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31

1. 

Adjust gas input to boiler by removing protective cap on 
pressure regulator

and turning screw clockwise 

 to 

increase input and counterclockwise 

 to decrease 

input. See Figure 12-1 page 27.

2. 

Manifold pressures are taken at outlet side of gas valve. 

See page 23 for proper pressure recommendations.

3. 

To check for proper flow of natural gas to boiler, divide 

input rate shown on rating plate by heating value of 

gas obtained from local gas company. This determines 

number of cubic feet of gas required per hour. 

4. 

Determine flow of gas through meter for two minutes 

and multiply by 30 to get hourly rate with all other gas 

appliances off. 

5. 

Make minor adjustments to gas input as described 

above. See Figure 12-1 page 27.

6. 

Change burner orifices if final manifold pressure varies 

more than plus or minus 0.3 inches water column from 

specified pressure listed on boiler rating plate.

 

7. 

Primary air adjustment is not necessary, therefore air 

shutters are not furnished.

CHECK SAFETY CONTROL CIRCUIT.  Test ignition 

system safety shutoff device after placing boiler in 

operation.

Test ignition 

system safety shutoff device 

after placing boiler in operation. Blocked vent switch 

and rollout switch can be tested by removing one of 

the wires.  See Figure 13-1 page 28.

8. 

Intermittent Pilot: With main burner operating, turn 

pilot gas adjusting screw clockwise 

 until pilot 

gas is turned off. Within 90 seconds main gas control 

closes, shutting off gas to main burner.

9. 

High Limit Control

: Remove front cover and 

note temperature setting. Refer to appendix A for 

adjustment procedure. Decrease setting to minimum 

and operate boiler. When boiler water temperature 

exceeds control temperature setting, control will open 

circuit, closing automatic main gas valve.

 

14.4 Adjusting Gas Input

14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS

 PN 240012807, Rev. C [11/15/2020]

Summary of Contents for GMGW-060K

Page 1: ...TENANCE MANUAL Models GMGW 060K GMGW 150K GMGW 095K GMGW 175K GMGW 120K GMGW 205K GMGW 235K Tested For 50 psi ASME Working Pressure C S A Certified For Natural Gas Or Propane Manufactured by ECR Inter...

Page 2: ...7 Wire Diagrams Document Package Junction Box Circulator Harness Items found in parts box included with your boiler Information and specifications outlined in this manual in effect at the time of prin...

Page 3: ...ectrical 24 10 1 Electrical Wiring 24 10 2 Thermostat Installation 24 11 Wiring Diagram 25 12 Lighting Instructions 27 12 1 Lighting Procedure For Boiler With Intermittent Pilot System 27 12 2 Operati...

Page 4: ...24 1 8 24 1 8 24 1 8 24 1 8 613 mm 613 mm 613 mm 613 mm 613 mm 613 mm 613 mm H Flue Diameter 4 5 6 6 7 7 7 102 mm 127 mm 153 mm 153 mm 178 mm 178 mm 178 mm Supply Return Tappings 1 1 4 NPT 1 1 4 NPT 1...

Page 5: ...and all requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can...

Page 6: ...Current NIOSH recommendations can be found on the NIOSH website https www cdc gov niosh topics silica NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear lo...

Page 7: ...evel solid base as near chimney as possible and centrally located with respect to heat distribution system as practical 6 Horizontal vent run to chimney shall be as short as practicable Refer to NFPA...

Page 8: ...ne etc Cleaning Solvents Hydrochloric acid muriatic acid Cements adhesives and glues Photo processing plants Garages with workshops Furniture refinishing areas and establishments Laundry Chemicals Lau...

Page 9: ...and or hot water during operation Discharge line shall A connect to relief valve outlet and piped down to safe point of disposal Check local codes for maximum distance from floor or allowable safe poi...

Page 10: ...a possibility install appropriate safeguards and alarms on the heating system to prevent property damage due to frozen and burst pipes should the boiler heating system become inoperative due to a pow...

Page 11: ...g cycle Do not expose boiler and piping to freezing temperatures Note WARNING Asphyxiation hazard Gradual flueway blocking resulting from condensate induced corrosion may block boiler passages resulti...

Page 12: ...losed water heating system Do not use automotive or ethylene glycol Do not expose boiler and piping to freezing temperatures Note Boiler installed above radiation level or as required by authority hav...

Page 13: ...CONNECTING SUPPLY RETURN PIPING Figure 4 3 Bypass Piping With Automatic Mixing Valve BACK FLOW VALVE PIPING LEGEND PURGE VALVE DRAIN VALVE ASME RELIEF VALVE Back Flow Valve PN 240012807 Rev C 11 15 2...

Page 14: ...PIPING Figure 4 4 Bypass Piping Fixed Low Temp Only With Zone Valve BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE Manually adjust until proper system temperature is reached Drain Valve Drain Valve...

Page 15: ...TING SUPPLY AND RETURN PIPING Figure 4 5 Bypass Piping 4 Way Valve Option With Circulator On Supply side BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE Back Flow Valve Drain Valve PN 240012807 Rev C...

Page 16: ...Figure 4 6 Single Zone System With DHW Priority BACK FLOW VALVE PIPING LEGEND 4 CONNECTING SUPPLY AND RETURN PIPING ASME RELIEF VALVE Back Flow Valve Drain Valve Purge Valve PN 240012807 Rev C 11 15 2...

Page 17: ...uires all domestic hot water DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and...

Page 18: ...ir Infiltration Rate See Table 5 1 for space with boiler only Use equation for multiple appliances Do not use an air infiltration rate ACH greater than 0 60 Volume 21 ft3 ACH x Total Input BTU HR 1 00...

Page 19: ...exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at...

Page 20: ...in good condition Installation must conform to requirements of the authority having jurisdiction or in absence of such requirements to The National Fuel Gas Code ANSI Z223 1 NFPA 54 7 4 Vent Pipe Con...

Page 21: ...te damper so it is accessible for servicing See Figure 8 2 4 Damper must be in the open position when appliance main burners are operating 5 Boiler is equipped with factory wired harness that plugs in...

Page 22: ...22 Figure 8 2 Vent Damper Placement Figure 8 3 Vent Damper Position Indicator 8 VENT DAMPER INSTALLATION INSTRUCTIONS PN 240012807 Rev C 11 15 2020...

Page 23: ...ER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury WARNING Fire explosion asphyxiation and burn h...

Page 24: ...ler 10 2 Thermostat Installation 1 Use a thermostat with dry contacts which does not pull any load from the control Use a separate transformer for zone valve wiring 2 Thermostat should be installed on...

Page 25: ...odification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life Figure 11 1 Integrated High Limit Electronic Ignition Control...

Page 26: ...26 11 WIRING DIAGRAM Figure 11 2 Integrated High Limit Electronic Ignition Control PN 240012807 Rev C 11 15 2020...

Page 27: ...fied service technician or your gas supplier 12 3 TO TURN OFF GAS TO THE APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3...

Page 28: ...ese instructions could result in death or serious injury A Power remains off until boiler water temperature drops below high limit setting B Circulator continues to operate under this condition until...

Page 29: ...lamp in flue collector through draft relief opening or flue inspection cover With mirror positioned above burners flue gas passageways can be checked for soot or scale Follow this procedure to clean...

Page 30: ...uildup Area around boiler shall be clear and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler room shall n...

Page 31: ...column from specified pressure listed on boiler rating plate 7 Primary air adjustment is not necessary therefore air shutters are not furnished CHECK SAFETY CONTROL CIRCUIT Test ignition system safet...

Page 32: ...e to be 120 Volts 15 Amps 60 Hz The MEA number for the this boiler is 19 79 E 1 Input rating for sea level to 2 000 ft 610m above sea level United States over 2000 ft 610m above sea level Reduce input...

Page 33: ...ntial 15 F default setting adjustable between 10 and 30 F F_ Degrees Fahrenheit Press UP or DOWN button until parameter has reached desired value After 60 seconds without any button inputs control aut...

Page 34: ...tch closes to do this The control is waiting for this to occur This may last up to one minute If the vent damper switch has not closed after one minute ERR 55 will be displayed e 17 Diagnostics Anothe...

Page 35: ...2 hard lockouts on this model m 15 Wait for limit to close One of the safety limits rollout vent spill or low water cutoff has been activated Control will resume normal operation once limit is reset U...

Page 36: ...models wait for retry or reset at thermostat Check for correct installation and wiring before replacing any component Control module cannot be repaired If it malfunctions it must be replaced Use only...

Page 37: ...ted reading 1 Check sensor is plugged into control board 2 Check sensor wiring is not damaged 3 Scroll display reading to bt and hold sensor bulb securely in you hand It should read a temperature clos...

Page 38: ...Check all electrical connections are tight 3 Check pilot rod is clean 4 Check for adequate draft 5 Check for adequate combustion air 64 Soft Lockout Internal failure Control is sensing something wron...

Page 39: ...module and pilot burner igniter sensor Check for good metal to metal contact between pilot burner bracket and the main burner Check ground lead from GND BURNER terminal on module to pilot burner Veri...

Page 40: ...lockwise to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Figure 12 1 page 27 3 If pilot does not stay...

Page 41: ...turns to closed position 4 Return thermostat to desired position 5 Place vent damper in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller 6 Thermos...

Page 42: ...o step v v Place jumper wire across orange and yellow wires in Molex plug see Figure 4 This will create bypass of the damper boiler should then ignite If boiler ignites Go to section B 4 Vent Damper T...

Page 43: ...POWER Between 4 1 When calling for heat 1 Thermostat not calling for heat 2 Burned out heat anticipator 3 Loose or broken connections 4 Off On operating limit pressure control or low water cut off 5...

Page 44: ...OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decre...

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