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Part Number 550-142-784/0812

G WA

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

certicate”foundonpage18.

Contents Page

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

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

3 Installwaterpiping ............................................................10

4 Installgaspiping ...............................................................13

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

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

7 Checkoutprocedure .........................................................18

8 DepartmentofEnergyCompliance ................................. 19

9 Sequenceofoperation ...................................................19

10 OperatingInstructions ....................................................23

11 Service and maintenance .................................................25

12 Troubleshooting ................................................................29

13 Replacement parts ........................................................... 40

14 Dimensions .......................................................................45

15 Ratings .............................................................................46

16 Notes ................................................................................ 47

Boiler Manual

Series 2

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 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 qualied 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

1 2 3 4 5 6 ... 47 48

Sommario

Pagina 1 - Boiler Manual

Part Number 550-142-784/0812G WA This manual must only be used by a qualiﬁed heating installer/service technician. Failure to comply could result in

Pagina 2 - Codes & checklist

Boiler modelnumberTosystemFromsystemGWA-052¾" ¾"GWA-0701" 1"GWA-1051" 1"GWA-1401" 1"GWA-1751¼" 1¼"GW

Pagina 3 - Flooring and foundation

11Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualNear-boiler piping continuedFigure 7 Piping refrigeration systemsWa

Pagina 4 - Vent system

12Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 9 Boiler bypass piping — use only for high water content sys

Pagina 5 - Products to avoid

13Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 10 Gas supply pipingTable 5 Pipe capacity for 0.60 specic

Pagina 6 - 2 Prepare boiler

14Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual5 Field wiring Foryoursafety,turnoffelectricalpowersupplya

Pagina 7 - 2 Prepare boiler continued

15Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFill the system with water1. Closemanualandautomaticairventsa

Pagina 8

16Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual6 Start-up continuedCheck system and boiler Eliminateallsystemle

Pagina 9

17Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual6 Start-up continued Checkthepilotignitionsystemusedfortheb

Pagina 10 - 3 Install water piping

18Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualBoiler model _______________________________________________________

Pagina 11 - Near-boiler piping continued

19Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual8 Department of Energy – Compliance9 Sequence of operation – spark

Pagina 12

2Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualInstallations must follow these codes:• Local,state,provincial,an

Pagina 13 - 4 Install gas piping

20Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual9 Sequence of operation – spark-ignited pilot boilers5. Thermostat

Pagina 14 - 5 Field wiring

21Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 15a Schematic wiring diagram — Spark-ignited pilot system9

Pagina 15 - 6 Start-up

22Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 15b Schematic wiring diagram — Spark-ignited pilot system9

Pagina 16 - 6 Start-up continued

23Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual10 Operating instructions – spark-ignited pilot boilersGas valve — H

Pagina 17

24Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual10 Operating instructions – spark-ignited pilot boilersGas valve — R

Pagina 18 - 7 Checkout procedure

25Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual11 Service and maintenance Followthe“Serviceandmaintenance”pro

Pagina 19 - IMPORTANT

26Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual The boiler should be inspected and started annually, at the begi

Pagina 20 - Part Number 550-142-784/0812

27Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualAir vents and air elimination1. Inspectautomaticairvents(ifuse

Pagina 21

28Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual11 Service and maintenance continuedo Check/test. . . . . . . . . .

Pagina 22

29Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting Verifyproperoperationafterservicing.•See

Pagina 23 - WHAT TO DO IF YOU SMELL GAS

BoilermodelMinimumfoundationlengthMinimumfoundationwidthGWA-052 25” 12”GWA-070 25” 12”GWA-105 25” 15”GWA-140 25” 18”GWA-175 25” 21”GWA-210 25” 24”GWA-

Pagina 24 - Gas valve — Robertshaw 7200

30Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 16 GWA Ignition cntrol module11 Troubleshooting – spark-igni

Pagina 25 - 11 Service and maintenance

31Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual11 Troubleshooting – spark-ignited pilot boilersControl indicator li

Pagina 26 - Inspect . . . . . . . . .

32Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 17 Control module connections12 Troubleshooting – spark-igni

Pagina 27 - Start-up. . . . . . . . .

33Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting – spark-ignited pilot boilersElectrical shock haz

Pagina 28 - Review with owner

34Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting – spark-ignited pilot boilersElectrical shock haz

Pagina 29 - 12 Troubleshooting

35Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting – spark-ignited pilot boilers• Reset boiler contr

Pagina 30 - Control module

36Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting – spark-ignited pilot boilers• Turn off power to

Pagina 31 - Control indicator lights —

37Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting – spark-ignited pilot boilers•TURN OFF POWERtob

Pagina 32

38Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual12 Troubleshooting – spark-ignited pilot boilersElectrical shock haz

Pagina 33

39Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualHandling ceramic ﬁber and ﬁberglass materialsREMOVAL OF COMBUSTION C

Pagina 34

4Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual1 Prepare boiler location continued Failuretofollowallinstructi

Pagina 35

ItemnumberDescription Part numbernot shownReplacementsection assemblyGWA-052GWA-070GWA-105GWA-140GWA-175GWA-210GWA-245321-114-345WT321-114-345WT321-11

Pagina 36

ItemnumberDescription Part numberBase assembly kit GWA-052GWA-070GWA-105GWA-140GWA-175GWA-210GWA-245381-354-355WT381-354-356WT381-354-357WT381-354-358

Pagina 37

ItemnumberDescription Part number Part number1Junction box, 2 x 4(Available at local supply house)2Jacket panel, left side with insulationGWA-052 GWA

Pagina 38

43Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 21 Trim assembly13 Replacement parts continuedItemnumberDesc

Pagina 39 - NIOSH stated First Aid

44Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 22 Gas control assembly13 Replacement parts continuedItemnum

Pagina 40 - 13 Replacement parts

BoilermodelnumberSupplytappings(inches NPT) Return tappings(inches NPT)Gas connection& manifold size(Note 3)(inches NPT)“A” Ventlocation(inches)“D

Pagina 41

46Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual InstallGWAboilersforresidentialradiantpanelsystems,convert

Pagina 42 - Figure 20 Jacket assembly

47Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual16 Notes

Pagina 43 - Figure 21 Trim assembly

GWA Series 2 Gas-Fired Water Boilers – Boiler Manual48Part Number 550-142-784/0812W-T8201 W. Calumet Rd.Milwaukee, WI 53223

Pagina 44

5Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual1 Prepare boiler location continued To prevent potential of sev

Pagina 45 - 14 Dimensions

LocationNatural gas Propane gasU.S.Sea level –2,000 ft2.00 mmover2,000 ft(Note 1)Sea level –2,000 ft1.30 mmover2,000 ft(Note 1)CanadaSea level –2,000

Pagina 46 - 15 Ratings

7Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualPerform hydrostatic pressure testPressure test boiler before atta

Pagina 47 - 16 Notes

8Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler Manual1. Connectfromdrafthoodorventdamperoutlettochimneyorvent

Pagina 48 - Milwaukee, WI 53223

9Part Number 550-142-784/0812GWA Series 2 Gas-Fired Water Boilers – Boiler ManualFigure 4 Vent damper assembliesDamper installation Donotmodifydr

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