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GWS-090E

 

Gas-Fired Water Boiler – 

Boiler Manual

40

Part Number 550-110-737/1108

W-T

8201 W. Calumet Rd.

Milwaukee, WI 53223

 

This  addendum  must  only  be  used  by  a 
qualified heating installer/service technician. 
Read  these  instructions  completely  before 
beginning the installation. Failure to comply 
could result in severe personal injury, death 
or substantial property damage.

(a) For all side wall horizontally vented gas fueled equipment 

installed  in  every  dwelling,  building  or  structure  used  in 
whole  or  in  part  for  residential  purposes,  including  those 
owned  or  operated  by  the  Commonwealth  and  where  the 
side wall exhaust vent termination is less than seven (7) feet 
above finished grade in the area of the venting, including but 
not limited to decks and porches, the following requirements 
shall be satisfied:

1. 

INSTALLATION  OF  CARBON  MONOXIDE  DETEC-
TORS

. At the time of installation of the side wall horizon-

tal vented gas fueled equipment, the installing plumber 

or  gas  fitter  shall  observe  that  a  hard  wired  carbon 

monoxide detector with an alarm and battery back-up 

is installed on the floor level where the gas equipment is 

to be installed. In addition, the installing plumber or gas 

fitter shall observe that a battery operated or hard wired 

carbon monoxide detector with an alarm is installed on 

each additional level of the dwelling, building or struc-

ture served by the side wall horizontal vented gas fueled 

equipment. It shall be the responsibility of the property 

owner to secure the services of qualified licensed profes-

sionals for the installation of hard wired carbon monoxide 

detectors 
a.    In the event that the side wall horizontally vented gas 

fueled equipment is installed in a crawl space or an 

attic, the hard wired carbon monoxide detector with 

alarm and battery back-up may be installed on the 

next adjacent floor level. 

b.    In the event that the requirements of this subdivision 

can not be met at the time of completion of installa-

tion, the owner shall have a period of thirty (30) days 

to  comply  with  the  above  requirements;  provided, 

however, that during said thirty (30) day period, a 

battery operated carbon monoxide detector with an 

alarm shall be installed.

2. 

APPROVED CARBON MONOXIDE DETECTORS

. Each 

carbon monoxide detector as required in accordance with 

the above provisions shall comply with NFPA 720 and be 

ANSI/UL 2034 listed and IAS certified. 

3. 

SIGNAGE

.  A metal or plastic identification plate shall 

be  permanently  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  appliance  or 

equipment. The sign shall read, in print size no less than 

one-half (1/2) inch in size, “GAS VENT DIRECTLY BE-

LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

4. 

INSPECTION

.    The  state  or  local  gas  inspector  of  the 

side wall horizontally vented gas fueled equipment shall 

not  approve  the  installation  unless,  upon  inspection, 

the inspector observes carbon monoxide detectors and 

signage  installed  in  accordance  with  the  provisions  of 

248 CMR 5.08(2)(a) 1 through 4.

(b) 

EXEMPTIONS

:  The  following  equipment  is  exempt  from 

248 CMR 5.08(2)(a)1 through 4:
1.  The equipment listed in Chapter 10 entitled “Equipment 

Not Required To Be Vented” in the most current edition 

of NFPA 54 as adopted by the Board; and

2.  Product Approved side wall horizontally vented gas fueled 

equipment installed in a room or structure separate from 

the dwelling, building or structure used in whole or in 

part for residential purposes.

(c) 

MANUFACTURER REQUIREMENTS — GAS EQUIPMENT 
VENTING SYSTEM PROVIDED

. When the manufacturer of 

Product Approved side wall horizontally vented gas equip-
ment  provides  a  venting  system  design  or  venting  system 
components with the equipment, the instructions provided 
by the manufacturer for installation of the equipment and 
the venting system shall include:
1.  Detailed instructions for the installation of the venting 

system design or the venting system components; and

2.  A  complete  parts  list  for  the  venting  system  design  or 

venting system.

(d) 

MANUFACTURER REQUIREMENTS — GAS EQUIPMENT 
VENTING SYSTEM NOT PROVIDED

. When the manufac-

turer of a Product Approved side wall horizontally vented gas 
fueled equipment does not provide the parts for venting the 
flue gases, but identifies “special venting systems”, the follow-
ing requirements shall be satisfied by the manufacturer:
1.  The referenced “special venting system” instructions shall 

be included with the appliance or equipment installation 

instructions; and

2.  The “special venting systems” shall be Product Approved 

by the Board, and the instructions for that system shall in-

clude a parts list and detailed installation instructions.

(e)  A copy of all installation instructions for all Product Approved 

side wall horizontally vented gas fueled equipment, all venting 
instructions, all parts lists for venting instructions, and/or all 
venting design instructions shall remain with the appliance 
or equipment at the completion of the installation.

Addendum Instruction for the 
Commonwealth of Massachusetts

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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