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Part Number 550-110-737/1108

GWS-090E

Gas-Fired Water Boiler –

Boiler Manual

Figure 19

Gas control assembly

13 Replacement parts

continued

Item

number Description

Manufacturer

Manufacturer’s

part number

Part number

Natural gas components

Gas valve, ½” x ½”, two-stage

Natural gas

Honeywell

VR8204Q2426

511-044-507WT

Pilot assembly kit with orifice and aluminum pilot gas

tubing

Weil-McLain

511-330-080WT

Propane gas components

Gas valve, ½” x ½”, two-stage

Propane

Honeywell

VR8204Q2442

511-044-509WT

Pilot assembly kit with orifice and aluminum pilot gas

tubing

Weil-McLain

511-330-081WT

Natural gas and propane gas components

Control module

United Technologies

1107-1

511-330-090WT

not shown

Wiring harness — control

Weil-McLain

591-391-952WT

not shown

Wiring harness — 120V

Weil-McLain

591-391-900WT

not shown

Timer harness #1

Weil-McLain

591-391-954WT

Air pressure switch

1.71 I.W.C. — GWS-090E

Cleveland

NS2-1047-08

511-624-656WT

Control transformer

511-842-370WT

Timer relay *

ABB

TS12190

510-350-468WT

not shown

Tubing, air pressure switch, 0.12 I.D. silicone

red, to collector hood

white, to transition

Lydall

590-317-650WT

590-317-651WT

* The ABB timer relay TS12190 is designed for 90-second delay, but operates for 60 seconds in the GWS-090E boiler.

Содержание GWS-090E

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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