Williamson-Thermoflo GWA 3 Series Manual Download Page 48

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Part Number 550-142-320/0720

GWA

Series 3

Gas-Fired Water Boilers –

Boiler Manual

Figure 31

Trim assembly

14 Replacement parts

continued

Item

number

Description

Part number

Pressure relief valve, ASME, 30 PSIG, ¾” male inlet

Pressure relief valve, ASME, 30 PSIG, ¾” female inlet

(Fittings shown are factory-installed on boiler.)

511-546-920WT

511-546-924WT

Combination pressure-temperature gauge, with 2½ short shank

510-218-099WT

Drain valve, ¾” NPT, 1-½ Shank

(Fittings shown are included with boiler.)

511-210-423WT

Circulator (Fittings shown are shipped loose with boiler.)

511-405-113WT

Circulator gasket, universal (2 per boiler)

590-317-535WT

not

shown

Circulator hardware kit, includes:

2 flanges, 4 nuts, 4 bolts, 2 pipe nipples —

1” NPT — GWA-038 through GWA-133

1¼” NPT — GWA-166 through GWA-233

381-354-525WT

381-354-526WT

Circulator wiring harness kit, spark-ignition with molex

(loose)

381-354-528WT

Summary of Contents for GWA 3 Series

Page 1: ...n when determin ing boiler location Any claims for damage or shortage in shipment must be filed immediately against the transpor tation company by the consignee USER Please read the following Failure...

Page 2: ...ks immediately to prevent pos sible accumulation of glycol Never use automotive antifreeze or ethylene glycol in the system Using these glycols can lead to hazardous leakage of glycol in the boiler sy...

Page 3: ...3 latest edition Before locating the boiler o Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power o Check area around boiler Remove any combustibl...

Page 4: ...perate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the operating instructions Adjust thermostat so appliance...

Page 5: ...utility Type B double wall metal vent pipe or single wall vent pipe may be used as a liner 4 Cold masonry chimneys also known as outside chimneys typically have one or more walls exposed to outside ai...

Page 6: ...olated contact proving the damper open in series with the thermostat input to the boiler The boiler will not start if this contact is open and will shut down should it open during operation 1 Prepare...

Page 7: ...er system Severe damage to boiler will occur resulting in substantial property damage Drain and remove fittings 1 Disconnect fill water hose from water source 2 Drain boiler at drain valve or out hose...

Page 8: ...lot systems See vent manufacturer s instructions to install plug shipped with damper in damper hole For spark ignited pilot boilers only install plug with no hole in vent damper hole Minimum clearance...

Page 9: ...de 3 Install damper harness between damper actuator and hole in jacket left side panel See Figure 3 page 8 Use strain relief connectors and locknuts to secure both ends of damper harness Keep wiring h...

Page 10: ...alve in cold water supply if required by local codes See Table 4 and Figure 5 diaphragm type or bladder type expansion tank or Figure 6 closed type expansion tank on page 11 for near boiler piping for...

Page 11: ...d in air handling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle Circulation of cold water thr...

Page 12: ...controls flow through the boiler 4 The purpose of this piping is to cause a high enough temperature rise in the boiler that the average temperature will be warm enough to prevent condensation of flue...

Page 13: ...ow rate without affecting primary circuit flow rate If Figures 12 or 13 cannot be used use the boiler bypass piping shown in Figure 14 or Figure 15 on page 18 You can also use the piping shown in Figu...

Page 14: ...type expansion tank pipe from top of air separator to tank fitting as in Figure 6 page 11 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansio...

Page 15: ...change in the heating circuit rate and temperature distribution Figures 12 or 13 on page 16 show suggested bypass ar rangements using primary secondary bypass piping pre ferred for low temperature sy...

Page 16: ...nk or connect to tank fitting closed type expansion tank DO NOT use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expan...

Page 17: ...rates are adjusted according to the instructions following Figures 14 or 15 are alternative piping suggestions for converted gravity large water content or steam systems or radiant heating system for...

Page 18: ...ystem temperature valves see instructions to the left for adjusting valves 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting...

Page 19: ...antial property damage SYSTEM bypass piping method This piping method Figure 16 is called a system bypass be cause part of the circulator flow bypasses the system through valve 7a This bypassed hot wa...

Page 20: ...le between cap and tee b Install ground joint union for servicing when required c Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requir...

Page 21: ...in thermostat to match power requirements of equipment connected to it If connected directly to boiler set for 0 4 Figure 18 Field wiring connections service switch DHW if used and thermostat or end...

Page 22: ...section failure Verify water chemistry Consult local water treatment companies for unusually hard water areas above 7 grains hardness or low pH water condi tions below 7 0 Boiler water pH of 7 0 to 8...

Page 23: ...ulates available hot water before turning on the boiler to attempt to satisfy a call for heat While attempting to satisfy the heat demand the control module also monitors the boiler temperature change...

Page 24: ...ilot flame 1 Overfired Large flame lifting or blowing past pilot flame sensor 2 Under fired Small flame Inner cone not engulfing pilot flame sensor 3 Lack of primary air Yellow flame tip 4 Incorrectly...

Page 25: ...as outlined by manufacturer Burners should be operating and should go off when controls are tested When controls are restored burners should reignite o Button on spill switch pushed in o Test ignitio...

Page 26: ...t control module will attempt to ignite pilot 2 more times with a 5 minute wait period after the second try and a 60 minute wait period after the third try If the ignition control does not sense pilot...

Page 27: ...w in the standby mode 7 Thermostat anticipator setting Set thermostat heat anticipator as instructed in Figure 22 page 28 10 Sequence of operation spark ignited pilot boilers Steps following step 7 cy...

Page 28: ...28 Part Number 550 142 320 0720 GWA Series 3 Gas Fired Water Boilers Boiler Manual Figure 22 Schematic wiring diagram Spark ignited pilot system 10 Sequence of operation spark ignited pilot boilers...

Page 29: ...29 Part Number 550 142 320 0720 GWA Series 3 Gas Fired Water Boilers Boiler Manual Figure 23 Schematic wiring diagram Spark ignited pilot system 10 Sequence of operation spark ignited pilot boilers...

Page 30: ...p 10 Turn gas control knob counterclockwise to ON Press down on White Rodgers 36C valve knob to turn 11 Turn on all electric power to the appliance 12 When equipped with Effikal vent damper place serv...

Page 31: ...31 Part Number 550 142 320 0720 GWA Series 3 Gas Fired Water Boilers Boiler Manual 11 Operating instructions Gas valve Robertshaw 7200...

Page 32: ...al for instructions A nnual start up o Inspect Reported problems Boiler area Air openings Flue gas vent system Pilot and main burner flames Water piping Boiler heating surfaces Burners base and inlet...

Page 33: ...ice and maintenance continued Water piping 1 Check the boiler interior piping and all system piping for signs of leaks 2 Repair any leaks before proceeding Do not use petroleum based cleaning or seali...

Page 34: ...log and no longer control pressurization The boiler relief valve will weep frequently 12 Service and maintenance continued o Check test Gas piping 1 Sniff near floor and around boiler area for any ind...

Page 35: ...ff Gas to Appliance instructions on boiler and Operating Instructions Do not drain boiler unless it will be exposed to freezing temperatures If using antifreeze in system do not drain 2 Follow shutdow...

Page 36: ...e Can be adjusted by regulator on gas valve c If gas pressure is incorrect or gas is not available to boiler contact gas supplier to correct before proceeding further 3 Check pilot operation Follow Op...

Page 37: ...ash 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 ALL LED S FLASHING Failure to establish pilot flame after...

Page 38: ...38 Part Number 550 142 320 0720 GWA Series 3 Gas Fired Water Boilers Boiler Manual Figure 27 Control module connections 13 Troubleshooting spark ignited pilot boilers...

Page 39: ...or fuses are good Remove 120 VAC IN plug Figure 27 Item 3 page 38 on control module Using voltmeter check across black and white wire pins of 120 VAC IN plug If in Low Water condition Power is disrup...

Page 40: ...on check and correct the external wiring This is a common problem when using 3 wire zone valves Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external...

Page 41: ...nd appropriate zone valves open The TSTAT CIRC and LIMIT lights should come on Does vent damper operate No Yes Wait 45 seconds Is Damper light flashing No Yes Remove damper wiring plug at damper and f...

Page 42: ...lve closed Turn off power to boiler at service switch or breaker Wait at least 45 seconds Turn on power to boiler Restart boiler following Operating instructions in this manual Section 11 or on boiler...

Page 43: ...as valve Turn on power to boiler and allow to cycle As soon as pilot is burning the MICROAMMETER should read at least 1 0 microamp Is flame signal at least 1 0 microamp No Yes Check the voltage across...

Page 44: ...et spill switch or replace rollout switch If rollout thermal fuse element or spill switch has opened determine cause and correct condition Failure to do so will cause severe personal injury death or s...

Page 45: ...018WT 460 003 017WT 2 Collector hood GWA 038 GWA 067 GWA 100 GWA 133 GWA 166 GWA 200 GWA 233 381 354 625WT 381 354 626WT 381 354 627WT 381 354 628WT 381 354 629WT 381 354 630WT 381 354 631WT 3 Draftho...

Page 46: ...ase assembly 8 Burner rest in Base assembly 9 Base insulation kit included insulation for all base parts above plus gasket material needed between block assembly and base GWA 038 to GWA 133 GWA 166 to...

Page 47: ...067 GWA 100 GWA 133 GWA 166 GWA 200 GWA 233 431 223 572WT 431 223 574WT 431 223 576WT 431 223 578WT 431 223 580WT 431 223 582WT 431 223 584WT 4 Jacket panel door GWA 038 070 GWA 100 GWA 133 GWA 166 G...

Page 48: ...924WT 2 Combination pressure temperature gauge with 2 short shank 510 218 099WT 3 Drain valve NPT 1 Shank Fittings shown are included with boiler 511 210 423WT 4 Circulator Fittings shown are shipped...

Page 49: ...GWA 200 GWA 233 511 044 356WT 511 044 366WT 2 Pilot kit w orifice aluminum pilot gas tubing 511 330 273WT Kit Conv Natural Gas to Liquefied Petroleum Propane GWA 038 210 510 811 940WT Kit Conv Natura...

Page 50: ...T Return tappings inches NPT Gas connection manifold size Note 3 inches NPT A Vent location inches D Vent diameter inches W Jacket width inches H Damper height inches GWA 038 1 1 5 4 10 45 GWA 067 1 1...

Page 51: ...he model number designates natural gas An L designates propane gas The letter after the designates the pilot ignition system I for spark ignited pilot For example a suffix L I means a propane spark ig...

Page 52: ...om the boiler and place it in a plastic bag for disposal o Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid o Eye Irrigate im...

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