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G W I

Boiler Manual

Series 2

Gas-Fired Water Boilers

Part Number 550-142-785/0812

This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in

severe personal injury, death or substantial property damage.

When calling or writing about the boiler— Please have: • boiler model number from the boiler rating label and

• CP number from the boiler jacket. You may list the CP number in the space provided on the “Installation and service

certificate” found on

page 21.

Hazards that 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.

INSTALLER

—

Read all instructions before in

stalling. Read page 2 first. Follow all instructions
in proper order to prevent personal injury or death.

• Consider piping and installation when determining

boiler location.

• Any claims for damage or shortage in shipment

must be filed immediately against the transporta-
tion company by the consignee.

USER

— Please read the following. Failure to

comply could result in severe personal injury,
death or substantial property damage.

•

This manual is for use only by your qualified
heating installer/service technician.

• Please see the User’s Information Manual for your

reference.

• Have the boiler serviced by a qualified service

technician, at least annually.

Hazards that will cause severe personal injury,

death or substantial property damage.

Hazards that can cause severe personal injury,

death or substantial property damage.

Hazard definitions

Contents

Page

1 Prepare boiler location ....................................................... 2

2 Prepare boiler ..................................................................... 6

3 Vent installation .................................................................. 7

4 Install water piping

............................................................ 13

5 Install gas piping

............................................................... 16

6 Field wiring ....................................................................... 17

7 Start-up ............................................................................ 18

8 Checkout procedure

......................................................... 20

9 Department of Energy Compliance

.................................. 21

9a Sequence of operation

..................................................... 22

10 Operating instructions ...................................................... 26

11 Service and maintenance ................................................. 27

12 Troubleshooting ................................................................ 31

13 Replacement parts ........................................................... 41

14 Dimensions ....................................................................... 46

15 Ratings ............................................................................. 47

Содержание GWI-047

Страница 1: ...lation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transporta tion company by the consignee USER Please read the following Fail...

Страница 2: ...erheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance 5 Do not use this b...

Страница 3: ...imum clearance to combustible materials 1 Hot water pipes must be at least from combustible material 2 Single wall vent pipe must be at least 2 inches from combus tible material 3 Type B double wall m...

Страница 4: ...isted vent cap must extend at least 3 feet above the highest point where it passes through a roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance o...

Страница 5: ...e personal injury or death check for products or areas listed below before installing boiler If any of these contaminants are found remove contaminants permanently OR isolate boiler and provide outsid...

Страница 6: ...ed air dampers If the air openings are fitted with motorized dampers electrically interlock the damper to Prevent the boiler from firing if the damper is not fully open Shut the boiler down should the...

Страница 7: ...at once Failure to do so can damage boiler resulting in substantial property damage Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulti...

Страница 8: ...tallation Code 2 To prevent downdrafts chimney should extend at least 3 feet above the highest point where it passes through a roof and at least 2 feet higher than any portion of a building within a h...

Страница 9: ...elbows Do not exceed data in Table 4 4 Select vent components from separate GWI Vent Component Supplement All components including the vent starter must be of the same vent manufacturer Do not mix co...

Страница 10: ...149 1 or B149 2 Installation Code Terminate vent no less than 6 feet from another com bustion air inlet 3 feet from any other building opening and 3 feet from any gas service regulator 13 See Figures...

Страница 11: ...integral screen Elbow and termination coupling with screen not available for StaR 34 6 Do not seal vent pipe slip connector for Saf T Vent to inside or outside plate 7 If passing through noncombustibl...

Страница 12: ...ual Using any termination other than one of those shown could cause nuisance outages and loss of heat resulting in substantial property damage Direct exhaust venting continued Figure 8 Sidewall vent t...

Страница 13: ...ould result in failure of the relief valve to operate result ing in possibility of severe personal injury death or substantial property damage Test the operation of the valve after filling and pres su...

Страница 14: ...tallation 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 other au tomatic means to pre...

Страница 15: ...nough 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...

Страница 16: ...ath or substantial property damage 5 Use pipe dope compatible with propane gases Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow 5 Install gas piping Fail...

Страница 17: ...ments of equipment con nected to it If connected directly to boiler seeWiring diagrams 6 Field wiring page 24 and 25 for anticipator setting For other devices see manufacturer s specifications Wiring...

Страница 18: ...rop Added water will dilute the antifreeze reducing the freeze protection level Preparation Fill the system with water 1 Close manual and automatic air vents and boiler drain cock 2 Fill to correct sy...

Страница 19: ...gy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management syste...

Страница 20: ...ff gas valve Manometer should confirm there is no gas flow Pilot will relight flame sensing element will sense pilot flame and main burners reignite Set limit control s to system temperature requireme...

Страница 21: ...ADJUST In the MIN position the time delay is zero and the IMPORTANT notice below must be observed IMPORTANT In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is...

Страница 22: ...es light and control module senses flame cur rent spark generator is turned off and main valve opens c Natural Gas If pilot does not light within 15 seconds pilot valve is closed and spark generator i...

Страница 23: ...23 Part Number 550 142 785 0812 GWI Series 2 Gas Fired Water Boilers Boiler Manual Figure 18 Control module sequence of operation status light indications 9a Sequence of operation...

Страница 24: ...24 Part Number 550 142 785 0812 GWI Series 2 Gas Fired Water Boilers Boiler Manual 9a Sequence of operation continued Figure 19 Schematic wiring diagram...

Страница 25: ...25 Part Number 550 142 785 0812 GWI Series 2 Gas Fired Water Boilers Boiler Manual Figure 20 Ladder wiring diagram 9a Sequence of operation continued...

Страница 26: ...upplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire depart ment What to do if you smell gas 1 Stop Read the safety information ab...

Страница 27: ...e could result in severe personal injury death or substantial property damage Service technician see following pages for instructions Owner maintenance see User s Information Manual for instructions A...

Страница 28: ...Severe damage to boiler will occur resulting in substantial property damage Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections...

Страница 29: ...valve seat 4 Replace cap by twisting all the way onto valve and then un screwing one turn Limit controls and cutoffs 1 Inspect and test the boiler limit control Verify operation by turn ing control se...

Страница 30: ...ning label Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read manual Section 4 page 13 before proceeding further Safety re...

Страница 31: ...check pressure switch setting if specified in Troubleshooting charts Make sure boiler water temperature is 100 F or cooler before starting procedure to obtain appropri ate readings 1 See Figure 21 an...

Страница 32: ...d 20 seconds OR ignition control will automatically restart sequence of operation after 1 hour waiting period INDICATOR LIGHT CONDITION POWER TSTAT CIRC High voltage detected on TSTAT circuit POWER PU...

Страница 33: ...33 Part Number 550 142 785 0812 GWI Series 2 Gas Fired Water Boilers Boiler Manual Figure 23 Control module connections 12 Troubleshooting components continued...

Страница 34: ...4 PURGE 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 Yes Usuall...

Страница 35: ...the boiler thermostat leads two 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 an...

Страница 36: ...lace 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 No Yes Rem...

Страница 37: ...ower to boiler Restart 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 b...

Страница 38: ...e ohmmeter 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 bu...

Страница 39: ...vice switch or breaker Check flame signal Detach sense lead from ignition control Figure 23 item 8 page 33 Connect negative lead of MICROAMMETER to control sense terminal Figure 23 item 8 page 33 Conn...

Страница 40: ...normal sequence of operation Figure 18 page 23 If you have less than sufficient heat Is vent piping free of blockage No Yes Correct conditions and recheck operation See Figure 30 page 38 for normal s...

Страница 41: ...t 460 003 700WT 2 Collector hood and transition assembly GWI 047 GWI 063 GWI 095 GWI 127 GWI 158 GWI 190 381 354 581WT 381 354 582WT 381 354 583WT 381 354 584WT 381 354 585WT 381 354 586WT 3 Temperatu...

Страница 42: ...ss tie assembly in Base assembly 4 Access panel in Base assembly 5 Base pan angle left side in Base assembly 6 Base pan angle right side in Base assembly 7 Base pan in Base assembly 8 Burner rest in B...

Страница 43: ...embly 13 Replacement parts continued The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 48 of this manual Failure to comply coul...

Страница 44: ...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 boiler Conbraco Hammond V...

Страница 45: ...355WT 3 Natural gas Pilot assembly kit with orifice and aluminum pilot gas tubing All 511 330 166WT 3 Propane gas Pilot assembly kit with orifice and aluminum pilot gas tubing All 511 330 211WT 4 Cont...

Страница 46: ...nsions 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 W Jacket width inches GWI 047 1 10 GWI 063 1 1...

Страница 47: ...pplica tions Install GWI boilers for residential radiant panel systems converted gravity heating systems or other low water temperature applications per instruc tions in this manual to avoid damage du...

Страница 48: ...it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh a...

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