Williamson-Thermoflo GWA-100 - User Manual

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

Summary

Hazard Definitions and Safety Warnings

Hazard Severity Levels

Defines DANGER, WARNING, and CAUTION levels for potential hazards.

Installer and User Safety Directives

Specific safety instructions for installers and users regarding boiler operation.

Important Safety Precautions

Boiler Operation and Servicing Safety

Precautions for boiler operation, servicing, and potential water damage.

1 Prepare Boiler Location

Installation Codes and Checklist

Ensuring compliance with installation codes and performing pre-installation checks.

Required Clearances and Foundation

Specifying minimum clearances for service and combustible materials, and foundation needs.

Vent System Requirements

Guidelines and warnings for installing vent systems and handling shared vents.

Air Openings and Damper Systems

Requirements for air openings and installation of motorized air dampers.

2 Prepare Boiler

Boiler Placement, Setup, and Inspection

Instructions for positioning, leveling, inspecting parts, and handling materials.

Hydrostatic Pressure Testing

Procedure for filling the boiler and performing a hydrostatic pressure test.

Draft Hood, Spill Switch, and Vent Damper

Installation of draft hood, spill switch, vent piping, and vent damper.

Vent Damper Installation Details

Specific steps for vent damper installation, wiring, and safety warnings.

3 Install Water Piping

Near-Boiler Piping Configurations

Diagrams for expansion tanks, circulators, and pipe sizing near the boiler.

Relief Valve and Expansion Tank Installation

Proper installation of relief valve, expansion tanks, and water piping.

Low Return Water Temperature Precautions

Warnings about condensation and corrosion from low return water temperatures.

System Bypass Piping Methods

Methods for system and boiler bypass to manage return water temperature.

4 Water Piping - Multiple Zones

Zoning Methods and Diagrams

Piping for multiple zones using circulators or zone valves, including diagrams.

Low Temperature System Piping

5 Install Gas Piping

Connecting Gas Supply to Boiler

Natural and Propane Gas Requirements

6 Field Wiring

Electrical Installation and Safety

Thermostat and Zone Wiring

7 Start-up

Pre-Start-up Preparations

System Filling and Air Purging

Operation Verification and Checks

8 Checkout Procedure

Boiler System Checkout Checklist

10 Sequence of Operation

Boiler Operating Sequence Steps

Spark-Ignited Pilot Boiler Operation

11 Operating Instructions

Operating Specific Gas Valves

Operating Robertshaw 7200 Gas Valve

12 Service and Maintenance

Annual Start-Up Procedures

Boiler Inspection Checklist

Component and System Checks

Expansion Tank, Relief Valve, and Cleaning

13 Troubleshooting

General Troubleshooting Preparations

Vent Damper and Temperature Sensor Issues

Control Module Indicator Lights

Control Module Wiring and Light Status

Troubleshooting Specific Light Combinations

Handling Ceramic Fiber and Fiberglass Materials

Safe Removal of Combustion Chamber Lining;Base Panels

Safe Handling of Fiberglass Materials

Williamson-Thermoflo GWA-100 Specifications