Williamson-Thermoflo GWS-090E Manual Download Page 35

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Part Number 550-110-737/1108

GWS-090E

Gas-Fired Water Boiler –

Boiler Manual

Figure 17

Jacket assembly

13 Replacement parts

continued

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on

page 21 of this manual. Failure to comply could result in severe personal injury.

Item number

Description

Part number

Jacket panel , left side, with insulation:

Natural gas

Propane

431-223-490WT
431-223-496WT

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

Jacket panel, right side, with insulation

431-223-488WT

Jacket panel, top

GWS-090E

431-223-493WT

Jacket panel, door

GWS-090E

431-223-489WT

Jacket cross tie, bottom front

GWS-090E

431-223-509WT

Jacket panel, interior, with insulation

GWS-090E

431-223-500WT

Jacket panel, rear, with insulation

GWS-090E

431-223-446WT

Air inlet fitting

560-907-635WT

Inlet air hose

562-302-575WT

Hose clamp, 3”

591-850-068WT

Summary of Contents for GWS-090E

Page 1: ...at 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 INS...

Page 2: ...and boiler regularly for leakage Repair any leaks immediately to prevent pos sible accumulation of glycol Never use automotive antifreeze or ethylene glycol in the system Using these glycols can lead...

Page 3: ...oded the boiler mounting area is not level 2 See Table 2 below for minimum foundation dimensions Residential garage installations Take the following special precautions when installing the boiler in a...

Page 4: ...hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle f After it has been determined that each appliance remaining connected to the common venting system prop...

Page 5: ...t is free of the contaminants listed in Table 3 Allowing the boiler to operate with contaminated air can cause damage to the boiler and vent system resulting in possible severe personal injury death o...

Page 6: ...s Code for dealing with other conditions Louver allowance The free area of openings means the area after reduction for any installed louvers or grilles Be sure to consider this reduction when sizing t...

Page 7: ...Part Number 550 110 737 1108 GWS 090E Gas Fired Water Boiler Boiler Manual Figure 2 Provide minimum air openings for GWS 090E boiler installations based on following 1 Prepare boiler location continue...

Page 8: ...ler 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...

Page 9: ...Set second control to minimum 20 F above setpoint of first control Maximum allowable setpoint is 240 F See page 18 for wiring A low water cutoff device is required when boiler is installed above radia...

Page 10: ...boiler Consult I B R Installation and Piping Guides If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or othe...

Page 11: ...gh to allow temperatures to level off It takes a while for the boiler water temperature to rise as the flow changes 3 Bypass valve 2 allows hot boiler outlet water to blend with colder return water ra...

Page 12: ...al Gas 1 See Table 6 for pipe length and diameter Base on rated boiler input divide by 1 000 to obtain cubic feet per hour Table 6 is only for gas with specific gravity 0 60 with a pressure drop throu...

Page 13: ...s which prohibit installation of fused disconnect or service switch on boiler install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code Wirin...

Page 14: ...ycol level to drop Added water will dilute the antifreeze reducing the freeze protection level Fill the system with water 1 Close manual and automatic air vents and boiler drain cock 2 Fill to correct...

Page 15: ...resh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure If you discover evidence of any gas leak shut down...

Page 16: ...est ignition system safety device Connect manometer to outlet side of gas valve Start boiler a allowing for normal start up cycle to occur and main burn ers to ignite With main burners on manually shu...

Page 17: ...pilot does light and control module senses flame current spark generator is turned off and main valve opens 4 The GWS 090E timer relay delays high fire for the first 60 seconds of main flame 5 During...

Page 18: ...GWS 090E Gas Fired Water Boiler Boiler Manual 18 Part Number 550 110 737 1108 Figure 13 Wiring diagram GWS 090E boilers 9 Sequence of operation continued...

Page 19: ...19 Part Number 550 110 737 1108 GWS 090E Gas Fired Water Boiler Boiler Manual 10 Operating instructions...

Page 20: ...ed problems Boiler area Air openings Flue gas vent system Pilot and main burner flames Water piping Boiler heating surfaces Burners base and inlet air box Condensate drain system o Service Inducer mot...

Page 21: ...place it in a plastic bag for dis posal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing...

Page 22: ...interior 3 Inspect the boiler vent outlet area and heating surfaces by looking through the opening 4 If the vent pipe or inducer interior show evidence of soot fol low Cleaning boiler heating surface...

Page 23: ...below boiler temperature Boiler should cycle off Return dial to original setting 2 Inspect and test additional limit controls or low water cutoffs installed on system Expansion tank 1 Expansion tanks...

Page 24: ...taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve direct ing the flow of hot water from the valve to...

Page 25: ...djusted by regulator on gas valve c Verify gas manifold pressure as shown on page 24 Check pressure switch setting Make sure boiler water temperature is 100 F or cooler before starting procedure to ob...

Page 26: ...rt 4 PRESS SWITCH light flashing FLAME light flashing For insufficient heat or no heat problem go to Chart 7 if POWER light is on steady with no other light flashing No Yes On steady not flashing No Y...

Page 27: ...black low voltage leads in J box Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading ac...

Page 28: ...ion 12 Replace if necessary Retest Try reseating plug in module receptacle and restart If inducer still does not work replace inducer assembly Retest No Yes Wait 45 seconds Does inducer motor operate...

Page 29: ...art boiler following Operating instructions in this manual Section 10 Do FLAME and POWER lights still flash Boiler should now operate normally Original flashing FLAME light caused by gas valve not ope...

Page 30: ...eter indicate the switch is closed Inspect and check wire harness from control module to pressure switch Reseat connector in control module receptacle If harness is intact and properly seated but prob...

Page 31: ...ach sense lead from ignition control Connect negative lead of MICROAMMETER to control sense terminal Connect positive lead of MICROAMMETER to sense wire DISCONNECT red wire connected to terminal MV of...

Page 32: ...ping free of blockage No Yes Correct conditions and recheck operation See Figure 12 page 17 for normal sequence of operation Check heat loss calculation versus boiler size Clock gas input Replace cont...

Page 33: ...of this manual Failure to comply could result in severe personal injury Item number Description Part number not shown Replacement section assembly GWS 090E 321 114 346WT 1 Radiation plate 1 per joint...

Page 34: ...e in Base assembly 5 Base left side panel in Base assembly 6 Base right side panel in Base assembly 7 Base back panel in Base assembly 8 Base front cross tie assembly in Base assembly 9 Pilot bracket...

Page 35: ...number 1 Jacket panel left side with insulation Natural gas Propane 431 223 490WT 431 223 496WT 2 Junction box 2 x 4 available at local supply house 3 Jacket panel right side with insulation 431 223 4...

Page 36: ...920WT Conbraco Watts 10 408 05 335 511 546 924WT 2 Combination pressure temperature gauge with 2 short shank Ametek ENFM PTA 1088 4104 510 218 099WT 3 Drain valve Fittings shown are included with boil...

Page 37: ...fice and aluminum pilot gas tubing Weil McLain 511 330 081WT Natural gas and propane gas components 3 Control module UnitedTechnologies 1107 1 511 330 090WT not shown Wiring harness control Weil McLai...

Page 38: ...IN INCHES 14 Dimensions Boiler model number Supply tapping inches NPT Return tapping inches NPT Gas connection size Note 3 inches NPT Gas manifold size Note 3 inches NPT A Air inlet pipe center inches...

Page 39: ...tings are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusual piping and pickup loads 4 The GWS 090E boiler requires special venting consistent with Categ...

Page 40: ...ermanently mounted to the exterior of the build ing at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appli...

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