ICP GWA 052 Manual

Manual is about: Gas-Fired Water Boilers

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Part Number 670 01 1001 00

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 • 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 18.

Contents

Page

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

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

Install water piping ............................................................ 10

Install gas piping ............................................................... 13

Field wiring ....................................................................... 14

Start-up ............................................................................ 15

Checkout procedure ......................................................... 18

Sequence of operation — standing pilot boilers ................. 19

Lighting instructions — GWA standing pilot boilers ........... 20

Service and maintenance ................................................. 22

Troubleshooting ................................................................ 27

Replacement parts ........................................................... 29

Dimensions ...................................................................... 34

Ratings ............................................................................. 35

Boiler Manual

Gas-Fired Water Boilers

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 determining

boiler location.

• Any claims for damage or shortage in shipment

must be filed immediately against the transportation

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

GWA Gas-Fired Water Boilers – Boiler Manual

Part Number 670 01 1001 00

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Summary of GWA 052

Page 1
Part number 670 01 1001 00 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 boil...
Page 2: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 2 part number 670 01 1001 00 installations must follow these codes: • local, state, provincial, and national codes, laws, regulations and ordinances. • national fuel gas code, ansi z223.1–latest edition. • standard for controls and safety devices for autom...
Page 3: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 3 part number 670 01 1001 00 service clearances 1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as listed in the table below: 2. Provide at least screwdriver clearance to jacket front panel scre...
Page 4: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 4 part number 670 01 1001 00 1 prepare boiler location continued failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. When removing boiler from existing common vent syste...
Page 5: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 5 part number 670 01 1001 00 table 2 corrosive contaminants and likely locations to prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found: • remove co...
Page 6: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 6 part number 670 01 1001 00 air openings continued 2 prepare boiler table 3 manifold orifice sizing place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. 2. Move entire crate and pallet next to selected ...
Page 7: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 7 part number 670 01 1001 00 perform hydrostatic pressure test pressure test boiler before attaching water or gas piping or electrical supply (except as noted below). Prepare boiler for test 1. Remove the shipping nipple (from gwa supply tapping) and remov...
Page 8: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 8 part number 670 01 1001 00 1. Connect from draft hood or vent damper outlet to chimney or vent with same size vent connector. 2. Where possible, vertical venting to the outside from the draft hood or vent damper outlet will offer best performance. 3. Whe...
Page 9: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 9 part number 670 01 1001 00 figure 4 vent damper assemblies damper installation do not modify draft hood or vent damper, or make another connection between draft hood and vent damper or boiler except as noted below. This will void csa certification and wi...
Page 10: Install Water Piping
Gwa gas-fired water boilers – boiler manual 10 part number 670 01 1001 00 table 4 water pipe size (based on 20 °f rise) general if installation is to comply with asme or canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolati...
Page 11: Install Water Piping
Gwa gas-fired water boilers – boiler manual 11 part number 670 01 1001 00 near-boiler piping continued figure 7 piping refrigeration systems water piping — refrigeration systems prevent chilled water from entering boiler install boiler so that chilled medium is piped in parallel with the heating boi...
Page 12: Install Water Piping
Gwa gas-fired water boilers – boiler manual 12 part number 670 01 1001 00 figure 8 system bypass piping in boiler loop with separate system circulator, using primary/ secondary piping. Figure 9 boiler bypass piping — use only for high water content systems —do not use for radiant panel systems. Near...
Page 13: Install Gas Piping
Gwa gas-fired water boilers – boiler manual 13 part number 670 01 1001 00 table 5 pipe capacity for 0.60 specific gravity natural gas 4 install gas piping natural gas: 1. See table 5 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 5 is ...
Page 14: Field Wiring
Gwa gas-fired water boilers – boiler manual 14 part number 670 01 1001 00 for your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring m...
Page 15: Start-Up
Gwa gas-fired water boilers – boiler manual 15 part number 670 01 1001 00 check for gas leaks before star ting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas le...
Page 16: Start-Up
Gwa gas-fired water boilers – boiler manual 16 part number 670 01 1001 00 check system and boiler eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. If you di...
Page 17: Start-Up
Gwa gas-fired water boilers – boiler manual 17 part number 670 01 1001 00 check the pilot ignition system used for the boiler. The boiler model suffix will contain an “s” for standing pilot or an “i” for spark-ignited pilot. See section 9, pages 20 and 21, for standing pilot boiler “lighting instruc...
Page 18: Checkout Procedure
Gwa gas-fired water boilers – boiler manual 18 part number 670 01 1001 00 7 checkout procedure ❏ boiler and heat distribution units filled with water? ❏ automatic air vent, if used, open one full turn? ❏ air purged from system? ❏ air purged from gas piping? Piping checked for leaks? ❏ correctly-size...
Page 19: Checkout Procedure
Gwa gas-fired water boilers – boiler manual 18 part number 670 01 1001 00 7 checkout procedure ❏ boiler and heat distribution units filled with water? ❏ automatic air vent, if used, open one full turn? ❏ air purged from system? ❏ air purged from gas piping? Piping checked for leaks? ❏ correctly-size...
Page 20: Start-Up
Gwa gas-fired water boilers – boiler manual 17 part number 670 01 1001 00 check the pilot ignition system used for the boiler. The boiler model suffix will contain an “s” for standing pilot or an “i” for spark-ignited pilot. See section 9, pages 20 and 21, for standing pilot boiler “lighting instruc...
Page 21: Start-Up
Gwa gas-fired water boilers – boiler manual 16 part number 670 01 1001 00 check system and boiler eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. If you di...
Page 22: Start-Up
Gwa gas-fired water boilers – boiler manual 15 part number 670 01 1001 00 check for gas leaks before star ting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas le...
Page 23: Field Wiring
Gwa gas-fired water boilers – boiler manual 14 part number 670 01 1001 00 for your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring m...
Page 24: Install Gas Piping
Gwa gas-fired water boilers – boiler manual 13 part number 670 01 1001 00 table 5 pipe capacity for 0.60 specific gravity natural gas 4 install gas piping natural gas: 1. See table 5 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 5 is ...
Page 25: Install Water Piping
Gwa gas-fired water boilers – boiler manual 12 part number 670 01 1001 00 figure 8 system bypass piping in boiler loop with separate system circulator, using primary/ secondary piping. Figure 9 boiler bypass piping — use only for high water content systems —do not use for radiant panel systems. Near...
Page 26: Install Water Piping
Gwa gas-fired water boilers – boiler manual 11 part number 670 01 1001 00 near-boiler piping continued figure 7 piping refrigeration systems water piping — refrigeration systems prevent chilled water from entering boiler install boiler so that chilled medium is piped in parallel with the heating boi...
Page 27: Install Water Piping
Gwa gas-fired water boilers – boiler manual 10 part number 670 01 1001 00 table 4 water pipe size (based on 20 °f rise) general if installation is to comply with asme or canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolati...
Page 28: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 9 part number 670 01 1001 00 figure 4 vent damper assemblies damper installation do not modify draft hood or vent damper, or make another connection between draft hood and vent damper or boiler except as noted below. This will void csa certification and wi...
Page 29: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 8 part number 670 01 1001 00 1. Connect from draft hood or vent damper outlet to chimney or vent with same size vent connector. 2. Where possible, vertical venting to the outside from the draft hood or vent damper outlet will offer best performance. 3. Whe...
Page 30: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 7 part number 670 01 1001 00 perform hydrostatic pressure test pressure test boiler before attaching water or gas piping or electrical supply (except as noted below). Prepare boiler for test 1. Remove the shipping nipple (from gwa supply tapping) and remov...
Page 31: Prepare Boiler
Gwa gas-fired water boilers – boiler manual 6 part number 670 01 1001 00 air openings continued 2 prepare boiler table 3 manifold orifice sizing place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. 2. Move entire crate and pallet next to selected ...
Page 32: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 5 part number 670 01 1001 00 table 2 corrosive contaminants and likely locations to prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found: • remove co...
Page 33: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 4 part number 670 01 1001 00 1 prepare boiler location continued failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. When removing boiler from existing common vent syste...
Page 34: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 3 part number 670 01 1001 00 service clearances 1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as listed in the table below: 2. Provide at least screwdriver clearance to jacket front panel scre...
Page 35: Prepare Boiler Location
Gwa gas-fired water boilers – boiler manual 2 part number 670 01 1001 00 installations must follow these codes: • local, state, provincial, and national codes, laws, regulations and ordinances. • national fuel gas code, ansi z223.1–latest edition. • standard for controls and safety devices for autom...
Page 36: Gwa
Part number 670 01 1001 00 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 boil...