ICP GWA 052 Manual 

Text of ICP GWA 052 User Guide:

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 11Part 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 boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 7 for typical installation of balancing valve and check valve. If system includes radiant heating circuits, provide piping and controls to regulate the temperature supplying the radiant circuits. Failure to comply could r

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 7Part 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 remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾" NPT pipe plug. 2. Remove 1¼" nipple, reducing tee and drain valve from accessory bag. Install in boiler return connection as shown on in Figure 19, item 3, page 32. Install circulator on either the return or supply. 3. Remove 1¼" nipple, 1¼" tee, bushing and pressure/temperature ga

• ICP GWA 052, GW A 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. Where horizontal vent connector is used, slope upward at least ¼" per lineal foot toward chimney or vent and support with hangers to prevent sagging. 4. Breeching must not be connected to any por

• GW A 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 discover evidence of any gas leak, shut down the boiler at once. Find the leak source with b

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 9Part 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 will not be covered by Williamson-Thermoflo warranty. Any changes will cause severe personal injury, death or substantial property damage. 1. Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions. Vent damper must be installed so that it serve

• ICP GWA 052, GW A 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-boiler piping continued Install all components specified above and adjust valves as described to prevent low temperature in the boiler. Failure to prevent low water temperature in the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage. 3 Install water piping continued Sy

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 5Part 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 contaminants permanently. — OR — • Isolate boiler and provide outside combustion air. See national, provincial or local codes for further information. Please review the following information on potential combustion air contamination problems. See Table 2 for products and areas which may cause contaminated combustion air. Air contaminati

• ICP GWA 052, GW A 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 must be N.E.C. Class 1. If rollout thermal fuse element wire as supplied with boiler must be replaced, type 200 °C wire or equivalent must be used. If other original wiring as supplied with boiler must be replaced, use only

• ICP GWA 052, GW A 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. Where horizontal vent connector is used, slope upward at least ¼" per lineal foot toward chimney or vent and support with hangers to prevent sagging. 4. Breeching must not be connected to any portion of a mechanical draft system that can operate under positive pressure. Long horizontal vent connector, excessive number of elbow or tee

• GW A 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 Automatically Fired Boilers, ANSI/ASME CSD-1, when required. • National Electric

• ICP GWA 052, GW A 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 must be N.E.C. Class 1. If rollout thermal fuse element wire as supplied with boiler must be replaced, type 200 °C wire or equivalent must be used. If other original wiring as supplied with boiler must be replaced, use only type 105 °C wire or equivalent. Boiler must be electri

• ICP GWA 052, GW A 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 isolation valve. Set second control to minimum 20 °F above setpoint of first control. Maximum allowable setpoint is 240 °F. See page 19 for wiring. A low water cutoff device is required when boiler is installed above radiation level or by certain state or local codes or insurance companies. Use low water cutoff designed for wate

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 17Part 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 Instructions”, or the Control Supplement for spark- ignited pilot “Operating Instructions”. Figure 12 Typical pilot burner flame Verify operation Check vent damper operation 1. Raise room thermostat to call for heat — Vent damper actuator will slowly open vent damper. 2. When vent damper is

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 13Part 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 only for gas with specific gravity 0.60, with a pressure drop through the gas piping of 0.30" w.c. For additional gas pipe sizing information, see ANSI Z223.1 (B149.1 or B149.2 for Canadian installations). 2. Inlet pressure req

• ICP GWA 052, GW A 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 system: At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting

• ICP GWA 052, GW A 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 discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected. Failure to comply could result in severe personal injury, death or substantial property damage. Do not use pe

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 11Part 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 boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 7 for typical installation of balancing valve and check valve. If system includes radiant heating circuits, provide piping and controls to regulate the temperature supplying the radiant circuits. Failure to comply could result in substantial property damage. Use Figure 5

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 9Part 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 will not be covered by Williamson-Thermoflo warranty. Any changes will cause severe personal injury, death or substantial property damage. 1. Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions. Vent damper must be installed so that it se

• ICP GWA 052, GW A Gas-Fired Water Boilers – Boiler Manual 3Part 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 screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing. Figure 1 Minimum clearances Clearances Service clearances: Mini

• 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 numb

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