoweris restored.

6. When the water temperature limit switch opens, the blower shutsoff,causingthepressureswitchtoopen.Theignitioncontrol then closes the main gas valve. The circulator continues to run.

7. Whenthethermostatopens(demandsatisfied),theignitioncontrol closes pilot and main gas valves. Blower and circulator shut down.

8 Boilerisnowintheoff(stand-by)cycle.

9. Repeatsteps1through7severaltimestoverifycontrolsareoperating correctly.

10.Returnthermostat(s)tonormalsetting.

11. Set the thermostat heat anticipator as instructed in the wiring diagram(andonboilerwiringdiagramlabel).

9a Sequence of operation

23Part Number 550-142-785/1215


Figure 18 Control module sequence of operation — status light indications

9a Sequence of operation

24 Part Number 550-142-785/1215


9a Sequence of operation continued

Figure 19 Schematic wiring diagram

25Part Number 550-142-785/1215


Figure 20 Ladder wiring diagram

9a Sequence of operation continued

26 Part Number 550-142-785/1215

10 Operating instructions

FOR YOUR SAFETY READ BEFORE OPERATING

Ifyoudonotfollowtheseinstructionsexactly,afireorexplosionmayresultcaus-ingpropertydamage,personalinjuryorlossoflife.

A. This appliance is equipped with an ignitiondevice which automatically lights the pilot. Do not try to light the pilot by hand.

B. Before OPERATING, smell all around the applianceareaforgas.Besuretosmellnextto the floor because some gas is heavier than air and will settle on the floor. See below.

C. Useonlyyourhandtodepressormovetheselectorarm.Neverusetools.Iftheselectorarmwillnotdepressormovebyhand,don’ttrytorepairit,callaqualifiedservicetechnician.Forceorattemptedrepairmayresultinafireorexplosion.

D. Donotusethisapplianceifanyparthasbeenunderwater.Immediatelycallaqualifiedservicetechniciantoinspecttheapplianceandtoreplaceanypartofthecontrolsystemandanygascontrol,whichhasbeenunderwater.

• Donottrytolightanyappliance.• Donottouchanyelectricswitch;donotuseanyphonein

your building.• Immediatelycallyourgassupplierfromaneighbor’sphone.

Followthegassupplier’sinstructions.• Ifyoucannotreachyourgassupplier,callthefiredepart-

ment.

WhAT TO DO IF YOU SMEll GAS

1. STOP!Readthesafetyinformationaboveonthislabel.

2. Set the thermostat to lowest setting.

3. Turnoffallelectricalpowertotheappliance.

4. Removejacketfrontpanel.

5. Thisapplianceisequippedwithanignitiondevicewhichautomaticallylightstheburner.Do not try to light the burner by hand.

6. Turn Gas control knobclockwise to OFF.

7. Waitfive(5)minutestoclearoutanygas.Thensmellforgas,includingnearthefloor.Ifyousmellgas,STOP!Follow“B”inthesafetyinformationabove.Ifyoudon’tsmellgas,gotothenextstep.

8. Turn Gas control knobcounterclockwise to ON.

9. Turn on all electric power to the appliance.

10. Set thermostat to desired setting.

11.If the appliance will not operate, follow the instructions “TO TURN OFF GAS TO APPLIANCE” below and call your service technician or gas supplier.

12.Replacejacketfrontpanel.

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO ThE APPlIANCE1. Set the thermostat to lowest setting.2. Turnoffallelectricpowertotheapplianceifserviceisto

beperformed.3. Removejacketfrontpanel.

4. Turn Gas control knobclockwise to OFF. Do not force.

5. Replacejacketfrontpanel.


27Part Number 550-142-785/1215

11 Service and maintenance


Theboilershouldbeinspectedandstartedannually,atthebeginningoftheheatingseason,onlybyaqualifiedservicetechnician.Inaddition,themaintenanceandcareoftheboilerdesignatedinTable 8, page 27,andexplainedonthefol-lowingpagesmustbeperformedtoassuremaximumboilerefficiencyandreliability.Failuretoserviceandmaintaintheboilerandsystemcouldcauseequipmentfailureresultinginseverepersonalinjury,deathorsubstantialpropertydamage.

Table 8 Service and maintenance schedules (service technician and user)

Followthe“Serviceandmaintenance”proceduresgiventhroughoutthismanualandincomponentliteratureshippedwiththeboiler.See“Readthisfirst”onpage 2.Failuretoperformtheserviceandmaintenancecouldresultindamagetotheboilerorsystem.Failuretofollowthedirectionsinthismanualandcomponentliteraturecouldresultinseverepersonal injury, death or substantial property damage.

Service technician (see following pages for instructions)

Owner maintenance (see User’s Information Manual for instructions)

An

nu

Al s

tAr

t-u

p

❏ Inspect:

•Reported problems

•Boiler area

•Air openings

•Flue gas vent system

•Pilot and main burner flames

•Water piping

•Boiler heating surfaces

•Burners and base

•Condensate drain system

❏ Service:

•Inducer motor

•Oiled-bearing circulators

•Temperature sensor

❏ 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

❏ Daily •Check boiler area

•Check boiler pressure/ temperature gauge

•Check air openings

❏ Monthly •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 (sidewall-vented boilers only)

❏ Periodically •Test low water cutoff (if used)

•Oil inducer motor

❏ Every 6 months •Operate relief valve

❏ End of season •Shut down procedure

28 Part Number 550-142-785/1215


11 Service and maintenance continued

Theboilercontainsceramicfiberandfiberglassmaterials.Usecarewhenhandlingthesematerialsperinstructionsonpage 48ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.

❏ Inspect ❏ InspectReported problemsInspect any problems reported by owner and correct beforeproceeding.

Boiler area1. Verify thatboilerarea is freeofanycombustiblematerials,

gasolineandotherflammablevaporsandliquids.2. Verify thatboilerarea (andair intake) is freeofanyof the

contaminants listed in Table 2 on page 5ofthismanual.Ifanyofthesearepresentintheboilerintakeairvicinity,theymustberemoved.Iftheycannotberemoved,installcombustionairpiping to the boiler in accordance with national, provincial or local codes.

Air openings1. Verify that combustion and ventilation air openings to the

boilerroomand/orbuildingareopenandunobstructed.Checkoperationandwiringofautomaticcombustionairdampers,ifused.

2. Verifythatboilerventdischargeandairintakearecleanandfreeofobstructions.

Flue gas vent system1. Visuallyinspectentirefluegasventingsystemforblockage,

deteriorationorleakage.Repairanyjointsthatshowsignsofleakageinaccordancewithventmanufacturer’sinstructions.

2. Verifythatmasonrychimneysarelined,liningisingoodcondi-tion, and there are not openings into the chimney.

Failuretoinspectfortheaboveconditionsandhavethem repaired can result in severe personal injury or death.

Pilot and main burner flames1. Visually inspect pilot burner and main burner flames as di-

rected under Section 7, page 20ofthismanual.

Water piping1. Checktheboilerinteriorpipingandallsystempipingforsigns

ofleaks.2. Repairanyleaksbeforeproceeding.

Electricalshockhazard—Turnoffpowertotheboilerbeforeanyserviceoperationontheboilerexceptasnoted otherwise in this instruction manual. Failure toturnoffelectricalpowercouldresultinelectricalshock,causingseverepersonalinjuryordeath.


Eliminateallsystemorboilerleaks.Continualfreshmakeupwaterwillreduceboilerlife.Mineralscanbuildup insections, reducingheat transfer,over-heatingcastiron,andcausingsectionfailure.Leak-ing water may also cause severe property damage.

Boiler heating surfaces1. Disconnect the vent pipe at the boiler inducer outlet connection

afterturningoffpowertotheboiler.2. Useabrightlighttoinspectthefluepipeinteriorandinducer

interior.3. Inspect theboilerventoutletareaandheatingsurfacesby

lookingthroughtheopening.

4. Iftheventpipeorinducerinteriorshowevidenceofsoot,fol-low“Cleaningboilerheatingsurfaces”,page 27, to remove thefluecollectorandcleantheboilerifnecessaryaftercloseinspectionofboilerheatingsurfaces.Ifthereisevidenceofrustyscaledeposits,checkthewaterpipingandcontrolsystemtomakesuretheboilerreturnwatertemperatureisproperlymaintained(perthismanual).

5. Reconnectventtoinduceroutlet(sealjointperpage 8) and replaceallboilercomponentsbeforereturningtoservice.

6. Checkinsideandaroundboilerforevidenceofanyleaksfromtheboiler.Iffound,locatesourceofleaksandrepair.

Burners and base1. Afterturningoffpowertotheboiler,removethejacketdoor

andbaseaccesspanel(Figure 21, item 4, page 42).2. Inspectburnersandallothercomponentsintheboilerbase.

3. Ifburnersmustbecleaned,raiserearofeachburnertoreleasefromsupportslot,slideforwardandremove.Thenbrushandvacuumtheburnersthoroughly,makingsureallportsarefreeofdebris.Carefullyreplaceallburners,makingsureburnerwithpilotbracket is replaced in itsoriginalpositionandallburnersareupright(portsup).

4. Inspectthebaseinsulation.a. Verifythattheinsulationisintactandsecureagainstall

foursidesofthebase.

Ifinsulationisdamagedordisplaced,donotoper-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.

Condensate drain system1. Ifventsystemisequippedwithacondensatedrain,checkthe

hoseandconnectionsfortightness.2. Verifythehoseisunobstructedandingoodconditionandthat

condensatecanflowfreely.Replacehoseifnecessary.

29Part Number 550-142-785/1215



Inducer motor1. With boiler power OFF,placeafewdropsofS.A.E.20motor

oilineachofthetwomotoroilingcups. UseonlyS.A.E.20motoroil to lubricate inducer

motor.Donotuseuniversalhouseholdoils.Motorcould be damaged, resulting possible severe prop-erty damage.

Oiled-bearing circulators1. ThecirculatorshippedwiththeGWIboileriswater-lubricated.

Nooilingisrequired.2. Check other circulators in the system. Oil any circulators

requiringoil,followingcirculatormanufacturer’sinstructions.Over-oiling will damage the circulator.

Temperature sensor1. The temperature sensor may accumulate deposits on the

probesurface.Annualinspectionandcleaningoftheprobewillimproveboilerperformance.Disconnectpower,unplugharnessfromsensor.a. Drain boiler water to a level below the sensor.b. Removesensorfromboiler.c. Wipeanybuiltupcontaminatesfromprobeandinsulator

surfaces.d. Reinstall sensor into boiler.

❏ Service

❏ Start-up1. Perform start-up procedures of Section 7, pages 18–20,

includingproceduretoverifyoperationofburnersonpage20.2. Verifycoldfillpressureiscorrectandthatfillsystemisworking

properly.3. Verifyantifreeze level (ifused) isat therightconcentration

and that inhibitor level is correct.4. Checkgaspiping,permanualSections 5 and 7,verifyingno

indicationsofleakageandallpipingandconnectionsareingood condition.

5. Readthe“Operatinginstructions”(page 26).6. Starttheboilerfollowingthe“Operatinginstructions”(page 26).

❏ Check/test

Gas piping1. Sniffnearfloorandaroundboilerareaforanyindicationofa

gasleak.

2. Test gas piping using bubble test, per Section 5, page 16ofthismanual,ifthereisanyindicationofaleak.

Cold fill and operating pressures1. While the system is cold, note the pressure reading on the

boilerpressure/temperaturegauge.Verifythatcoldfillpressureis 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 waterloggedorundersizedexpansiontank.

Air vents and air elimination1. Inspectautomaticairvents(ifused).Alsoinspectairsepara-

tors to ensure they are operational.

2. The cap must be unscrewed one turn to allow air to escape.3. Iftheairventisleaking,removecapandbrieflypushvalve

— 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 cutoffs1. Inspectandtesttheboilerlimitcontrol.Verifyoperationbyturn-

ing control set point below boiler temperature. Boiler should cycleoff.Returndialtooriginalsetting.

2. Inspectandtestadditionallimitcontrolsorlowwatercutoffsinstalled on system.

Expansion tank1. Expansiontanksprovidespaceforwatertomoveinanoutas

theheatingsystemwaterexpandsduetotemperatureincreaseorcontractsasthewatercools.Tanksmaybeopen,closedor diaphragm or bladder type. See Section 4, page 13ofthismanual forsuggested locationsofexpansion tanksandaireliminators.

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 ispartiallyfilledwithwater, leavinganaircushionforexpansion.

• Makesure this typeof tank is fittedwitha tank fitting,suchastheB&GTank-TrolorTacoTaco-Trol.Thisfittingreduces gravity circulation of air-saturated tank waterbacktothesystemandpreventstheairfrombubblingupthroughthewaterasitreturnsfromthesystem.

• Donotuseautomaticairvents insystemswithclosed-typetanks.Theairwillescapefromthesysteminsteadofreturningtothetank.Eventually,thetankwillwaterlogandnolongercontrolpressurization.Theboilerreliefvalvewillweepfrequently.

Diaphragm- or bladder-type — welded gas tight with a rub-bermembranetoseparatethetankpressurizingairandthewater.Maybelocatedatanypoint inthesystem,butmostoftenfoundneartheboiler.• Systemswiththistypeofexpansiontankrequireatleast

oneautomaticairvent,preferablylocatedontopofanaireliminator,asshowninexamplesinmanualSection 4, page 13.

2. Ifreliefvalvehastendedtoweepfrequently,theexpansiontankmaybewaterloggedorundersized.

Closed-type tank—tank ismost likelywaterlogged. Installatankfittingifnotalreadyinstalled.Thencheckfilllevelperfittingmanufacturer’sinstructions.Iffillleveliscorrect,checktanksizeagainstmanufacturer’sinstructions.Replacewithalargertankifnecessary.

Diaphragm-orbladder-type—first,checktanksizetobesureitislargeenoughforthesystem.Ifsizeistoosmall,addad-ditionaltank(s)asnecessarytoprovidesufficientexpansion.Iftanksizeislargeenough,removetankfromsystemandcheckchargepressure(usually12psigforresidentialapplications).Iftankwon’tholdpressure,membranehasbeendamaged.Replacetank.

❏ Check/test

30 Part Number 550-142-785/1215


❏ Check/test ❏ Review with owner1. ReviewtheUser’sInformationManualwiththeowner.2. Emphasizetheneedtoperformthemaintenanceschedule

specifiedintheUser’sInformationManual(andinthismanualas well).

3. Remindtheowneroftheneedtocallinalicensedcontractorshouldtheboilerorsystemexhibitanyunusualbehavior.

4. Remindtheownertofollowthepropershutdownprocedureandtoscheduleanannualstart-upat thebeginningof thenextheatingseason.

1. Shut down boiler:• Follow“ToTurnOffGastoAppliance”instructionsonboiler

and“Operatinginstructions”.• Donotdrainboilerunlessitwillbeexposedtofreezing

temperatures.Ifusingantifreezeinsystem,donotdrain.2. Follow shutdown procedure.3. Remove venting system connection to boiler.4. Removetopjacketpanel.Turnbackinsulation.5. Removecollectorbox/transitionassembly.Cleansealantfrom

assembly and sections.6. Remove radiation plates hanging between sections.7. Removeburners frombase.Brushandvacuumburners to

removealldustandlint.Verifythatallburnerportsarefreeofdebris.

8. Placenewspapersinbaseofboilertocollectsoot.9. Cleanbetweensectionswithwirefluebrush.10. Remove newspaper and soot. Vacuum or brush base and

surrounding area.11. Reinstall radiation plates.12.Replacecollectorbox/transitionassembly.Sealwithsealant.

Obtain gas-tight seal to prevent flue gas spillage and carbon monoxideemissions, resulting in severepersonal injuryordeath.

13.Replaceinsulationandjackettoppanel.14.Startupboilerfollowingpages 18 –20ofthismanualandthe

boiler “Operating Instructions”.Excessive sooting indicatesimpropergascombustion.Iffoundcheckforpropercombus-tionandmakeanynecessaryadjustments.

❏ Cleaning boiler heating surfaces

Boiler relief valve1. Inspectthereliefvalveandliftthelevertoverifyflowasinthe

followingwarnings, excerpted froma relief valvemanufac-turer’swarninglabel.Beforeoperatinganyreliefvalve,ensurethatitispipedwithitsdischargeinasafeareatoavoidseverescald potential. Read manual Section 4, page 13, beforeproceedingfurther.

SafetyreliefvalvesshouldbereinspectedATLEASTONCE EVERYTHREEYEARS, by a licensedplumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and toensure that the valve and discharge line have not been altered or tampered with illegally. Certainnaturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency — not by the owner. Failuretoreinspecttheboilerreliefvalveasdirectedcouldresultinunsafepressurebuildup,whichcanresult in severe personal injury, death or substantial property damage.

2. Afterfollowingtheabovewarningdirections,ifthereliefvalveweepsorwillnotseatproperly,replacethereliefvalve.Ensurethatthereasonforreliefvalveweepingisthevalveandnotover-pressurization of the system due to expansion tankwaterlogging or undersizing.

Following installation, the valve lever must be op-eratedATLEASTONCEAYEAR toensure thatwaterways are clear. Certain naturally occurringmineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, waterwilldischargeandprecautionsmustbetakento avoid contact with hot water and to avoid water damage.Beforeoperatinglever,checktoseethata discharge line is connected to this valve direct-ingtheflowofhotwaterfromthevalvetoaproperplaceofdisposalotherwiseseverepersonalinjurymayresult. Ifnowaterflows,valve is inoperative.Shutdownboileruntilanewreliefvalvehasbeeninstalled.

The boiler contains ceramic fiber and fiberglass materials.Usecarewhenhandlingthesematerialsper instructions on page 48ofthismanual.Failureto comply could result in severe personal injury.


31Part Number 550-142-785/1215


12 Troubleshooting Labelallwirespriortodisconnectionwhenservic-

ing controls. Wiring errors can cause improper and dangerous operation.

Neverjumper(bypass)rolloutthermalfuseelementoranyotherdeviceexceptformomentarytestingasoutlinedin“Troubleshooting”charts,pages 34 - 40. 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 onignitionofmainflame.Severepersonalinjuryorsubstantial property damage will result.

Before troubleshooting:1. Havethefollowingitems:

a. Voltmeterthatcancheck120VACand24VAC.b. Microammeterwithaminimumscalerangeof0-25.c. Continuitychecker.d. U-tubemanometere. Inclinedmanometerwith0–2”w.c.range.

2. Checkfor120VAC(minimum102VACtomaximum132VAC)to boiler.

3. Makesurethermostatiscallingforheatandcontacts(includ-ingappropriatezonecontrols)areclosed.Checkfor24VACbetween thermostat wire nuts and ground.

Check the following:1. Wire connectors to control module are securely plugged in at

module and originating control.2. Gaspressures(connectU-tubemanometeratgasvalvetap-

pings):a. Withboileroff—13”w.c.maximumnaturalorpropane

gaspressureupstreamofgasvalve.b. With boiler on:• 5”w.c.minimumnaturalgaspressureor11”w.c.propane

gaspressureupstreamofgasvalve.• 3.5”w.c.minimumnaturalgaspressureor10”w.c.propane

gaspressuredownstreamtappingongasvalve—Canbe adjusted by regulator on gas valve.

How to check pressure switch setting (if specified in Troubleshooting charts)

Makesureboilerwater temperature is100 °Forcoolerbeforestartingproceduretoobtainappropri-ate readings.

1. See Figure 21 and Table 9.2. Remove both air pressure switch hoses from air pressure

switch.3. Install tees and tubing as shown in Figure 21 to inclined

manometer.4. Turnoffgasvalveandsetthermostattocallforheat.Inducer

will run but burners will not ignite.5. Checkfor24VACbetweenbothairpressureswitchterminals.6. Ifmanometerreadingisabovethesetpointoftheswitch(see

Table 9),butthereisnot24VACbetweenairpressureswitchterminals“C”and“NO”—replaceairpressureswitch.

Troubleshooting air pressure reading1. Ifmanometerreadingislowerthanthesetpointoftheswitch

(seeTable 9)—checkforpossiblecauses:• blockageinhoses• obstructionininducerhousingoutlet• looseinducerwheelonmotorshaft• inducermotornotinproperrpm• inducerbackplatenotsealedproperly• blockageinblockassembly• blockageinfluepipeortermination• incorrectpressureswitch

Return to normal operationWhen 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 switch hoses are correctly located. The red hose connectsfromtherightside(negative)hosebarbtothefluecollector.Thewhitehoseconnectsfromtheleftside(positive)hosebarboftheswitchtotheconnectorbox(betweenfluecollectorandinducer)as shown in Figure 21.

Table 9 Pressure switch setpoint (for elevations above 2,000 ft, contact your local supplier for details.)

Boiler model number Inches W.C.GWI-047 and GWI-063 1.19

GWI-095 1.08GWI-127 0.86GWI-158 0.61GWI-190 0.76

Figure 21 Checking pressure switch

32 Part Number 550-142-785/1215


Control module Solder or water splatter between plugs and circuit board can cause improper operation of controlmodule. Place a shield over the boiler internal con-trols and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage.

Make sure ground wiring is installed per wiring diagram. Good grounding is extremely importantforproperoperation.

Control indicator lights — LOCKOUT modes

SeeCharts 1through7inthissectionfordetailedtrouble-shootingprocedures.

Control indicator lights —HARD LOCKOUT Summary (Flashing LED’s)MAY remove 120VAC power for more than 2 seconds to clear lockout OR ignition control will automatically restart sequence of operation after 1 hour waiting period after fault condition is cleared.

12 Troubleshooting – components (continued)

INDICATOR LIGHT CONDITIONPOWER Flashes once per second 120 VAC connection to boiler reversed or there is insufficient earth ground.Flash code 2* Internal fault, microprocessor or memory.Flash code 3* Unused.Flash code 4* Unused.Flash code 5* Internal fault, water thermistors disagree.Flash code 6* Internal fault, gas valve circuit.

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

SOFT LOCKOUT Summary (Flashing LED’s)MAY remove 120VAC power for more than 2 seconds, cycle thermostat for between 2 and 20 seconds, OR ignition control will automatically restart sequence of operation after 1 hour waiting period.INDICATOR LIGHT CONDITIONPOWER + TSTAT/CIRC High voltage detected on TSTAT circuit.

POWER + PURGE Pressure Switch stuck open or closed.

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

CAUTION Summary (Flashing LED’s)INDICATOR LIGHT CONDITIONPURGE Pressure switch opened after it had been proven closed.LIMIT Fault detected in temperature sensing hardware.FLAME Flame loss or flame not sensed during trial for ignition.

Troubleshooting the control module

SeeFigure 23,page 33,forlocationofharnessplugreceptaclesandplugsonthecontrolmodule.

Sensor resistance values

Temp (°F)

Sensor ohms Temp (°F)

Sensor ohms

Min Max Min Max

32 34265 37871 120 4517 4992

40 27834 30764 130 3698 4088

50 21630 23907 140 3043 3364

60 16944 18727 150 2517 2782

70 13372 14780 160 2091 2311

80 10629 11747 170 1744 1928

90 8504 9399 180 1461 1615

100 6847 7568 190 1229 1359

110 5545 6129 200 1038 1147

Temperature sensor1. The boiler temperature sensor is a resistance-type device.

2. TheChartbelowshowsthecorrectvaluefor thesensoratvarious temperatures.

3. Usetheresistancevaluesat32°F,60°F,70°Fand212°Ftomeasurethesensorresistanceatknowntemperatures(icepoint, room temperature and sea level boiling point). For ice point and boiling point, insert the sensor in water at that tem-perature.Useanohmmetertoreadresistancevaluebetweenthermistor # and thermistor common. See Figure 30, page 50, forsensorplugdetails.

Sensor resistance values

Figure 22 Control module

33Part Number 550-142-785/1215


Figure 23 Control module connections

12 Troubleshooting – components (continued)

34 Part Number 550-142-785/1215


12 Troubleshooting continued

CHART 1 –– Troubleshooting POWER light status

–– Usually indicates reversed 120 VAC polarity if POWER light flashes by itself –– 120

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.

Replace control module.

Retest.

Boiler should now operate normally.

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

Havesystemcheckedbyalicensed electrician.

Ifproblempersists,callyourlocal Williamson-Thermoflo sales representative.

TSTAT/CIRC light flashing

CHART 2

PURGE light flashing

CHART 3

CHART 5

FLAME light flashing

CHART 4

CHART 6

Forinsufficientheatornoheatproblem,goto CHART 7 ifPOWER light is on steady, with no other light is flashing.

Is POWER light off?

No Yes

• Makesureserviceswitchorcircuitbreakerisonor fusesaregood.

• Remove 120 VAC INplug(Figure 23, Item 3, page 33) on control module.

• Usingvoltmeter,checkacrosstopandbottompinsof120 VAC IN plug.

Does voltmeter indicate 120 VAC?

No Yes

• Reconnect 120 VAC IN plug.

• Remove 120 VAC IN transformerPrimary plug (Figure 23, Item 2 page 33) on control module.

• Usingvoltmeter,checkacrosstopandbottompinsof Primary receptacle.


No Yes

• Reinstall 120 VACtransformerPrimary plug.

• Remove 24 VACtransformerplug(Figure 23, Item 5, page 33) on control module.

• Usingvoltmeter,checkpinsofplug.


No Yes

Replacetransformer. Retestandcheckforbackfeedofvoltagefrom system wiring.

Replace control module. Retest.• Usuallyindicatespolarityonincoming120 VAC power

lineiswrongorhasinsufficientearthground.

• Check grounds to make sure unit has sufficient grounding.

• ▲ TURN OFF POWER ▲atserviceswitchorbreaker,thenreversetheHOTandNEUTRALwiresenteringtheboilerintheJ-box.

• Restore POWERatserviceswitchorbreaker.

Is POWER light flashing now?

No Yes

Is POWER light . . .

Flashing alone?

Flashing with anotherlight?

On steady (NOTflashing)?

35Part Number 550-142-785/1215



CHART 2 –– TSTAT CIRC & POWER lights flashing

–– Usually indicates 48 VAC on thermostat circuit (stray voltage) –– 120


• Ifnovoltageisfoundunderanyconditionoftheexternalthermostat circuit, connect the two boiler thermostat connectionleadstogether(orjumpertheboileraquastatT-T terminals).

• Turnoffpowertotheboilerfor1minute.

• Turn on power and allow boiler to cycle.

Does the TSTAT and POWER lights still flash?

No Yes

• Disconnect the two external wires connected to the boilerthermostatleads(twoblacklowvoltageleadsinJ-box).

• Connect a voltmeter across these two incoming wires. Closeeachthermostat,zonevalveandrelayintheexternalcircuit one at a time and check the voltmeter reading across the wires.

• ThereshouldNEVERbeavoltagereading.

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

• Oncetheexternal thermostatcircuitwiring ischeckedand corrected if necessary, reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle.

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

Yes No

• Boilershouldnowoperateperthenormalsequenceof operation(Figure 18, page 23).

• Leaveexternalboilerthermostatconnectionwires disconnectedfromboiler.

• Troubleshoottheexternalthermostatcircuituntilyoufind thesourceofthestrayvoltage.(Paycloseattentionto the wiring connections to 3-wire zone valves.)

• Correcttheproblemandrepeatthevoltmetertestabove, verifyingthereisnolongeravoltagereadingunderany conditionintheexternalthermostatcircuit.

• Anisolatingrelaymayberequired.

Replace control module.

Retest.

36 Part Number 550-142-785/1215



• Resetboilercontrolbyturningoffpoweratserviceswitchorturningdownthermostatforatleast45seconds.

• Thermostatshouldcallforheatandappropriatezonevalvesopen.

Does inducer motor operate?

No Yes

• Replace control module.

• Retest.

• Checkairpressureswitch per manual Section 12 .

• Replaceifnecessary.

• Retest.

• Clearpassagesandrecycleboiler.

• Recheckboileroperation.

• Try reseating plug in module receptacle and restart.

• Ifinducerstilldoesnot work,replaceinducer assembly.

• Retest.

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied and inducer has completed its post-purge cycle.

• Remove INDUCERplug(Figure 23, Item 6, page 33) fromplugreceptacleofcontrolmodule.

• Place voltmeter leads across the 120 VAC N and 120 VAC H pinsoftheINDUCERreceptacle(leftcolumncenterandrightcolumn bottom pins).

Does the voltmeter indicate 120 VAC?

No Yes

• Removeoneofthewiresconnectedtothepressure switch.

• Checkcontinuityacrosstheswitchterminals.

Does the ohmmeter indicate the switch is closed?

No Yes

• Wait 5 minutes.

Is PURGE light flashing?

No Yes

• Wait 45 seconds.

Does Inducer motor operate?

No Yes

Are vent or combustion air passages blocked?

No Yes

CHART 3 –– PURGE & POWER lights flashing

–– Usually indicates pressure switch stuck closed or failed to make within 5 minutes –– 120


37Part Number 550-142-785/1215



• ▲ TURN OFF POWER ▲ to boiler at service switch orbreaker.

• Open main manual gas valve.

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

• Restart boiler per operating instructions.

• Performstart-up procedures in boiler manualtoverifyproper operation.

• Boiler may now be operating normally.

• Performstart-up procedures in boiler manual to verifyproper operation.


• Retest.

Are manual main shutoff valve and gas valve open?

No Yes

• Replace gas valve.

• Retest boiler.

Are FLAME & POWER lights flashing?

No Yes


• Retest.

• Boiler should now operate normally.

• Original flashing FLAME light caused by gas valve not operating properly.

• See normal sequenceof operation, Figure 18, page 23.

• Turnoffpowertotheboileratserviceswitchorbreaker.

• Wait at least 45 seconds.• Turn on power to boiler.• Restartboiler,followingOperating instructions in this

manual(Section10).

• Lookthroughthepilotinspectionporttoseeifthepilotisburningduringtheprepurgeperiod(first30secondsofoperation).

Is pilot burning during prepurge period?

No Yes


• Retest.

• Leavemainmanualgasvalveclosed.• Turnoffpowertoboileratserviceswitchorbreaker.• Wait at least 45 seconds.• Turn on power to boiler.• Restartboiler,followingOperating instructions in this

manual(Section10).

Do FLAME and POWER lights still flash?

No Yes

• Allowboilertocontinuecycling.

Are FLAME & POWER lights flashing?

No Yes

CHART 4 –– FLAME & POWER lights flashing

–– Usually indicates flame sensed when it shouldn’t be there –– 120


38 Part Number 550-142-785/1215



CHART 5 –– PURGE lights flashing and POWER light on steady

–– Usually indicates pressure switch opened during run cycle –– 1–– May also be caused by wind gusts in excess of 31 mph for non-direct vent sidewall-vented boilers ––


• Resetboilercontrolbyturningoffpoweratserviceswitchorturningdownthermostatforatleast45seconds.

• Thermostatshouldcallforheatandappropriatezonevalvesopen.

Does inducer motor operate?

No Yes

• Inspectandcheckwire harnessfromcontrol module to pressure switch.

• Reseat connector in control module receptacle.

• Ifharnessisintactand properly seated, but problem persists, replace control module.

• Retest.

• CheckairpressureswitchpermanualSection12.

• Replaceifnecessary.Retest.

• Clearventandrecycleboiler.

• Recheckboileroperation.

• Replace inducer assembly.

• Retest.• Boiler should be in

normal operating sequence.

• Observe operation until thermostat is satisfied and inducer has completed its post- purge cycle.

• Remove INDUCERplug(Figure 23, Item 6, page 33) fromplugreceptacleofcontrolmodule.

• Place voltmeter leads across the 120 VAC N and 120 VAC HpinsoftheINDUCERreceptacle(leftcolumncenter and right column bottom pins).

Does the voltmeter indicate 120 VAC?

No Yes

• Removeoneofthewiresconnectedtothepressure switch.

• Checkcontinuityacrosstheswitchterminals.

Does the ohmmeter indicate the switch is closed?

No Yes

• Wait 5 minutes.

Is PURGE light flashing?

No Yes

Is vent blocked?

No Yes

39Part Number 550-142-785/1215



• Ispilotflamevisiblethroughinspectionport?

No Yes

Are main manual shutoff valve and gas valve open?

No Yes

•▲TURNOFFPOWER▲to boiler at service switch or breaker.

• Removeburnershield(seeFigure 25, item 4, page 42 forlocation.

• Contactgassuppliertocorrect pressure or gas supply.

• CheckthevoltageacrossterminalsPVandCofthe gas valve.

Is 24 VAC present there?

Yes No

• Makesuregroundwire terminalissecurelyfastenedto control module mounting screw.

• Verifyinletgaspressureatgasvalve:Natural gas –5.0”w.c.min/14.0”w.c.maxPropane –11.0”w.c.min/14.0”w.c.max

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

No Yes

• CheckthevoltageacrossterminalsofMVandC ofthegasvalve.

Is 24 VAC present there?

No Yes

• Ifthewiringfromthe control module to gas valve is intact, replace the control module.

• Retest.

• Verifyinletgaspressureatgasvalve:Natural gas –5.0”w.c.min/14.0”w.cmaxPropane –11.0”w.c.min/14.0”w.cmax

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

Yes No

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied and blower has completed its post-purge cycle.

• Verifypilotgaslineisnotkinked,obstructedor damaged and is correctly attached to pilot and gas valve.

• Verifypilotignitionelectrode,electrodeceramicandsparkleadwirefromcontrolareingoodcondition.Sparkgapshouldbeapproximately1/8”.

• Correctanyaboveproblems,replacingpilotifburneror wiring is damaged.

• Reinstall burner shield to operateboilerforretestafterany changes or corrections.

• Ifnoneoftheabovecorrectsproblems, then replace the control module and retest.

• ▲TURNOFFPOWER▲to boiler at service switch or breaker.

• Removeburnershield(seeFigure 25, item 4,page42forlocation.

• Ifnoneoftheprevioussteps(includingreplacingpilot)corrects problem, then replace the control module, reinstall burner shield and retest.

• Ifthewiringfromthe control module to gas valve is intact, replace the control module and retest.

• ▲TURNOFFPOWER▲toboileratserviceswitchorbreaker.

• Openmainmanualshutoffvalveandboilergasvalve(per Operating instructions in this manual). Wait at least 45 seconds.

• Turnonpoweratserviceswitchorbreaker.Allowboilertocycle.

Does FLAME light flash now?

No Yes

• ▲TURNOFFPOWER▲toboileratserviceswitchorbreaker.• Checkflamesignal–Detachsenseleadfromignitioncontrol

(Figure 33, Item 8, page 33).

• ConnectnegativeleadofMICROAMMETERtocontrolsenseterminal (Figure 23, Item 8, page 33).ConnectpositiveleadofMICROAMMETERtosensewire.

• DISCONNECTredwireconnectedtoterminalMVofthegasvalve.

• Turnonpowertoboilerandallowtocycle.Assoonaspilotisburning,theMICROAMMETERshouldreadatleast1.0microamp.

Is flame signal at least 1.0 microamp ?

No Yes

• Verifypilotburnerissecurely attachedtopilotbracket,bracketis securely attached to cross tie, and there is no corrosion on thepartswhichwouldaffectthegroundpathforflamesense.

• Verifythatpilotflamerod,flamerodceramicandleadwirefromcontrol module to flame rod are in good condition.

• Correctanyaboveproblems,replacingpilotifburnerorwiringis damaged.

CHART 6 –– FLAME lights flashing and POWER light on steady

ALSO –– Troubleshootingfailuretoestablishmain flame


40 Part Number 550-142-785/1215



CHART 7 –– Insufficient heat or no heat to system (POWER light on steady)


• Has it been at least 5 minutes since setting thermostat to callforheat?Ifnot,wait5minutes.Issystemheating?

• Isthermostatsettocallforheat?Removethermostatwiresatboilerandcheckcontinuityacrossthetwowires. Ifcircuitisn'tclosed,checkexternalthermostat(zonevalve,relay,etc.)wiring.Correctproblemsandretry.

• Reconnectexternalthermostatwiringatboiler.Is thermostat circuit closed (continuity across wires)?

No Yes

Is boiler System circulator operating?

No Yes

• Wait 5 minutes.Is FLAME light on?

Yes No

Is LIMIT light on?

No Yes

Are all red lights off?

No Yes

• Wait 30 seconds.

Are all red lights off?

No Yes

• Replace rollout switch.

Ifrolloutthermalfuseelementhasopened, determine cause and correct condition. Failure to do so will cause severe personal injury, death or substantial property damage.

• Checktemperature sensorforcorrect resistance.

Are resistance values correct?

No Yes


• Retest.


• Retest.

• Repair/replace circulator. Retest.

• Repair/replace wiring. Retest.

• Checkanyotherlimit controls wired into the limit circuit.Ifallare OK,thenreplacecontrol module.

• Retest.

• Correctconditionsandrecheckoperation.

• See Figure 18, page 23 fornormalsequenceof operation.

• Boiler is in standby.

• Setthermostattocallforheatandrecheckoperation.

• VerifySequence of operation, Figure 18, page 23.

• Remove CIRCULATORharnessplugfromCIRCULATORplugreceptacle(Figure 23, Item 7,page33).Checkwithvoltmeteracrosspinsofcontrol module receptacle.

Does voltmeter show 120 VAC across pins?

No Yes


• Retest.

• Ifyouhavesufficientheat–boilershouldbeinnormaloperatingsequence.(Seenormalsequenceofoperation,Figure 18, page 23.

• Ifyouhavelessthansufficientheat– Is vent piping free of blockage?

No Yes

• Replace temperature sensor.

• Retest.

• Checkheatloss calculation versus boiler size.

• Clockgasinput.

Check rollout switch

continuity – Is switch closed?

No Yes

41Part Number 550-142-785/1215


Item number Description Part number

not shown Replacement section assembly

GWI-047&GWI-063GWI-095GWI-127GWI-158GWI-190

321-114-345WT321-114-346WT321-114-347WT321-114-348WT321-114-349WT

1 Radiationplate(1perjoint) 460-003-700WT

2 Collectorhoodandtransitionassembly GWI-047GWI-063GWI-095GWI-127GWI-158GWI-190

381-354-581WT381-354-582WT381-354-583WT381-354-584WT381-354-585WT381-354-586WT

3 Temperature/ Sensor Tasseron TSL055D 381-356-577WT

4 Inducerfanassemblykit,includesinducerassembly,gasketandnuts:

GWI-047toGWI-190 381-354-588WT

5 Gasket,inducer GWI-047toGWI-190 590-317-627WT

Figure 24 Section assembly, flue collector, draft hood and vent damper

13 Replacement parts

42 Part Number 550-142-785/1215


Figure 25 Base assembly, manifold, orifices and burners

13 Replacement parts continued

Theboilercontainsceramicfiberandfiberglassmaterials.Usecarewhenhandlingthesematerialsperinstructionsonpage 48 ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.

Item number

Description Part number

Base assembly kit(includes base panels items 1, 2, 3, 4, 5, 6, and 7, plus insulation, air box gaskets, and hardware)

GWI-047 & GWI-063GWI-095GWI-127GWI-158GWI-190

381-354-800WT381-354-801WT381-354-802WT381-354-803WT381-354-804WT

1 Base side panel (in Base assembly)

2 Base front cross-tie assembly (in Base assembly)

3 Base back cross-tie assembly (in Base assembly)

4 Access panel (in Base assembly)

5 Base pan angle, left side (in Base assembly)

6 Base pan angle, right side (in Base assembly)

7 Base pan (in Base assembly)

8 Burner rest (in Base assembly)

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

GWI-047 to GWI-127GWI-158 & GWI-190

381-354-518WT381-354-519WT

10 Boiler leg kit 590-424-252WT

11 Manifold GWI-047GWI-063GWI-095GWI-127GWI-158GWI-190

591-126-615WT591-126-616WT591-126-617WT591-126-618WT591-126-619WT591-126-556WT

12 Main burner orifice, sea level Natural gasPropane gas

560-529-122560-529-120

13 Burner, stainless steel 512-200-077WT

14 Burner with pilot bracket (not shown)

Natural gasPropane gas

512-200-078WT512-200-079WT

15 Screw, 10-32 x 3/8 STP type D hx, washer head slot ZP available at local supply house

16 Rollout thermal fuse element 512-050-230WT

43Part Number 550-142-785/1215

Itemnumber

Description Part number

5 Jacket panel,top

GWI-047 & -063GWI-095GWI-127GWI-158GWI-190

431-223-439WT431-223-440WT431-223-441WT431-223-442WT431-223-443WT

6 Jacket cross- tie GWI-047 & -063GWI-095GWI-127GWI-158GWI-190

431-223-507WT431-223-508WT431-223-509WT431-223-510WT431-223-511WT

7 Jacket panel,interior,with insulation


431-223-427WT431-223-428WT431-223-429WT431-223-430WT431-223-431WT

8 Jacket panel,rear,with insulation


431-223-444WT431-223-445WT431-223-446WT431-223-447WT431-223-448WT


Figure 26 Jacket assembly


Theboilercontainsceramicfiberandfiberglassmaterials.Usecarewhenhandlingthesematerialsperinstructionsonpage 48 ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.

Itemnumber

Description Part number Part number

1 Junction box, 2 x 4(Available at local supply house)

2 Jacket panel, left side with insulation

GWI-047GWI-063GWI-095GWI-127GWI-158GWI-190

Natural Gas 431-223-604WT431-223-606WT431-223-608WT431-223-610WT431-223-612WT431-223-614WT

Propane Gas 431-223-616WT431-223-617WT431-223-618WT431-223-619WT431-223-620WT431-223-621WT

3 Jacket panel, right side with insulation

GWI-047GWI-063GWI-095GWI-127GWI-158GWI-190

431-223-605WT431-223-607WT431-223-609WT431-223-611WT431-223-613WT431-223-615WT

4 Jacketpanel,door


431-223-598WT431-223-599WT431-223-600WT431-223-601WT431-223-602WT

44 Part Number 550-142-785/1215


Figure 27 Trim assembly


Itemnumber

Description Manufacturer Manufacturer’s part number

Part number

1 Pressurereliefvalve,ASME,30PSIG,¾”NPTmaleinlet

Pressurereliefvalve,ASME,30PSIG,¾”NPTfemaleinlet (Fittings shown are factory-installed on boiler.)

ConbracoWatts

10-407-05M330 511-546-920WT

ConbracoWatts

10-408-05335 511-546-924WT

2 Combinationpressure-temperaturegauge,with2½”shortshank ¼” NPT

Ametek ENFM

PTA-1088 4104 510-218-099WT

3 Drain valve, ¾” NPT (Fittings shown are included with boiler.)

ConbracoHammond Valve

Matco-NorcaWatts

31-606-01710

205F04BD-2C

511-210-423WT

4 Circulator(Fittings shown are shipped loose with boiler.) Taco 007 511-405-113WT

5 Circulatorgasket,universal(2perboiler) 590-317-535WT

not shown Circulatorhardwarekit,includes: 2 flanges, 4 nuts, 4 screws, 2 pipe nipples — 1”NPT—GWI-047throughGWI-127 1¼”NPT—GWI-158throughGWI-190

381-354-525WT381-354-526WT

6 Circulatorwiringharness 591-391-976WT

45Part Number 550-142-785/1215


Figure 28 Gas control assembly


Item number

Part descriptionBoiler model

numberManufacturer

Manufacturer’s part number

Part number

1 Ignition Control All United Technologies 1135-611 381-330-016WT

2 (Natural gas)

Gas valve, ½” x ½”, Natural gas GWI-047 to GWI-158 HoneywellWhite-Rodgers

VR8204A-200136E36-266 511-044-381WT

Gas valve, ¾” x ¾”, Natural gas GWI-190 HoneywellWhite-Rodgers

VR8304P-434836C-478 511-044-353WT

2 (Propane

gas)

Gas valve, ½” x ½”, Propane GWI-047 to GWI-158 HoneywellWhite-Rodgers

VR8204M-270136E36-291 511-044-354WT

Gas valve, ¾” x ¾”, Propane GWI-190 HoneywellWhite-Rodgers

VR8304M-401036C68-479 511-044-355WT

3(Natural gas)

Pilot assembly kit with orifice and aluminum pilot gas tubing All 511-330-218WT

3(Propane gas)

Pilot assembly kit with orifice and aluminum pilot gas tubing All 511-330-219WT

4 Control transformer Honeywell 381-356-578WT

5

Pressure switch, 1.19 Inches W. C.Pressure switch, 1.08 Inches W. C.Pressure switch, 0.86 Inches W. C.Pressure switch, 0.61 Inches W. C.Pressure switch, 0.76 Inches W. C.

GWI-047 & GWI-063GWI-095GWI-127GWI-158GWI-190

Cleveland Controls

NS2-1053-00 NS2-1053-01 NS2-1053-02 NS2-1053-03 NS2-1053-04

511-624-350WT511-624-351WT511-624-352WT511-624-353WT511-624-354WT

not shown Wiring harness, junction box to control module Williamson-Thermoflo 591-391-975WT

not shown Wiring harness, controls to control module Williamson-Thermoflo 591-391-978WT

not shown Wiring harness, thermostat Williamson-Thermoflo 591-391-994WT

not shown Wiring harness, sensor Williamson-Thermoflo 591-391-995WT

46 Part Number 550-142-785/1215


Figure 29 Dimensional drawing — ALL DIMENSIONS IN INCHES

14 Dimensions

Boilermodelnumber

Supply tapping

(inches NPT)

Return tapping

(inches NPT)

Gasconnection size

(Note 3) (inches NPT)

Gasmanifold size

(Note 3) (inches NPT)

“W”Jacket width

(inches)

GWI-047 1 ¼ ¾ ½ ½ 10

GWI-063 1 ¼ 1 ½ ½ 10

GWI-095 1 ¼ 1 ½ ½ 13

GWI-127 1 ¼ 1 ½ ½ 16

GWI-158 1 ¼ 1 ¼ ½ ½ 19

GWI-190 1 ¼ 1 ¼ ¾ ¾ 22

Note 3: Gas piping from meter to boiler to be sized per local utility requirements.

47Part Number 550-142-785/1215


15 Ratings

Notes:1. See information at rightformodelnumbersuffixes.

2. BasedonstandardtestproceduresprescribedbytheUnitedStatesDepartmentofEnergy.

3. NetAHRIratingsarebasedonnetinstalledradiationofsufficientquantityfortherequirementsofthebuildingandnothingneedbeaddedfornormalpipingandpickup.Ratingsarebasedonapipingandpickupallowanceof1.15.Anadditionalallowanceshouldbemadeforunusualpipingandpickuploads.

4. VentsizeshownisforCategoryIIIventing(pressurizedvent).Seepage 8forrequiredventsizingwhenchimneydraft(CategoryI)venting.

5. Contactyourlocaldealerregardinginformationandpartsforhighaltitudeapplica-tions.

InstallGWIboilersforresidentialradiantpanelsystems,convertedgravityheating systems or other low water temperature applications per instruc-tions in this manual to avoid damage due to condensation.

GWIboilersareCSAdesigncertifiedforinstallationoncombustibleflooring. GWIboilersareASMEratedfor50psigworkingpressure.

AHRICertifiedRatings

Boiler ModelNumber

InputHeatingCapacity

Seasonal Efficiency

NetWater Input

Boiler Water content Vent

0–2,000feetaltitude

2,000–4,500feetaltitude

(Note 1) (Btuh) (Btuh) (Note 2) AFUE % (Btuh)

(Note 3)(Btuh)

(Note 5) (Gallons) (size)(Note 4)

GWI-047 47,000 40,000 83.0 35,000 45,000 1.5 3”

GWI-063 63,000 53,000 83.3 46,000 60,300 1.5 3”

GWI-095 95,000 79,000 83.0 69,000 90,000 2.1 3”

GWI-127 127,000 106,000 82.7 92,000 119,700 2.7 3”

GWI-158 158,000 131,000 82.4 114,000 150,300 3.3 3”

GWI-190 190,000 157,000 82.1 137,000 180,000 3.8 3”

DOE

48

W-T 8201 W. Calumet Rd.Milwaukee, WI 53223


Part Number 550-142-785/1215

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS

The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials that have been identified as carcinogenic, or possibly carcinogenic, to humans.Ceramicfiberscanbeconvertedtocristobaliteinveryhightemperatureapplications.TheInternationalAgencyforResearchonCancer(IARC)hasconcluded,“Crystallinesilicainhaledintheformofquartzorcristobalitefromoccupationalsourcesiscarcinogenictohumans

(Group1).”:■ Avoidbreathingdustandcontactwithskinandeyes.

• UseNIOSHcertifieddustrespirator(N95).ThistypeofrespiratorisbasedontheOSHArequirementsforcristobaliteatthetimethisdocumentwaswritten.Othertypesofrespiratorsmaybeneededdependingonthejobsiteconditions.CurrentNIOSHrecommendationscanbefoundontheNIOSHwebsiteathttp://www.cdc.gov/niosh/homepage.html.NIOSHapprovedrespirators,manufacturers,andphonenumbersare also listed on this web site.

• Wearlong-sleeved,loosefittingclothing,gloves,andeyeprotection.

■ Applyenoughwatertothecombustionchamberliningorbaseinsulationtopreventairbornedust.

■ Removecombustionchamberliningorbaseinsulationfromtheboilerandplaceitinaplasticbagfordisposal.

■ Washpotentiallycontaminatedclothesseparatelyfromotherclothing.Rinseclotheswasherthoroughly.

NIOSH stated First Aid.■ Eye:Irrigateimmediately

■ Breathing: Fresh air.

REMOVAL OF FIBERGLASS WOOL — OR —

INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASE PANELS:

Thisproductcontainsfiberglassjacketinsulationandceramicfibermaterialsincombustionchamberliningorbase

panelsingasfiredproducts.AirbornefibersfromthesematerialshavebeenlistedbytheStateofCaliforniaasapossiblecauseofcancerthroughinhalation.

■ Avoidbreathingdustandcontactwithskinandeyes.

• UseNIOSHcertifieddustrespirator(N95).ThistypeofrespiratorisbasedontheOSHArequirementsforfiberglasswoolatthetimethisdocumentwaswritten.Othertypesofrespiratorsmaybeneededde-pendingonthejobsiteconditions.CurrentNIOSHrecommendationscanbefoundontheNIOSHwebsite at http://www.cdc.gov/niosh/homepage.html.NIOSHapprovedrespirators,manufacturers,andphonenumbers are also listed on this web site.

• Wearlong-sleeved,loosefittingclothing,gloves,andeyeprotection.

■ Operationssuchassawing,blowing,tearout,andsprayingmaygenerateairbornefiberconcentrationrequiringadditional protection.

■ Washpotentiallycontaminatedclothesseparatelyfromotherclothing.Rinseclotheswasherthoroughly.

NIOSH stated First Aid.■ Eye:Irrigateimmediately

■ Breathing: Fresh air.

Handling ceramic fiber and fiberglass materials

gwi · gwi series 2 gas-fired water boilers – boiler manual 1 prepare boiler location continued...

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