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Williamson-Thermoflo GWA-067 - User Manual

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Part Number 550-142-320/0720
Boiler Manual
Series 3
Gas-Fired Water Boilers
GWA
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
• Consumer Protection (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 25.
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
installing. Read page 2 first. Follow all
instructions in proper order to prevent
personal injury or death.
Consider piping and installation 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 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 ...........................................3
2 Prepare boiler ..........................................................7
3 Install water piping ...............................................10
4 Water piping — multiple zones ............................13
5 Install gas piping ................................................... 20
6 Field wiring ............................................................ 21
7 Start-up .................................................................22
8 Checkout procedure .............................................25
9 Department of Energy – Compliance ................... 26
Contents .......................................................... Page
10 Sequence of operation .........................................26
11 Operating instructions ..........................................30
12 Service and maintenance .....................................32
13 Troubleshooting ....................................................36
14 Replacement parts ...............................................45
15 Dimensions ...........................................................50
16 Ratings ..................................................................51

Table of Contents

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Summary

Hazard Definitions

DANGER and WARNING Definitions

Hazards causing severe personal injury, death, or substantial property damage.

Read This First! Critical Safety Warnings

1 Prepare Boiler Location - Continued

Vent System Requirements

Critical safety information for flue gas venting.

3 Install Water Piping

3 Install Water Piping - System Configurations

3 Install Water Piping - Bypass Piping Methods

4 Water Piping - Multiple Zones

4 Water Piping - Multiple Zones - Diagrams

4 Water Piping - Low Temperature Systems

Primary;Secondary Bypass Piping for Low Temp

Preferred method for radiant and converted gravity systems.

4 Water Piping - Low Temperature Systems - Diagrams

Primary;Secondary Piping with Circulators

Figure 12 showing circulator zoning setup.

Primary;Secondary Piping with Zone Valves

Figure 13 showing zone valve zoning setup.

4 Water Piping - Boiler Bypass Piping

Boiler-Bypass Piping Method

Method for preventing condensate in low temp systems.

4 Water Piping - Boiler Bypass Piping Diagrams

Boiler-Bypass Piping with Circulators

Figure 14 illustrating bypass with circulators.

Boiler-Bypass Piping with Zone Valves

Figure 15 illustrating bypass with zone valves.

4 Water Piping - System Bypass Piping

System-Bypass Piping Method

Method for controlling return water temperature.

Figure 16 System Bypass Piping Diagram

Visual guide for system bypass zoning.

5 Install Gas Piping

Connecting Gas Supply Piping

Steps for connecting natural and propane gas lines.

6 Field Wiring

Wiring Connections and Safety

General wiring rules and electrical safety.

7 Start-up - Preparation

Pre-Start Check for Gas Leaks

Crucial safety steps before initial operation.

7 Start-up - Filling, Inspection, and Operation

7 Start-up - Verifying Operation

Boiler Start-up Checks and Flame Inspection

Troubleshooting common start-up issues and inspecting burner flames.

8 Checkout Procedure

Pre-Operation Checklist

Comprehensive list of checks before final system sign-off.

10 Sequence of Operation

10 Sequence of Operation - Spark-Ignited Pilot

Spark-Ignited Pilot Boiler Sequence

Detailed steps and status light indications for ignition.

10 Sequence of Operation - Wiring Diagrams

Schematic Wiring Diagram - Spark-Ignited Pilot

Detailed wiring diagram for spark-ignited pilot systems.

10 Sequence of Operation - Wiring Details

Spark-Ignited Pilot Wiring Schematics

Further schematic details and component connections.

11 Operating Instructions - Honeywell;White-Rodgers Gas Valves

Safety Warnings Before Operating

Critical safety information related to gas valve operation.

Operating Instructions for Gas Valves

Step-by-step guide for using specific gas valves.

11 Operating Instructions - Robertshaw 7200 Gas Valve

Safety Warnings for Robertshaw 7200 Valve

Specific safety precautions for this gas valve.

Operating Instructions for Robertshaw 7200

Steps for operating the boiler with this valve.

12 Service and Maintenance Schedules

General Service and Maintenance Warnings

Importance of following maintenance guidelines.

12 Service and Maintenance - Inspection Points

12 Service and Maintenance - Checks and Tests

12 Service and Maintenance - Boiler Relief Valve and Cleaning

13 Troubleshooting - Vent Damper Issues

Troubleshooting Vent Damper Failures

Steps for diagnosing and resolving vent damper malfunctions.

13 Troubleshooting - Spark-Ignited Pilot Systems

Control Module Indicator Lights

Understanding error codes indicated by control module lights.

13 Troubleshooting - Control Module Connections

Control Module Connection Diagram

Visual guide to wiring connections for the control module.

13 Troubleshooting - POWER Light Status

Troubleshooting Chart 1: POWER Light Status

Diagnosing issues based on the POWER light.

13 Troubleshooting - TSTAT;CIRC & POWER Lights

Troubleshooting Chart 2: TSTAT;CIRC & POWER Lights

Diagnosing issues indicated by TSTAT/CIRC and POWER lights.

13 Troubleshooting - DAMPER Light Flashing

Troubleshooting Chart 3: DAMPER Light Flashing

Diagnosing issues indicated by DAMPER light.

13 Troubleshooting - FLAME & POWER Lights

Troubleshooting Chart 4: FLAME & POWER Lights

Diagnosing issues indicated by FLAME and POWER lights.

13 Troubleshooting - FLAME Light and Main Flame

Troubleshooting Chart 5: FLAME Light and Main Flame

Diagnosing issues related to pilot flame and main burner ignition.

13 Troubleshooting - Insufficient Heat or No Heat

Troubleshooting Chart 6: Insufficient Heat or No Heat

Diagnosing issues causing lack of heating.

Handling Ceramic Fiber and Fiberglass Materials

Williamson-Thermoflo GWA-067 Specifications

General IconGeneral
BrandWilliamson-Thermoflo
ModelGWA-067
CategoryBoiler
LanguageEnglish

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